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Self-Consolidating Concrete The Real Story MO128 Richard S. Szecsy, PhD, PE President & CEO Texas Aggregates and Concrete Association www.tx-taca.org Monday, January 23, 2012

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Page 1: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Self-Consolidating Concrete

The Real Story

MO128

Richard S. Szecsy, PhD, PE

President & CEO

Texas Aggregates and Concrete Association

www.tx-taca.org

Monday, January 23, 2012

Page 2: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

AIA Credits

Hanley Wood is a Registered Provider with The American Institute of

Architects Continuing Education Systems. Credit earned on completion

of this program will be reported to CES Records for AIA members who

sign in with their AIA member ID. Electronic Certificates of Completion

for all attendees will be available 6-7 weeks post show.

This program is registered with the AIA/CES for continuing professional

education. As such, it does not include content that may be deemed or

construed to be an approval or endorsement by the AIA of any material

of construction or any method or manner of handling, using or

distributing or dealing in any material or product.

Questions related to specific materials, methods and

services will be addressed at the conclusion of this

Presentation.

Page 3: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

1. Recognize and understand the basic technology

behind self-consolidating concrete

2. Evaluate the price and cost impacts on jobs using

self-consolidating concrete—design, materials and

placement

3. Summarize the QC/QA aspects of self-consolidating

concrete including durability and longer life

expectancy of structures

4. Develop a course of action to begin using self-

consolidating concrete

Learning Objectives

Page 4: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Seminar Overview

• Historical Perspective

• Current Market Status

• SCC Technology

• Testing and Measurement

• Bottom Line Economics

• Market Impact

• Getting Started

Page 5: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Seminar Overview

• Historical Perspective

• Current Market Status

• SCC Technology

• Testing and Measurement

• Bottom Line Economics

• Market Impact

• Getting Started

Page 6: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Historical Perspective

• Where and When?

• Movement Within

North America

• SCC Definition

• Technology Goals

• Innovation = Profitability?

Video provided by: Lattimore Materials Company, 972-221-4646 www.lattimorematerials.com

Page 7: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

SCC Development Timeline

1983 First considerations in Japan

1986 First suggested solution by OKAMURA/Univ. Tokyo

1988 First practical prototypes in Japan

1989 First publication at EASEC-2

1992 Publication CANMET & ACI-Int’l Conference/Istanbul

1994

ACI Workshop/Bangkok

Start of worldwide research and development

1995 Beginning of intensive research in US

1997 RILEM Committee for SCC

1998

Start of intensive activities

Introduction of technology to US

2002 1st

North American Conference on SCC (300+)

2005 2nd

North American Conference on SCC (500+)

2008 3rd

North American Conference on SCC

Page 8: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Technology Acceptance

Time

Reference: “Hype Curve” adapted from WIRED, August 2002, p.042

Trough of

Disillusionment

Slope of

Enlightenment

Plateau of

Productivity

Peak of Inflated

Expectations

Technology

Trigger

Page 9: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Case Example: McDougal St. Bridge

Photos provided by: Euclid Chemical Company, 19218 Redwood Rd., Cleveland, OH 44110, www.euclidchemical.com

• Year built: 2000

• SCC volume: 130 yd3

• Location: Toronto

• Project Highlights:

– Tight reinforcement

– Continuous pour

– Zero patching

Page 10: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Case Example: Toronto International Airport

• Year built: 1999 to 2009

• SCC volume: 2,750 yd3

ytd

• Location: Toronto

• Project Highlights:

– 4.4$B, 500,000yd3

– 81 columns, 100 ft. tall

pumped from bottom up

Photo provided by: Euclid Chemical Company, 19218 Redwood Rd., Cleveland, OH 44110, www.euclidchemical.com

Page 11: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Case Example: Habitat for Humanity

• Year built: 2001

• SCC volume: 200 yd3

• Location: Houston, TX

• Project Highlights:

– Sandwich wall system

– Safe, simple construction

by volunteers

– Cast and strip in same day

Photo provided by: Master Builders, 1-800-MBT-9990, www.masterbuilders.com

Page 12: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Case Example: Rosenthal Contemporary Art Center

• Year built: 2002

• SCC volume: 500 yd3

• Location: Cincinnati, OH

• Project Highlights:

– 5 stories, small footprint

– Curved panels, diamond

columns

– Dead areas within formwork

Photos provided by: Master Builders, 1-800-MBT-9990, www.masterbuilders.com

Page 13: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Case Example: Rosenthal Contemporary Art Center

Photos provided by: Master Builders, 1-800-MBT-9990, www.masterbuilders.com

Page 14: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Case Example: The Citadel

• Year built: 2002 to 2003

• SCC volume: 10,000 yd3

• Location: Charleston, SC

• Project Highlights:

– Continuous pour with

numerous blockouts

– 6” walls with 2 layers of

seismic reinforcement

Photo provided by: Master Builders, 1-800-MBT-9990, www.masterbuilders.com

Page 15: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Case Example: High-Five

• Year built: 2002 to 2006

• SCC volume: 25,000 yd3

• Location: Dallas, TX

• Project Highlights:

– Precast (20K), site cast (5K)

– 3000psi/8h, 6500psi/28d

– 30% fly ash, 7.5 sk total

Video provided by: CHRYSO Inc., P.O Box 6, Allen, Texas 75013, 1-800-936-7553, www.chrysoinc.com

Page 16: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Case Example: American-Indian Museum

• Year built: 2003

• SCC volume: 30,000 yd3

• Location: Wash., D.C.

• Project Highlights:

– Poured in single lift (30 ft)

– No right angles

– 75% reduction in column

pour time

Photo provided by: Sika Corporation, 201 Polito Ave, Lyndhurst, NJ 070701, 201-993-8800, www.sikaconstruction.com

Page 17: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Case Example: National Aquarium

• Year built: 2003

• SCC volume: 25,000 yd3

• Location: Baltimore, MD

• Project Highlights:

– Paintable surface, zero patching

– 80 ft columns in single lift

– SCC initially in columns, until

labor reduction realized, then

slabs, walls

Photo provided by: Sika Corporation, 201 Polito Ave, Lyndhurst, NJ 070701, 201-993-8800, www.sikaconstruction.com

Page 18: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Case Example: Tub Girders for T-Rex

• Year built: 2003 to 2008

• SCC volume: 10,000 yd3

ytd

• Location: Denver, CO

• Project Highlights:

– Poured from one side

– $1.67B project

– 7000 psi in 10h, 11,500 psi, 28d

Photo provided by: Master Builders, 1-800-MBT-9990, www.masterbuilders.com

Page 19: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Case Example: 2 Hour House

• Year built: 2005

• SCC volume: 47 yd3

• Location: Tyler, TX

• Project Highlights:

– 5 minute placement

– 22 minute set time

– Entire home constructed

in 2 hrs, 52 min, 29 sec.

Photo provided by: Master Builders, 1-800-MBT-9990, www.masterbuilders.com

Page 20: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Case Example: Trump International Tower

• Year built: 2006 to 2009

• SCC volume: 5,000 yd3

• Location: Chicago, IL

• Project Highlights:

– 5000 yd3 continuous mat pour

– Largest SCC pour to date

– 10,000 psi requirement

Photo provided by: Master Builders, 1-800-MBT-9990, www.masterbuilders.com

Page 21: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Case Example: Azure Tower

• Year built: 2006 to 2007

• SCC volume: 1,600 yd3

ytd

• Location: Dallas, TX

• Project Highlights:

– Largest continuous mat pour

– 51% fly ash replacement

– 9,000+psi, 5,000psi req.

Photo provided by: Lattimore Materials Company, www.lattimorematerials.com

Page 22: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Case Example: Comcast Building

• Year built: 2005 to 2007

• SCC volume: 40,000 yd3

• Location: Philadelphia, PA

• Project Highlights:

– Pumping 700 to 900 ft vertical

– Increased truck turn around

– Full compaction, reduced patching

Photo provided by: Sika Corporation, 201 Polito Ave, Lyndhurst, NJ 070701, 201-993-8800, www.sikaconstruction.com

Page 23: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

SCC Definition - PCI

A highly workable concrete that can flow

through densely reinforced or complex

structural elements under its own weight

and adequately fill voids without

segregation or excessive bleeding without

the need for vibration.

Interim Guideline for the use of Self-Consolidating

Concrete in the Precast/Prestressed Concrete

Institute member plants, TR-6-03, Precast/

Prestressed Concrete Institute.

Page 24: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

SCC Definition - ACI

Highly flowable, non-segregating concrete

that can spread into place, fill the formwork,

and encapsulate the reinforcement without

any mechanical consolidation.

ACI International, Committee 237 Self-Consolidating

Concrete, July 2003

Page 25: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

SCC Definition – ASTM

Concrete that can flow around reinforcement

and consolidate under its own weight without

additional effort and without exceeding

specified limits of segregation.

ASTM C125-06A Terminology

Page 26: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Innovation = Profitability?

• The business of technology

• What is your customer base?

• What is your market base?

• How to apply technology?

• Where are profits from

technology?

Video provided by: Lattimore Materials Company, 972-221-4646 www.lattimorematerials.com

Page 27: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Changes in Methods = Profitability?

• Versatile concrete placement

– Concrete flows into hard-to-reach places

• Earlier job completion – increased productivity?

• Reduce/eliminate vibration process

• Reduce concrete pumping time

– Minimize work/labor effort – less errors?

– Improve safety – lowers accident potential?

• More efficient use of labor resources

• Improve/optimize surface appearances

Page 28: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Seminar Overview

• Historical Perspective

• Current Market Status

• SCC Technology

• Testing and Measurement

• Bottom Line Economics

• Market Impact

• Getting Started

Page 29: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Precast Producers

Year Yards SCC Yards %

2000 23,000,000 50,000 0.22%

2001 23,000,000 200,000 0.87%

2002 22,500,000 1,000,000 4.4%

2003 20,700,000 2,000,000 9.7%

2004 21,500,000 3,000,000 14.0%

2005 23,900,000 3,500,000 14.6%

2006 26,000,000 5,000,000 19.2%

2007 28,500,000 7,500,000 26.3%

2008 30,000,000 8,000,000 26.7%

2009 27,500,000 9,000,000 32.7%

2010 28,000,000 10,000,000 35.7%

2011 26,000,000 11,000,000 42.3%

Statistics provided by: Master Builders, 1-800-MBT-9990, www.masterbuilders.com

Page 30: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Ready-Mix Producers

Year Yards SCC Yards % Incr. % Total

2000 395,613,794 0 0.00%

2001 406,091,077 0 0% 0.00%

2002 390,301,000 20,000 0% 0.01%

2003 404,333,000 850,000 4150% 0.21%

2004 431,498,000 2,800,000 229% 0.65%

2005 458,290,000 6,000,000 114% 1.31%

2006 456,412,000 10,000,000 67% 2.19%

2007 414,644,000 14,000,000 40% 3.38%

2008 351,673,000 16,000,000 14% 4.55%

2009 257,458,000 17,500,000 9% 6.80%

2010 258,484,000 18,000,000 3% 6.96%

2011 254,000,000 17,500,000 -3% 6.89%

Statistics provided by: National Ready Mixed Concrete Association, www.nrmca.org, December 2000 to 2010

Page 31: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Seminar Overview

• Historical Perspective

• Current Market Status

• SCC Technology

• Testing and Measurement

• Bottom Line Economics

• Market Impact

• Getting Started

Page 32: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

SCC Technology

• Technology vs. Concrete

• SCC Materials

• Admixture Chemistry

• Aggregate Gradation

• Cement and Pozzolans

• Precast Mix Proportioning

• Ready-Mix Proportioning

Video provided by: Lattimore Materials Company, 972-221-4646 www.lattimorematerials.com

Page 33: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

SCC Technology vs. SCC Concrete

• Workability cannot be measured under

current standards (until now…)

• No new engineering properties

• Concrete does not remember…

• Not a new concrete, despite of

marketing efforts!

Page 34: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

When is Concrete SCC?

SCC

Page 35: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

SCC Material Proportioning

• Normal to higher cement

factors

• Pozzolanic replacement

• Potentially lower coarse

aggregate volumes

• Polycarboxylate-based

superplasticizer

• Viscosity-modifying

admixture

Video provided by: Lattimore Materials Company, 972-221-4646 www.lattimorematerials.com

Page 36: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Admixture Chemistry

• Electrostatic Repulsion

– Electrical attachment to cement

– Grains repel each other

• Steric Hindrance

– Size of molecule prevents contact

– Admixture reacts longer

Page 37: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Cement and Water

Graphic supplied by: W.R. Grace, 62 Whittemore Ave, Cambridge, MA, 02140 617-876-1400, www.graceconstruction.com

Page 38: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Cement and Water

Graphic supplied by: W.R. Grace, 62 Whittemore Ave, Cambridge, MA, 02140 617-876-1400, www.graceconstruction.com

Page 39: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Cement and Water

Graphic supplied by: W.R. Grace, 62 Whittemore Ave, Cambridge, MA, 02140 617-876-1400, www.graceconstruction.com

Page 40: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Cement, Water, and Admixture

Page 41: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Viscosity-Modifying Admixtures (VMA)

• Thickening-Type

– Thickens concrete

making it cohesive

(molecular obstruction)

• No negative impact on

concrete properties VMA 1

VMA 1

VMA 1

VMA 1

VMA 1

VMA 1

VMA 1

H2O

H2O

H2O

H2O

H2O

H2O

Photos provided by: Master Builders, 1-800-MBT-9990, www.masterbuilders.com

Page 42: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Viscosity-Modifying Admixtures (VMA)

• Binding-Type

– Binds water in concrete

– More potent

– Controls bleeding

– Adds thixotropic properties

H2O

H2O

H2O

H2O

H2O

H2O

VMA 2

VMA 2

VMA 2 VMA 2

VMA 2 VMA 2

VMA 2

VMA 2

Graphic provided by: Master Builders, 1-800-MBT-9990, www.masterbuilders.com

Page 43: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Aggregate Gradation

• Aggregate grading vs. particle

packing

• Lots of models to choose from

• Make grading work for you

– Smooth grading = less paste

– Coarse/Gap grading = more paste

• Aggregate shape/texture

• Aggregates must move with paste

through forms and reinforcement

Page 44: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Ready-Mix Gradation

0.0

5.0

10.0

15.0

20.0

25.0

0.001 0.010 0.100 1.000

Sieve Size (in.)

% R

eta

ine

d

SCC

Normal Concrete

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Ready-Mix Gradation

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

80.0

90.0

100.0

0.001 0.010 0.100 1.000

Sieve Size (in.)

% P

as

sin

g

SCC

Normal Concrete

Page 46: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Cement and Pozzolans

• Higher performance concrete

• Lower cost per yard

• Cannot produce HPC without

• Increase in workability

– “ball bearing effect”

• More cohesive paste

Page 47: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Cement

Photo source unknown

Page 48: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Class C Fly Ash

Photo provided by: Boral Material Technologies Inc., 45 Northeast Loop 410, Suite 700, San Antonio, Texas 78216

Page 49: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Class F Fly Ash

Photo source unknown

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Precast Mix Proportioning

0% 0% Fly Ash%

$63.56 $56.72 Mix Cost

0.39 0.41 w/cm

1.0 fl. oz/cwt 0.0 fl. oz/cwt VMA

7.0 fl. oz/cwt 0.0 fl. oz/cwt Type F

1.0 fl. oz/cwt 14.5 fl. oz/cwt Type A

275 lb 250 lb Water

0 lb 0 lb Fly Ash

700 lb 610 lb Cement

1414 lb 1555 lb Fine Agg.

1529 lb 1696 lb Coarse Agg.

SCC Conventional Material

21%

$59.05

0.39

1.0 fl. oz/cwt

7.0 fl. oz/cwt

1.0 fl. oz/cwt

275 lb

147 lb

553 lb

1280 lb

1529 lb

SCC w/ pozz

Financial data from: Engineering News Record, December 6, 2007, www.enr.com

Page 51: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Ready-Mix Proportioning

Material Normal SCC SCC

Coarse Agg. 1696 lb 1466 lb 1690 lb

Int. Agg. 0 300 lb 0 lb

Fine Agg. 1534 lb 1253 lb 1540 lb

Cement 376 lb 388 lb 388 lb

Fly Ash 94 lb 129 lb 129 lb

Water 252 lb 267 gal 265 gal

AEA 0.0 fl. oz/cwt 0.0 fl. oz/cwt 0.5 fl. oz/cwt

Type A 4.0 fl. oz/cwt 0.0 fl. oz/cwt 0.0 fl. oz/cwt

Type F 0.0 fl. oz/cwt 8.0 fl. oz/cwt 8.0 fl. oz/cwt

VMA 0.0 fl. oz/cwt 0.0 fl. oz/cwt 2.0 fl. oz/cwt

Sack Content 5.0 sk/ 20% 5.5 sk/25% 5.5 sk/25%

Air Content 1.5% 1.5% 4.5%

Mix Cost $45.30 $54.61 $50.74

Financial data from: Engineering News Record, December 6, 2010, www.enr.com

Page 52: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Seminar Overview

• Historical Perspective

• Current Market Status

• SCC Technology

• Testing and Measurement

• Bottom Line Economics

• Market Impact

• Getting Started

Page 53: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Testing and Measurement

• Rheology Basics

• Test Methods

• QCQA Approach

– Precast

– Ready-Mix

Video provided by: Advanced Engineering Solutions, McKinney, Texas, 972-529-1951

Page 54: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Rheology Definitions

• Yield stress

– Pressure necessary to make

concrete begin to move

• Viscosity

– How fast concrete moves,

once yield stress is exceeded

Page 55: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Rheology Basics

Low Yield Stress Concrete High Yield Stress Concrete

Video provided by: Lattimore Materials Company, 972-221-4646 www.lattimorematerials.com

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Rheology Basics

Low Viscosity Concrete High Viscosity Concrete

Videos provided by: Master Builders, 1-800-MBT-9990, www.masterbuilders.com

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Rheology Basics

Sh

ea

r S

tre

ss, t

Shear Rate, g

Yield Stress, to

1

Plastic viscosity,h

Page 58: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Rheology Basics

Sh

ea

r S

tre

ss, t

Shear Rate, g

1

Plastic viscosity,h

1

Plastic viscosity,h

Page 59: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Rheology Basics

Sh

ea

r S

tre

ss, t

Shear Rate, g

Yield Stress, to

Page 60: Self-Consolidating · PDF file1. Recognize and understand the basic technology behind self-consolidating concrete 2. Evaluate the price and cost impacts on jobs using self-consolidating

Test Methods

• Several methods, no standard

– Slump Flow ASTM C1611

– Visual Stability Index ASTM C1611

– J-Ring ASTM C1621

– Col. Segregation ASTM C1610

– L-Box

• How to deal with job

specifications

• Laboratory qualification vs. field

acceptance

• Trained and qualified laboratory

personnel

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Test Method: Slump Flow (ASTM C1611)

Photo provided by: Master Builders, 1-800-MBT-9990, www.masterbuilders.com

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Test Method: Slump Flow (ASTM C1611)

Video and Photo provided by: Advanced Engineering Solutions, McKinney, Texas, 972-529-1951

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Test Method: Visual Stability Index

• Scale Rating System

• Flow Appearance

– Does concrete “creep” (good)

– Does concrete “run” (bad)

• Edge Halo

– No halo (good)

– or > half inch halo (bad)

• Surface Bleed

– “Floating” aggregate (good)

– “Sinking” aggregate (bad)

• Large Aggregate Distribution

– Even distribution (good)

– Aggregate in center or pushed to edge (bad)

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Stability Impact of a VMA

Photo provided by: Master Builders, 1-800-MBT-9990, www.masterbuilders.com

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Test Method: Visual Stability Index

Photo supplied by: W.R. Grace, 62 Whittemore Ave, Cambridge, MA, 02140 617-876-1400, www.graceconstruction.com

0 Highly Stable

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Test Method: Visual Stability Index

Photo supplied by: W.R. Grace, 62 Whittemore Ave, Cambridge, MA, 02140 617-876-1400, www.graceconstruction.com

1 Stable

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Test Method: Visual Stability Index

Photo supplied by: W.R. Grace, 62 Whittemore Ave, Cambridge, MA, 02140 617-876-1400, www.graceconstruction.com

2 Unstable

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Test Method: Visual Stability Index

Photo supplied by: W.R. Grace, 62 Whittemore Ave, Cambridge, MA, 02140 617-876-1400, www.graceconstruction.com

3 Unstable

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Test Method: J-Ring (ASTM C1621)

Photos and video provided by: Master Builders, 1-800-MBT-9990, www.masterbuilders.com

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Test Method: Column Segregation (ASTM C1610)

Photos provided by: Master Builders, 1-800-MBT-9990, www.masterbuilders.com

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Test Method: L-Box

Graphic source unknown

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Test Method: L-Box

Video provided by: Sika Corporation, 201 Polito Ave, Lyndhurst, NJ 070701, 201-993-8800, www.sikaconstruction.com

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Test Method Status

• ASTM Working on Standards

– Slump flow, VSI, T50 (ASTM C1611)

– J-Ring (ASTM C1621)

– Column seg. (ASTM C1610)

– L-Box (ASTM WK#)

• ACI Development

• PCI Interim Guidelines

• Impact on Test Methods?

– Cylinders, air, unit weight, etc.

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QC/QA for Precast

• Batching Elements

– Aggregate moisture

– Initial water slump

– Type of mixing equipment

– Length of mixing time

• Delivery Method

– Belt system

– Ready-mix truck

– Crane and bucket

– Pumping

Video supplied by: W.R. Grace, 62 Whittemore Ave, Cambridge, MA, 02140 617-876-1400, www.graceconstruction.com

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Why Develop a Model?

• Profitable for the Producer

– Maintain current margin

• More Profits for Contractor

– No incentive to change if profits

are “just as good”

• Decrease Cost for Owner

• Do Not Recreate the Wheel

– Fast financial assessment

– Scalable for size and scope

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QC/QA for Precast

• Placement Technique

– Use delivery energy

– Pour in one direction

• Tight and Level Forms

• Batching Speed =

Placement Speed

• Large Discharge =

Enhanced Flowing

Photos provided by: Master Builders, 1-800-MBT-9990, www.masterbuilders.com

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QC/QA for Ready-Mix

• Minimal Production Changes

– Margin for error is smaller

– Small differences

= big Impact

• Lab/Test Program

• Batching Elements

– Aggregate moisture

– Initial water slump

– Plant or site addition

– Load size

Video provided by: Advanced Engineering Solutions, McKinney, Texas, 972-529-1951

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QC/QA for Ready-Mix

• On-site

– Truck spacing

– Discharge method

– Placement technique

– Form tolerances

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QC/QA for Ready-Mix

• Testing On-site

– Slump flow

– Cylinders

– Air

– Temperature

– Unit weight

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Seminar Overview

• Historical Perspective

• Current Market Status

• SCC Technology

• Testing and Measurement

• Bottom Line Economics

• Market Impact

• Getting Started

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Bottom Line Economics

• Engineered Products are

Never Inexpensive

• Where Does SCC Generate

Profits?

– Producer/manufacturer

– Contractor

– Customer

– Owner

• How to Evaluate

Technology Investment

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Commercial Perspective: Historical/Present

Price

•Price per unit focus

Service

•Job focus

Quality

•Product focus

DANGER

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Commercial Perspective: Present/Future

Price

•Price per unit focus

Service

•Job focus

Quality

•Product focus

DANGER

Cost

•Cost per unit in-place

X

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When Concrete is a Commodity

• Where is the opportunity?

• Where is the competition?

• Migrate from commodity to

engineered product?

Price

•Price per unit focus

Service

•Job focus

Cost

•Cost per unit in-place

X

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Ready-Mix Model Overview

PRODUCER CONTRACTOR ADMIXTURE

CO

ST

S

1. Material

2. Production rate

1. Materials

2. Labor burden

3. Place and pour

1. Material

PR

OF

IT

1. Selling price

2. Margin

1. Selling Price

2. Margin

1. Selling price

2. Margin

DECISION

MODEL

PRODUCER CONTRACTOR ADMIXTURE

CO

ST

S

1. Material

2. Production rate

1. Materials

2. Labor burden

3. Place and pour

1. Material

PR

OF

IT

1. Selling price

2. Margin

1. Selling Price

2. Margin

1. Selling price

2. Margin

DECISION

MODEL

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Ready-Mix Model Inputs - Example

• 3000 ft2 post tension slab

• 96 yd3 total

• Normal concrete

– 4 hrs to place, 4 hrs to finish

– $86.59 yd3

• SCC

– 1 hr to place, 3 hrs to finish

– $95.90 yd3

• Pump vs. No Pump

Financial data from: Engineering News Record, December 6, 2006, www.enr.com

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Ready-Mix Model Inputs

Normal SCC

Time to Place 4.00 1.00

Time to Finish 4.00 3.00

Total man hours 48 22

Savings

$/man hour $27.65 $27.11 $0.54

Total Labor Cost $1,327.20 $596.40 $730.80

Financial data from: Engineering News Record, October 6, 2006, www.enr.com

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Ready-Mix Model Results

$0.00

$0.05

$0.10

$0.15

$0.20

$0.25

$0.30

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Hours

$/h

ou

r/sq

.ft

Conventional

SCC

Financial data from: Engineering News Record, December 6, 2006, www.enr.com

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Ready-Mix Model Results

Financial data from: Engineering News Record, December 6, 2006, www.enr.com

Normal SCC

Concrete $8,313 $9,206

Pump $968 $0

Labor $1,327 $596

Other $4,500 $4,800

Savings

Total Cost $15,107 $14,603 $505

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Ready-Mix Model Results

Gross Profit

Conventional $18,492.66

SCC $18,997.20

Difference $504.54 $/slab

$0.17 $/ft2

Is SCC Viable Solution? YES

Financial data from: Engineering News Record, December 6, 2006, www.enr.com

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Ready-Mix Model Results

• 4.5% Profit Increase

• 45% Reduction in

man hours

• Reduction/Eliminate

Pumping Costs

• Opportunity Costs?

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Precast Model Overview

Pouring efficiency

Patching minimization

Improved aesthetics

Flexibility in design

Safety

Form maintenance

Reputation

DECISION

MODEL

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Precast Model Inputs: Double T, 520 ft

Conventional SCC

Time to pour (hrs) 2.5 2

Total man hours 32.5 22

$/man hour $18.50 $18.50

Total Labor $601.25 $407.00

yd3/bed 125 137

Ft poured/bed 520 570

Savings

Labor Burden/ft $1.16 $0.71 $0.44

Labor Burden/yd3

$4.81 $2.97 $1.84

Data supplied by: Master Builders, 1-800-MBT-9990, www.masterbuilders.com

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Precast Model Inputs: Double-T, 520 ft

Conventional SCC

Time to patch (hrs) 9.5 9.5

Total man hours 19 9.5

$/man hour $18.50 $18.50

Total Labor $351.50 $175.75

yd3/bed 125 137

Ft poured/bed 520 570

Savings

Labor Burden/ft $0.68 $0.31 $0.37

Labor Burden/yd3

$2.81 $1.28 $1.53

Data supplied by: Master Builders, 1-800-MBT-9990, www.masterbuilders.com

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PreCast Model Inputs: Double-T, 520 ft

per yd3per ft.

Additional Cost of Materials $3.56 $0.85

Production Savings

Labor Time $1.84 $0.44

Vibration $1.53 $0.37

Patching $0.40 $0.10

Total $3.77 $0.91

Cost Improvement with SCC $0.21 $0.06

Data supplied by: Master Builders, 1-800-MBT-9990, www.masterbuilders.com

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Precast Model Results

• 20% reduction in pour time

• 32% reduction labor cost

• Increased bed length, 520

feet to 570 feet

• Extra Double-T produced

each day

• Minimized vibration costs

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Seminar Overview

• Historical Perspective

• Current Market Status

• SCC Technology

• Testing and Measurement

• Bottom Line Economics

• Market Impact

• Getting Started

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Market Impact

Video provided by: Master Builders, 1-800-MBT-9990, www.masterbuilders.com

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Market Impact

• Do not let stats fool you

– Trickle down technology

• Commodity to engineered

product

• Proprietary mix proportions

– Performance vs. prescription

• Answers to continual debate

– Higher price vs. lower cost

– Value added vs. definable value

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Value Added vs. Definable Value

Precast Producers

• Improved finished product

• Wear/tear on forms/equipment

• Safety and workers comp.

• Improved working environment

– Noise reduction

– Hazard reduction

• Patching material costs

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Value Added vs. Definable Value

Ready-Mix Producers

• Faster truck turn around

– Higher utilization

– Less time in hazard environment

• First mover opportunity

– Marketplace image

– Customer intimacy

• Placement problem solutions

– Less effort for placement

– Consolidation and congestion issues

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Value Added vs. Definable Value

Contractors

• Labor Demand

– Less people, same work

– Less exposure to hazard

• First mover opportunity

– Marketplace image

– Customer intimacy

• Equipment Demand

– Pump time improvement

– Higher production rates?

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Application Within the Precast Industry

Manufacturing Sophistication

Te

ch

nic

al A

bility

X

X X

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Application within the Ready-Mix Industry

Producer Sophistication

Te

ch

nic

al A

bility

•Small target market

•Sophistication is key

–Technical

–Economic

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Technology Acceptance

Time

Reference: “Hype Curve” adapted from WIRED, August 2002, p.042

Trough of

Disillusionment

Slope of

Enlightenment

Plateau of

Productivity

Peak of Inflated

Expectations

Technology

Trigger

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Seminar Overview

• Historical Perspective

• Current Market Status

• SCC Technology

• Testing and Measurement

• Bottom Line Economics

• Market Impact

• Getting Started

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Getting Started – Action Plan

• Questions for the way home:

– How does my company

approach technology?

– Do we have customers

(internal/external) who

understand cost vs. price?

– Can we sell those customers

(internal/external)?

– Who will champion/implement?

– Can I protect my technology/investment?

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Getting Started – Action Plan

• Questions once you get home:

– Can I actually make SCC in

the lab? In a plant/truck?

– Who will help?

– What production changes

are necessary?

– What metric will I use to prove

the value?

– Which internal/external

customers will I use for trial?

– How will the market react?

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Getting Started - Resources

Self-Compacting Concrete: Bibliography of Resources (250 Technical reports, journal articles, and references)

American Society for Testing and Materials Subcommittee C09.47, Self-Compacting Concrete

ACI International Committee 237, Self-Compacting Concrete

Center for Advanced Cement-Based Materials Proceedings of the 1st North American Conference on SCC

Precast/Prestressed Concrete Institute

Interim Guideline for the Use of SCC, TR-6-03

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Getting Started - Resources

Master Builders, 23700 Chagrin Blvd., Cleveland, OH

44122, 1-800-MBT-9990, www.masterbuilders.com

W.R. Grace, 62 Whittemore Ave, Cambridge, MA, 02140

617-876-1400, www.graceconstruction.com

Sika Corporation, 201 Polito Ave, Lyndhurst, NJ 070701,

201-993-8800, www.sikaconstruction.com

Euclid Chemical Company, 19218 Redwood Rd, Cleveland,

OH, 44110, 216-531-9222, www.euclidchemical.com

CHRYSO, P.O Box 6, Allen, Texas 75013, 1-800-936-

7553, www.chrysoinc.com

AXIM Concrete Technologies, 8282 Middlebranch Road

Middlebranch, OH 44652, 800-899-8795, www.aximconcrete.com

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Special Thanks and Recognition

• Jean Marie Keith, Account Executive, Sika Corporation, 315 Ebrite St.,

Mesquite, Texas 75149, 972-289-6480 www.sikaconstruction.com

• Lew Cook, General Manager-North America, Chryso, Inc., P.O Box 6,

Allen, Texas 75013, 1-800-936-7553, www.chrysoinc.com

• Joe Daczko, Product Line Manager, Master Builders, 23700 Chagrin Blvd.,

Cleveland, OH 44122, 1-800-MBT-9990, www.masterbuilders.com

• Bill Phelan, Senior Vice President of Marketing and Technical Services,

Euclid Chemical Company, 19218 Redwood Road, Cleveland, Ohio, 44110,

216-531-9222, www.euclidchemical.com

• Glenn Schaefer, Regional Product Manager, W.R. Grace, 62

Whittemore Ave, Cambridge, MA, 02140 617-876-1400,

www.graceconstruction.com

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Richard S. Szecsy, PhD, PE President & CEO

Texas Aggregates and Concrete Association

www.tx-taca.org

512-451-5100 phone

214-202-1379 cell

[email protected]

This concludes the American Institute of Architects

Continuing Education Systems Program.

Any Questions?