Solutions for Crack-Free, Joint-Free & Maintenance-Free Floors
1. SOLUTIONS FLOORS
for Crack-Free, Joint-Free & Maintenance-Free
By Matt Jabbari, M.S. Civil Engineer
CTS Cement Manufacturing Corp.
800-929-3939 Ext. 173
www.ctscement.com
2. Matt Jabbari
B.S. Civil Engineer University of Minnesota
M.S. Eng. Management Northeastern University
Design & Field Engineer
Millstone III Nuclear Power Plant; Waterford, CT
Research Engineer
W.R. Grace & Company; Cambridge, MA
Engineering Contractor, Public Works & Private
Site Development Company; Santa Ana, CA
Project Manager Consultant; P.W.
City of La-Canada-Flintridge, CA
Affiliations: ASCE, ACI, PTI, SEAOC, ICRI, and
Public Works Greenbook Sub-Committee Member
3. Typical Industries Requiring Perfect Floors
Pharmaceutical Companies
Distribution Centers: Target, K-Mart, Costco
Production & Manufacturing Facilities
Parts & Inventory Warehouses
Computer Production & Assembly Facilities
Food Warehouse & Distribution Centers
Beverage Production & Bottling Facilities
Meat & Poultry Grinding/Packaging Facilities
Anyone who wants to INCREASE
PRODUCTION and DECREASE
maintenance DOWN TIME!!!
9. There are FOUR FACTORS
that contribute to this
ONE TWO THREE FOUR
High ambient High concrete Low humidity High winds
temperatures temperatures
10. Water to Cement Ratio
200
Pounds
Water
500 Pounds
Cementitious
W/C = 200/500 = .40
11. Excess water in one cubic yard of concrete
with 500 pounds of cement
400 4
350
POUNDS OF WATER
3
300
2
250
1
200
150
100
50
0
.25 .30 .35 .40 .45 .50 .55 .60 .65 .70 .75
WATER C EMENT R ATIO
12. Learning Objectives
SHRINKAGE & CRACKING
Understand why traditional concrete shrinks, cracks, curls and needs joints
CURLING
Understand why Shrinkage-Compensating Concrete doesn’t
shrink, crack, curl or need joints
FUTURE JOINT MAINTENANCE COSTS
Consider joint spacing of 150’ by 150’
RETURN ON INVESTMENT
Learn how Shrinkage-Compensating
Concrete lowers initial and life-cycle costs
DISCUSS SOME TYPICAL APPLICATIONS
23. SHRINKAGE ZONE CHART
No Shrinkage / No Crack Zone
Shrinkage / Crack Zone
All panels were 50’ long by 6’ wide, 6” thick and had 7 days wet cure
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™)
28. PROBLEM: Number of Joints
PORTLAND SLAB SLAB
TYPICAL SLABS 210’ by 240’ 50,400 ft2
29. PROBLEM: Number of Joints
PORTLAND SLAB SLAB
Portland Concrete Shrinkage-Compensating
6270 linear ft. of joints 210 linear ft. of joints
TYPICAL SLABS 210’ by 240’ 50,400 ft2
30. PROBLEM: Number of Joints
PORTLAND SLAB SLAB
Typical 1 day pour
25,200 square feet
SAVES
OVER
A
MILE
OF
JOINTS
Portland Concrete Shrinkage-Compensating
6270 linear ft. of joints 210 linear ft. of joints
TYPICAL SLABS 210’ by 240’ 50,400 ft2
31. PROBLEM: Number of Joints
PORTLAND SLAB SLAB
Typical 1 day pour
25,200 square feet
$12,000 $2,000
Portland Concrete Shrinkage-Compensating
6270 linear ft. of joints 210 linear ft. of joints
TYPICAL SLABS 210’ by 240’ 50,400 ft2
36. PROBLEM: Cracks & Joints
Curling may occur
at the intersections
of all the joints
37. PROBLEM: Cracks & Joints
PORTLAND SLAB SLAB
Typical 1 day pour
25,200 square feet
SAVES
OVER
A
MILE
OF
JOINTS
Portland Concrete Shrinkage-Compensating
6270 linear ft. of joints 210 linear ft. of joints
TYPICAL SLABS 210’ by 240’ 50,400 ft2
39. Shrinkage Reducing Admixtures
but they should be called
Shrinkage Delaying Admixtures
.01
0
Elongation (%)
-.01
Shrinkage Reducing
-.02
-.03 Control
-.04
-.05
-.06
0 100 200 300 400 500 600
Time (days)
64. United National Foods Distribution Center
York, Pennsylvania
675,000 sq. ft.
Built in 2008
Computer and robotic
aided distribution center
65. High-Speed, High-Capacity Food Distribution
New York
New Jersey
Pennsylvania
Delaware
Maryland
Ohio
Virginia
and West Virginia
66. Albertsons Warehouse
Tolleson, Arizona
672,000 square feet
Joint spacing 162’
Pallet jacks
10 years old
NO REPAIRS
67. Toyota Parts Center
Ontario, California
760,000 ft2
Super Flat
Joint spacing 120’ by 120’
Built in 1995
$10,000/year repairs
in other centers
None needed here
70. When You Want Concrete
Without Joints
Without Cracks
Without Curling
Without Spalling
Without Maintenance
With Lower Initial Costs
With Lower Life-Cycle Costs
71. Same
Design, Contractor, and
Ready-Mix Company. The
only difference is Shrinkage-
Comp Cement.
Drying shrinkage tends to happen in the middle of the concrete like the centerline of this parking garage ramp.
Crazing cracks, map cracks, alligator cracks or whatever you call them.
Have the audience come up with the answers.
Only .25 W/C is required for proper cement hydration. Everything above the red line is “Water of convenience”. Its just there to help the contractor get the concrete placed. Even at .40 W/C which is low, there is an extra cubic foot of water that leaves a cubic yard of concrete. That’s 1 cubic foot out of 27. It no surprise that the concrete cracks. The only surprise is that it doesn’t crack worse.
Typically 100’ of concrete will shrink 5/8”.
In a perfect world the subgrade were perfectly flat and there would be no friction, so it would just get 5/8” smaller and there would be no cracks. That isn’t going to happen
There is restraint from the subgrade, reinforcement, and surrounding concrete.
So here is what happens. The concrete gets a little smaller and we get cracks. The total is still 5/8”. This is why we put joints in concrete. We try to anticipate where the cracks will be. Usually we guess right, but sometimes we guess wrong.
This is one of our cement mills where we make Calcium SulfoAluminate Cement not Portland Cement. We use the same basic raw ingredients but different ratios. We burn at different temperatures and grind for longer and get a cement with very different properties.
This is the test equipment. Bars are 3” by 3” by 10”.
Full scale testing on strips 50’ by 6’. The red curve is Portland and .15% rebars. The blue curve is Komponent with the same amount of rebars. The green curve is System-K with K-Fiber and no steel. The System-K performs at least as well as SCC and rebar. The length to width ratio is over 8 to 1. ACI recommends 1.5 to 1 and a maximum of 2 to 1. These are now almost a year old and get continuous forklift traffic. The Portland strip has many cracks and the other strips have none.
Two slabs about the same size as a typical grocery store.
Traditionally with 15’ joint spacing 6270 linear feet of joints.
SCC ban have 150’ joint spacing so only 459 linear feet of joints. That saves over a mile of joints on this relatively small slab. That’s a mile of joints that don’t have to be sawcut, don’t have to be filled, and don’t have to be maintained for the life of the building.
The curl will always be worst at the corners because it curls from two directions. When there is a point load or impact load four corner cracking is common. This project wasn’t even completed yet. Notice the differential vertical movement as well.
Flatter joints.
These are quotes from the admixture literature. So at 1 year you have only half as many cracks.