Solutions for Crack-Free, Joint-Free & Maintenance-Free Floors
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Transcript of Solutions for Crack-Free, Joint-Free & Maintenance-Free Floors
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CTS Cement Manufacturing Corp.800-929-3939 Ext. 173www.ctscement.com
By Matt Jabbari, M.S. Civil Engineer
SOLUTIONSfor Crack-Free, Joint-Free & Maintenance-Free FLOORS
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Matt Jabbari
B.S. Civil Engineer University of MinnesotaM.S. Eng. Management Northeastern University
Design & Field EngineerMillstone III Nuclear Power Plant; Waterford, CT
Research Engineer W.R. Grace & Company; Cambridge, MA
Engineering Contractor, Public Works & PrivateSite Development Company; Santa Ana, CA
Project Manager Consultant; P.W.City of La-Canada-Flintridge, CA
Affiliations: ASCE, ACI, PTI, SEAOC, ICRI, andPublic Works Greenbook Sub-Committee Member
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Typical Industries Requiring Perfect Floors
Pharmaceutical Companies
Distribution Centers: Target, K-Mart, Costco
Production & Manufacturing Facilities
Parts & Inventory Warehouses
Computer Production & Assembly Facilities
Anyone who wants to INCREASE PRODUCTION and DECREASE maintenance DOWN TIME!!!
Food Warehouse & Distribution Centers
Beverage Production & Bottling Facilities
Meat & Poultry Grinding/Packaging Facilities
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Types of Cracks
CRACKS OVERVIEW
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When water evaporates off the surface TOO RAPIDLY,
cracking usually occurs.
Why are cracks Important?
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Plastic Shrinkage Cracks
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Drying Shrinkage Cracks
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Crazing Cracks
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There are FOUR FACTORS that contribute to this
ONE
High ambient temperatures
TWO
High concrete temperatures
THREE
Low humidity
FOUR
High winds
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Water to Cement Ratio
W/C = 200/500 = .40
200 Pounds Water
500 PoundsCementitious
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0
50
100
150
200
250
300
350
400
WATER CEMENT RATIO
POU
ND
S O
F W
ATER
EXTRA CUBIC FEET OF WATER
12
3
4
.25 .30 .35 .40 .45 .50 .55 .60 .65 .70 .75
Excess water in one cubic yard of concrete with 500 pounds of cement
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Learning Objectives
SHRINKAGE & CRACKINGUnderstand why traditional concrete shrinks, cracks, curls and needs joints1
DISCUSS SOME TYPICAL APPLICATIONS
CURLINGUnderstand why Shrinkage-Compensating Concrete doesn’t shrink, crack, curl or need joints2
FUTURE JOINT MAINTENANCE COSTSConsider joint spacing of 150’ by 150’
3RETURN ON INVESTMENTLearn how Shrinkage-Compensating Concrete lowers initial and life-cycle costs4
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Problem / Solution
SHRINKAGE & CRACKING
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PROBLEM: Shrinkage & Cracking
Typical Drying Shrinkage is .05%= 5/8” in 100’
100’
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PROBLEM: Shrinkage & Cracking
Without Resistance(Floating Space)A B
Total Shrinkage = A +B = 5/8”
99’ 11 3/8”
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PROBLEM: Shrinkage & Cracking
But There is Resistance
Subgrade Friction
100’
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PROBLEM: Shrinkage & Cracking
Shrinkage + Resistance = Cracks
Subgrade Friction
1/16” 1/16”
99’ 11 3/8”
1/8” 1/8” 1/8” 1/8”
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SOLUTION:Shrinkage Compensating Cement
Tetracalcium Trialumino Sulfate
What is shrinkage compensating cement?
Type-K or Expansive Cement
85% Portland
15% C4A3S
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Also known as Type K Concrete
Compensates for dry shrinkage of cement
SOLUTION:Shrinkage Compensating Cement
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All you need to do is ADD 15% KOMPONENTto your Local Portland Cement
Portland Cement
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CEMENT PRODUCTION PLANTCalcium Sulfo Aluminate Cement C4A3S
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ASTM C 878
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SHRINKAGE ZONE CHART
No Shrinkage / No Crack Zone
Shrinkage / Crack Zone
Traditional Portland Concrete with Rebar (#4 @ 24”oc) Type K Concrete with Rebar (#4 @ 24”oc) Type K Concrete with K-Fibers™ (aka: System-K™)
All panels were 50’ long by 6’ wide, 6” thick and had 7 days wet cure
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Types of joints and their purpose
JOINTS OVERVIEW
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Tooled Joints
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Saw-Cut Joints
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Tooled Joints vs. Saw-Cut Joints
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PROBLEM: Number of Joints
TYPICAL SLABS 210’ by 240’ 50,400 ft2
PORTLAND SLAB SLAB
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PROBLEM: Number of Joints
PORTLAND SLAB SLAB
Portland Concrete6270 linear ft. of joints
Shrinkage-Compensating 210 linear ft. of joints
TYPICAL SLABS 210’ by 240’ 50,400 ft2
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PROBLEM: Number of Joints
PORTLAND SLAB SLAB
Typical 1 day pour 25,200 square feet
SAVES OVER
AMILEOF
JOINTS
Portland Concrete6270 linear ft. of joints
Shrinkage-Compensating 210 linear ft. of joints
TYPICAL SLABS 210’ by 240’ 50,400 ft2
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PROBLEM: Number of Joints
PORTLAND SLAB SLAB
Typical 1 day pour 25,200 square feet
$12,000 $2,000
Portland Concrete6270 linear ft. of joints
Shrinkage-Compensating 210 linear ft. of joints
TYPICAL SLABS 210’ by 240’ 50,400 ft2
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PROBLEM: Cracks & Joints
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PROBLEM: Cracks & Joints
Differential drying causes curling
Cracks (joints) form in “V” shape
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Mitigates drying shrinkage cracks
Eliminates curling
SOLUTION:Shrinkage Compensating Cement
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Problems / Solutions
CURLING OVERVIEW
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Curling may occur at the intersections of all the joints
PROBLEM: Cracks & Joints
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PORTLAND SLAB SLAB
Typical 1 day pour 25,200 square feet
SAVES OVER
AMILEOF
JOINTS
PROBLEM: Cracks & Joints
Portland Concrete6270 linear ft. of joints
Shrinkage-Compensating 210 linear ft. of joints
TYPICAL SLABS 210’ by 240’ 50,400 ft2
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SOLUTION:Shrinkage Compensating Cement
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Elo
ng
ati
on
(%
)
-.01
-.04
-.03
-.02
0 100 200 300 400 500 600
Time (days)
-.06
-.05
Shrinkage Reducing
Control
0
.01
Shrinkage Reducing Admixtures
but they should be called
Shrinkage Delaying Admixtures
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Mitigates drying shrinkage cracks
Eliminates curling
SOLUTION:Shrinkage Compensating Cement
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FUTURE JOINTS MAINTENANCE
COSTSPROBLEMS / SOLUTIONS
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PROBLEM: Future Joint Maintenance
Typical Costly Epoxy Repair
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PROBLEM: Future Joint Maintenance
Typical Spall Repair
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By eliminating joints, you also eliminate the need for costly joint repair and maintenance
SOLUTION:Shrinkage Compensating Cement
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NO JOINTS = NO REPAIRS
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Cost Analysis
RETURN ON INVESTMENT
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• Downtime
• Facility closures
• Loss of load on pallet
• Accidents
• Performance − does not slow down workflow
• Insurance claims and employee compensations
• Bacteria growth
• Unsanitary conditions
PROBLEM: Costly Joint Repairs
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TYPICAL APPLICATIONS
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TYPICAL APPLICATIONS FOR SHRINKAGE-COMPENSATING
CONCRETE
Water Treatment
Tanks
Reservoirs
Secondary Containment
Hazardous Waste
Piers/Wharves
Ice Skating Rinks
Tennis Courts
Skateboard Parks
Basements
Manufacturing
Warehouses
Retail Stores
Hangars
Runways
Paving
Bridges
Parking Structures
Walls
Roofs
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Cracks Normally Occur at:1. Mid-Panel 2. Columns in the Slab (notice no boxouts)3. Perimeter Columns4. Bollards5. Re-entrant Corner6. Plastic and Crazing
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Sofa ExpressPortland, Tennessee
April 2004
70,000 square feetMax Joint Spacing 130’
No cracks
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Menards Home Improvement CentersOver a dozen locations done to date
4” slabs with 120’ by 160’ joint spacing
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Floors only 4” thick
120’ by 160’
panels
No saw-cut joints!
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Parking
Structures at
John Wayne Airport
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John Wayne Airportwith Portland Cement and
Post-Tensioning
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$1,000,000
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Typical Costly Epoxy Repair
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Basement moisture is the #1 cause of
mold
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With Shrinkage-Compensating Cement and Post-Tensioning
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Same Design, Contractor, and Ready-Mix Company.
The only difference is Shrinkage-Comp Cement.
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THIS? OR THIS?
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United National Foods Distribution CenterYork, Pennsylvania
675,000 sq. ft.Built in 2008
Computer and robotic aided distribution center
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High-Speed, High-Capacity Food Distribution
New YorkNew Jersey
PennsylvaniaDelawareMaryland
OhioVirginia
and West Virginia
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Albertsons WarehouseTolleson, Arizona
672,000 square feetJoint spacing 162’
Pallet jacks10 years old
NO REPAIRS
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Toyota Parts Center Ontario, California
760,000 ft2 Super Flat
Joint spacing 120’ by 120’Built in 1995
$10,000/year repairs
in other centersNone needed here
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Conclusion
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When You Want Concrete
Without Joints
Without Cracks
Without Curling
Without Spalling
Without Maintenance
With Lower Initial Costs
With Lower Life-Cycle Costs
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Same Design, Contractor, and Ready-Mix Company.
The only difference is Shrinkage-Comp Cement.
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THIS? OR THIS?
Q & A