Pervious Concrete VI

Last weeks blog covered a recent pervious concrete seminar and demonstration hosted by contractor-client, The Bazella Group of Allentown, PA.  This weeks blog will discuss some of the different surface finish methods used for the pervious concrete samples.

Compressor Finisher

Compressor finish is a relatively  new surface-finish method for pervious using a non-weighted pan machine, developed by Dave Mitchell of Bunyan Industries.  Immediately after the roller-screed pass for leveling, the non-weighted pan is floated several times across the surface, and provides a relatively dense yet still pervious surface.  Though John Bazella is currently doing trials with a conventional motor-mounted pan mixer, the Bunyan version used an off-machine compressor for power, and the long handled-pan allows the operator to finish without walking on the new surface.  The compressor also powers the roller-screed used for initial strike-off.

Pan-Finish

Pan-finish uses a non-weighted pan method leaves a fairly closed and level surface, almost resembling a base-course asphalt mix, and eliminates hand-troweling except for slab edging.  Low spots are easily filled in with additional fresh mix panned in, and high spots are quickly leveled by the low-rpm pan.

Bean Oil

Bean Oil is immediately used after panning, a light coat is applied by sprayer as a moisture stabilizer for the surface.  This is an eco-friendly soybean-based light oil that has universal uses.

Plastic Cover

Plastic sheeting is immediately placed over the concrete and generally left in place for 7 days.  The entire process from truck chute to roller-screed to finish, spray, and cover, is typically only about 15 minutes – a far cry from waiting for conventional slabs to gel, bleed, finish, etc.

For more information, please visit: www.forta-ferro.com

Pervious Concrete V

FERRO-GREEN® Pervious Mix

FORTA® was recently invited to speak at, and participate in, a pervious concrete seminar and demonstration by contractor-client The Bazella Group of Allentown, PA.  The 2-day event was attended by approximately 30 owners, specifiers, and water-management government officials to learn more about the basics of pervious concrete.  The Bazella current focus is to re-educate project candidates from the old, cumbersome, and poorly-performing pervious mixes of yester-year, and provide more advanced design and practice ideas that result in a much more durable and tougher in-place pervious pavement. 

The seminar began with a Pennsylvania Aggregates and Concrete Association (PACA)-sanctioned pervious certification class and test for several contractor personnel, led by Bruce Cody who has become a statewide association resource and expert in pervious concrete.  Presentations also included topics such as available government grant funding for sustainable projects, basic pervious design and concepts, evolution of pervious mixes and placement practices, colored and resin overlays for decorative pervious, and enhancements to toughness and freeze/thaw durability courtesy of macro synthetic fibers. After the presentations, attendees were able to witness 2-days of pervious concrete placements and demonstrations, all of which contained 5 lbs/cu yd of FERRO-GREEN® 2 ¼” fiber. 

The Bazella Group consists of 2 brothers – Justin who runs the Allentown division of approximately 150 employees, and John who operates a smaller group from Greensburg, PA.  Both groups focus on decorative concrete applications, and have become experts in the practice and placement of pervious concrete as well.  They are convinced that the use of a medium dosage of FERRO-GREEN® will solve all durability problems of the past with pervious concrete, and allow its use to grow exponentially as a result.

Over the course of 2 days, the ‘experts’ (program speakers) placed 14 cubic yards of FRP in formed pads, some of which were to be retained and stored for future client use.  Attendees could take away samples of the FRP for their reference.

Berks Products supplied the mix as prescribed by Bazella, and their sales and Quality Control staff observed to compare to their standard pervious mixes.  They were impressed with the ease-of-discharge for this mix, as well as the uniform mixing and distribution of the high-dosage fibers.  

For these trial FORTA® mixes, the fiber was added on the aggregate belt into the central batch for the first load, and added at the tail-end of the truck for the second load.  In both cases, the fiber mixed well and distributed throughout with no evidence of balling. The fiber used was FERRO-GREEN® mix. Even with the sharp long aggregate, the 2 ¼” fiber mixed quickly and uniformly throughout, and sufficient paste was available to coat all of the fibers.

Please stay tuned in during the month of May for weekly updates on the project trials that resulted from this educational seminar.

For more information, please visit:www.forta-ferro.com

College Concrete Competitions

The NJIT ball after loading with FERRO®, showing considerable post-crack behavior at a 2% volume addition rate

FORTA® Corporation has been a long time supporter of college concrete competitions such as Concrete Canoe Competitions and Concrete Bowling Ball Competitions.  Our family of fibers have been donated for decades to support college construction and engineering programs that challenge teams to demonstrate the effect of fibers in reinforcing concrete.

The competitions provide students with the ability to apply practical principles they have learned in the classroom.  The students are able to display design, construction, technical, presentation and leadership skills which are imperative skills to enter the job market.  In addition, students learn team and project management skills that are also needed for their future careers.

FORTA® fibers have been used in concrete canoe and bowling ball competitions for many years.  In 1995 Louisiana Tech University  placed in the top 5 with their concrete concrete canoe, utilizing fibers from FORTA®.  Recently at the ACI 2014 Spring Convention in Reno, NV the New Jersey Institute of Technology used FORTA® products in their specimen  and placed 3^rd in the presentation portion of the competition.  

The FRC Bowling Ball Competition continues to grow and mature, to the degree that ACI has requested more frequent competitions.  The competition includes a variety of performance and strength requirements, including an actual bowling score as an exciting highlight of the competition.  The competition appears to be a program that is well-received by the students and universities, and creates much discussion and experience with a wide variety of fiber types being used.

1995 Louisiana Tech University Concrete Canoe Regional Competition

For more information, please visit: www.forta-ferro.com

FORTA® Career Opportunities

2014 represents the 36^th year in the fiber reinforcement business for FORTA® Corporation of Grove City, Pennsylvania.  As the first of its kind, FORTA® has developed, produced, and promoted a complete family of synthetic fiber reinforcements for a wide variety of concrete applications.  These fibers have involved FORTA® in projects ranging from precast vaults, tanks, and wall panels, to site-cast floors, parking lots, and bridge decks.  These products and projects have helped change the face of concrete reinforcement worldwide.

FORTA® is currently recruiting Independent Sales Representatives for the following territories:

• New England
• New York City
• Northern California
• Tennessee
• Mississippi/Louisiana
• Northern Texas/Oklahoma
• South Texas
• Oregon
• Idaho/Montana/Wyoming

This is a 100% commissioned sales representative position.  You will be responsible for your own expenses.  However, you will benefit from an industry-leading commission program, as well as product, technical, sales and engineering support.  We offer an excellent training program to introduce you to the wide variety of products and services.

For more information, please visit: http://www.forta-ferro.com/contact-information/career-opportunities/

Slab on Ground Concrete

The 5” thick slab on ground for the Yuma Federal Courthouse expansion posed a considerable number of construction issues for the engineers, designers, concrete supplier, and contractors.  For a variety of reasons, measures to reduce shrinkage and the resulting cracking were paramount in many construction areas.  With day-time temperatures reaching 100 degrees F in windy conditions, pours were adjusted to a night-time schedule requiring three all-night placements.  

The slab also contained myriad areas of cut-outs, slab protrusions for water and electrical conduits, and many slab interruptions for walls, small rooms, and offices.  The 3,500 psi concrete design was also optimized to reduce the tendency for shrinkage by increasing coarse aggregate size and using a relatively low cement content, thereby maintaining a low W/C ratio.  One of the key shrinkage-reducing measures was the use of a high dosage of macrosynthetic fiber reinforcement in lieu of conventional temperature-steel reinforcement, which offered a uniform three-dimensional non-corrosive way to reduce cracking.  

FORTA-FERRO® macro fiber was used at a dosage of 7.0 lbs/cu yd in approximately 30,000 square feet of floorslab, requiring over 450 cubic yards of concrete.  In addition, FORTA-FERRO® was used successfully in 1,300 square feet of slab on metal deck construction, and dramatically reduced cracking found in other similar deck placements that had been placed previously.  Even at the high dosages, the macro fiber mixed, distributed, pumped and finished extremely well throughout, offering a cost-effective and labor-free alternate to conventional temperature reinforcement.  

Project Details:

Owner:  United States Federal Courthouse, Yuma, AZ

Design & Construction Manager:  General Services Administration, Design and Construction Division, Region 9, San Francisco, CA

Project Manager:  Abacus Project Management, Inc., Phoenix, AZ

Structural Engineer:  Caruso Turley Scott Inc., Tempe, AZ

Design/Build Contractor:  Sundt Construction, Tempe, AZ

Concrete Consultant:  Structural Services LLC, Atlanta, GA

Mix Design Consultant:  Geotechnical Testing Services Inc., Yuma, AZ

Ready-Mix Supplier:  BLT Ready Mix, Yuma, AZ

Pumping Contractor:  BLT Ready Mix, Yuma, AZ

Fiber:  FORTA-FERRO® macro-synthetic 2 ¼” @ 7.0 lbs/cu yd

For more information, please visit: www.forta-ferro.com

The Benefits of Synthetic Fiber vs. Wire Mesh

In the March 20, 2014  edition of ForConstructionPros.com. published an article "Not Meshing Around." The article discuss the safety benefits of using synthetic fiber in concrete projects versus wire mesh on job sites.

In the past construction of slabs on metal deck involved the use of a concrete slab with a supporting platform made up of structural steel beams and a metal deck.  Historically, a typical steel deck consisted of a corrugated steel sheet with a concrete topping reinforced with welded wire mesh.  The purpose of the wire mesh is to act as a secondary (non-structural) reinforcement to prevent concrete cracks.

The present day now offers the use of synthetic fibers, primarily macro-synthetic fibers, as a more effective way to reduce and control cracking.  Synthetic fibers meet and exceed established standards and business codes established by the Steel Deck Institute (SDI), Underwriters Laboratories (UL), American Society of Testing and Materials (ASTM) and the American Concrete Institute (ACI).  Beyond the cost savings and reduction or prevention of cracking is the time and labor savings by simply adding synthetic fibers to the concrete mix.

In addition to the benefits of synthetic fiber in the concrete mix as a cost-effective solution is they also eliminate any head aches when is comes to removing potential hazards from the work site.  Synthetic fibers offer a safer alternative to placing and working with wire mesh for construction workers.  Using synthetic fiber eliminates worry of injury to workers for construction businesses and project foremen.

Biddle, Daniel T. "Not Meshing Around." ForConstructionPros.com. March 20,2014

To read the full article, please visit: http://www.forconstructionpros.com/article/11355163/synthetic-fibers-are-safer-than-wire-mesh-in-slab-on-metal-deck-projects

Ground and Polished Concrete

Macrosynthetic fibers played an important reinforcing role in the $9 million expansion project at the Erie Art Museum in Erie, PA. The museum owner's desire for an eye-catching and joint-free floor surface for their 10,000 sq. ft. addition prompted concrete contractor Tom Maya to submit high-volume macrosynthetic fibers as an alternate to the specified matt-steel reinforcement. Based on previous macro-fiber experiences, Maya felt fibers offered the best opportunity to minimize joints and cracking on the high-profile gallery floor.

Critical to success however, would be the fibers' ability to mix and distribute uniformly and finish well, even at the high dosages required (7.5 lbs.cu.yd.), while not affecting the aesthetics of the grind-and-polish surface treatment. While the results speak for themselves, the FORTA-FERRO® macrosynthetic fiber succeeded in controlling shrinkage, cracking, and curling in the large and irregularly shaped joint-free floor sections. The final floor finish was impressive enough to cause concern by museum curators that the floor might actually divert attention from the gallery exhibitions. 

The floor system included a 1 1/2" thick fiber-reinforced mud matt required due to poor sub-grade conditions, and topped with a 5" thick concrete floor separated by a double slip-sheet to allow for possible movement. The floor was comprised of a 3,000 psi high-performance exposed-aggregate concrete, that involved a 5-step grind-and-polish process. Grinding contractor Diamond Designer Concrete of Erie plans to use the project as a showcase reference for their fiber-reinforced, polished-floor system. 

For more information, please visit: www.forta-ferro.com

Decorative Concrete

Typically decorative concrete contractors shy away from the use of the second generation macro synthetic fibers for use in stamped and decorative concrete for fear of having visible fibers on the surface after completion. Recently a contractor who uses the FORTA-FERRO® macro fibers in his standard slab-on-grade projects had a stamped concrete patio project come up and he wanted to test the FORTA-FERRO® for finish ability in this application. 

A dosage of 7.5 lbs. per cubic yard of 2 ¼” length FORTA-FERRO® was chosen in this 4” thick, 5 yard stamped concrete slab. The surface of the integral colored concrete was first striked off and then 2 different shake colors were then applied to the surface, after which the surface was bull floated and lastly a Fresno was used. Once this was complete the shake hardener was applied. 

The end result after pressure washing the surface was a fiber-free surface on the stamped concrete patio. Many stamped concrete contractors use micro fibers for the main reason they do not show on the surface. This patio shows that macro synthetic fibers, which offer better hardened concrete benefits, will also yield excellent results when it comes to the visual finish of the decorative concrete.

Project Details:
Application: Decorative Patio
Owner: Private Residential
Location: Grove City, PA
General Contractor: Ron Minor – Minor Industries, Stoneboro, PA
Concrete Contractor: Ron Minor – Minor Industries,Stoneboro, PA
Ready-Mix Supplier: R.W. Sidley, Pennsylvania
Fiber/ Dosage: FORTA-FERRO® 2 1/4” 7.5 lbs. /CY

For more information, please visit: www.forta-ferro.com

Slab on Grade

Stephen Scibetta, Concrete Contractor, for Design Concrete Inc. completed a project for Chik-fil-A Dwarf House in Forest Park, GA.  The project was replacing a portion of a failed asphalt parking lot.  Scibetta specified 3lbs per cubic yard of FORTA-FERRO® in a 6” slab on grade concrete application.

Project Details:

Application: Slab on Grade

Owner: Chik-fil-A

Location: Forest Park, GA

Concrete Contractor/Specifier: Stephen Scibetta, Design Concrete Inc.

Concrete Supplier: Walker Concrete

Fiber Reinforcement: FORTA-FERRO® 3lbs per cubic yard

For more information, Please visit: www.forta-ferro.com

Make the Switch to Macro Synthetic Fiber

Many companies are reinforcing their concrete projects with FORTA-FERRO® macro synthetic fibers.  FORTA-FERRO® was developed in the late 90's as an alternate to traditional steel.  FORTA-FERRO® has become a leading macro synthetic fiber for secondary reinforcement for concrete because of its superior mixing and finishing characteristics.

Traditional wire mesh has been used since the early 1900's as a way to hold broken pieces of concrete together.  Due to the difficulties of placing wire mesh in the top-third of the concrete cross section, the wire mesh does not get the chance to aid in holding broken pieces of concrete together.   Other potential issues with using labor intensive wire mesh are: delivery, storage, corrosion and cost.

The wire reinforcement institute states, "Only when the reinforcing steel is properly selected, placed and supported can its use be recommended and it's cost warranted."

FORTA-FERRO® is a three dimensional reinforcement fiber that eliminates the need for concern if steel reinforcement is placed in the proper location.  FORTA-FERRO® is chemically inert, so it will not corrode like steel.  In most instances macro synthetic fibers will also save time and labor costs versus steel.

Let FORTA® Corporation show you how FORTA-FERRO® can be a better alternative for your next concrete pavement or interior concrete slab project.  FORTA® offers engineering services, as well as a seasoned and knowledgeable field team nationwide to assist you. 

Contact FORTA® Corporation to reach a local representative:

1-800-245-0306

For more information, Please visit: www.forta-ferro.com

CONEXPO-CON/AGG 2014

Please visit FORTA® at our Booth

South Hall #61411

March 4-8, 2014 at the Las Vegas Convention Center

FORTA® can be found this year in South Hall.  Look for the red booth with fibers in South Hall #61411.  Stop by and learn more about using FORTA-FERRO® to save money, submit alternate reinforcing bids and place better floors.

Learn more about:

·         Reinforced polished concrete floors

·         Replace significant steel reinforcement

·         Reduce tripping hazards for slab-on-deck

·         Reinforce and toughen pervious concrete

·         Stretch normal joint spacing.

For more information, please visit: www.forta-ferro.com

Concrete Overlay

FORTA-FERRO® was recently specified in 2013 by Desmone Associates & Architects in The Doughboy Apartment Complex and Retail Shops building project.  The building plan consisted of 42 apartments and 2 retail stores.  FORTA-FERRO® was used as an overlay for the precast beams that were used at the top of the parking garage to reduce cracking.  FORTA-FERRO® was pumped from a concrete truck.  The 3” slab was finished with a steel trowel.  FORTA-FERRO® replaced 6x6-10 gauge steel reinforcement.

Project Details:

Application: Overlay

Owner: Cushman

Location: Lawrenceville, PA

Engineer/Specifier: Desmone Associates & Architects

General Contractor: Mistick

Ready-Mix Supplier: 43^rd Street Concrete

Concrete Contractor: Hoy Construction

Fiber Reinforcement: FORTA-FERRO® 2.25” length, 3 lbs per cubic yard

For More Information, Please Visit: www.forta-ferro.com

2014 World of Concrete ACI Commercial/Industrial Finishing Certification

The ACI Commercial/Industrial Finishing Certification class and exam, led by Bob Simonelli and Jerry Holland of Structural Services Inc. completed a concrete slab at World of Concrete 2014 in Las Vegas, NV.  The fiber used was a commercial/industrial macro fiber dosage of 7.5 lbs/cubic yards typical of column-line floor slab use, and reinforced 12 cubic yards of concrete.  Trainees were required to place and finish the demo slab, and show competence under a variety of conditions.  

The high-fiber concrete placed, floated, and finished extremely well, and caused no issues with regards to surface finish or flatness and levelness.  Over 35 contractor personnel participated in the event, with several hundred onlookers from all across the concrete construction spectrum.  FORTA® has donated macro fiber reinforcement to many World of Concrete events over the years, including a macro fiber pervious concrete application for the new ACI logo placement that was created during the show.   FORTA® celebrated their 33rd World of Concrete, missing only the first 7 years of show existence.

Please watch the project video: http://youtu.be/qa9qUSpuZPk

Pervious Concrete IV

Auburn University Fisheries Building Parking

Auburn, Alabama

2011

Dr. Michael Hein from Auburn University and and his structure class students completed a pervious parking lot in 2011.  The parking lot is located at the Auburn University Fisheries Building in Auburn, Alabama. Hydro Max Internal Curing Admixture and FORTA FERRO-GREEN® was added at the slump rack.  The AU Engineering students were the pervious concrete place and finish crew.  Though micro fibers have been used frequently in the past for pervious pavement applications, FORTA® continues to promote and research the use of synthetic macro fibers to add toughness and durability to medium and heavy-duty pervious pavements.  Even at high fiber dosages, the FERRO-GREEN® macro fiber is very user-friendly during lay-down, and offers no issues regarding placement and finishing.  Though the mix design used on the Auburn University Fisheries Parking Lot offered a few small cement balls during mixing, the FERRO-GREEN® fiber mixed and distributed very uniformly throughout the mix.

Please watch the project video: http://www.youtube.com/watch?v=FjIO5tADxnw

Project Details:

Application: Parking lot

Owner: Auburn University Fisheries Facility Phase 1

Location: Auburn, Alabama

Pervious Concrete Consultant: Dale Fisher

Ready-Mix Supplier: USA Ready Mix

Concrete Contractor: Dr. Michael Hein and students from his structure class

Fiber Reinforcement: FERRO-GREEN® 2.25" length, 5 lbs per yard

Volume: 20 yards

For more information, please visit: www.forta-ferro.com

Pervious Concrete III

GRTA Park & Ride

Newnan, Georgia

November 2010

The Georgia Regional Transit Authority commuter park and ride facility in Newnan, GA chose pervious concrete as an eco-friendly material to help manage storm-water issues on their large parking lot site.  To provide early stability and additional toughness to the pervious matrix, consultant Dale Fisher specified a synthetic fiber reinforcement that would not rust or break down over time.  In keeping with the green building theme, Walker Concrete supplied FORTA® Green-Net ® fiber as reinforcement.  

The fiber pervious concrete was used in over 30,000 square feet of car-parking lot and has performed well in this high traffic facility that services Newnan to downtown Atlanta. This popular Route # 450 cycles 13 times daily, and is part of the State of Georgia authority's effort to improve regional mobility, air quality, and land use practices.  The GRTA mission is to reduce ozone and particulate matter levels in the air to help metro counties meet local air quality standards and sustainability requirements.

Project Details:

Application: Pervious Parking Lot

Owner: Georgia Regional Transit Authority (GRTA)

Location: Newnan, GA

Pervious Concrete Consultant: Dale Fisher

Ready-Mix Supplier: Walker Concrete LLC, Stockbridge, GA

Concrete Contractor: Curb Specialists Inc., Conyers, GA

Fiber Reinforcement: FORTA® Green-Net ®, 1 1/2" length, 1.5 lbs per cubic yard

Volume: 560 cubic yard of fiber reinforced pervious concrete

Dimensions: 6" thick, approximately 30,000 square feet

For more information, please visit: www.forta-ferro.com

Pervious Concrete II

ForConstructionPros.com published an article on December 6, 2013 titled:

Pervious Concrete Pavements Gets Fiber Reinforcement

The article outlines a pervious project that replaced deteriorated asphalt.  The project used 6 inch thick pervious pavement over 1,150 square feet with 2 different types of synthetic fiber reinforcement to add durability.

Please click the following link for the full article:

www.forconstructionpros.com/article/11268346/pervious-concrete-pavement-gets-fiber-reinforcement

Project Details:

Application: Pervious Concrete Parking Lot

Fiber Type/Length:
1.       Green-Net ® 1.5” length dosed at 1.5 pounds per yard.
2.       Forta-Ferro ® 1.5” length dosed at 7.5 pounds per yard.

Cubic Yards: 21 total cubic yards

Finishing Method: Roller-screed strike off; covered with plastic and rolled; plastic cover cure.

Slab Thickness/Dimensions: 6” thick; approximately 1,150 square feet

For more information, please visit:www.forta-ferro.com

Pervious Concrete I

Pervious Concrete has been used in many countries for many years, and is now becoming more than just an oddity in the United States. The driving force behind this surge in pervious application is a growing need to take full advantage of shrinking building sites, and to accommodate storm-water runoff in the process.  Essential to the air-void nature of pervious, or porous concrete, is the potential for a lack of durability and toughness, which often impacts application choices and project volume.

Experts in the art of pervious materials and practice have long sought out ways to improve the material's durability, and to add to the long-term comfort level of owners that choose it and specifiers that specify it. Synthetic fibers have been tested and used for many years to add an element of crack control, however these fibers have been somewhat limited by shape and dosage, and have not offered a contribution level that could be considered as significant to this long-term durability goal.  The advent of second-generation synthetic macro fibers has opened a door of opportunity for this application, one that continues to morph and change with new project experience and laboratory study.

Please stay tuned for more features that show the benefits of pervious concrete and synthetic macro fiber uses.

For more information, please visit: www.forta-ferro.com

World Of Concrete 2014

Please Visit FORTA® at our NEW Booth and NEW location

Central Hall # C-4235

January 21-24, 2014 at Las Vegas Convention Center

FORTA® will be easy to find in our new location this year!  Central Hall #C-4235.  Look for the NEW big red booth with fibers.  Stop by and learn more about using FORTA-FERRO® to save money, submit alternate reinforcing bids, and place better floors.  FORTA® will be participating in the WOC Walk and Win!  Stop by to search our booth for your scavenger hunt clues.

Learn more about:

·         Reinforced polished concrete floors.

·         Replace significant steel reinforcement.

·         Reduce tripping hazards for slabs-on-deck.

·         Reinforce and toughen pervious concrete.

·         Stretch normal joint-spacing.

For more information, please visit: www.forta-ferro.com

Technical Services

Do you have any of the following questions:

• Why use fiber?
• Which fiber to use?
• How much fiber to use?

If you are currently interested adding fiber to your concrete project, but have many questions- FORTA® can offer a solution to your questions through our Technical Services Department. FORTA® Technical Services offers a convenient way to answer dosage questions for concrete projects.  Dosage questions can be answered by filling out a questionnaire and submitting to our Technical Department. 

To request a free technical services questionnaire, please contact:

1-800-245-0306

For more information, please visit: www.forta-ferro.com