solutions for crack-free, joint-free & maintenance-free floors

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

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

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

Types of Cracks

CRACKS OVERVIEW

When water evaporates off the surface TOO RAPIDLY,

cracking usually occurs.

Why are cracks Important?

Plastic Shrinkage Cracks

Drying Shrinkage Cracks

Crazing Cracks

There are FOUR FACTORS that contribute to this

ONE

High ambient temperatures

TWO

High concrete temperatures

THREE

Low humidity

FOUR

High winds

Water to Cement Ratio

W/C = 200/500 = .40

200 Pounds Water

500 PoundsCementitious

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

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

Problem / Solution

SHRINKAGE & CRACKING

PROBLEM: Shrinkage & Cracking

Typical Drying Shrinkage is .05%= 5/8” in 100’

100’

PROBLEM: Shrinkage & Cracking

Without Resistance(Floating Space)A B

Total Shrinkage = A +B = 5/8”

99’ 11 3/8”

PROBLEM: Shrinkage & Cracking

But There is Resistance

Subgrade Friction

100’

PROBLEM: Shrinkage & Cracking

Shrinkage + Resistance = Cracks

Subgrade Friction

1/16” 1/16”

99’ 11 3/8”

1/8” 1/8” 1/8” 1/8”

SOLUTION:Shrinkage Compensating Cement

Tetracalcium Trialumino Sulfate

What is shrinkage compensating cement?

Type-K or Expansive Cement

85% Portland

15% C4A3S

Also known as Type K Concrete

Compensates for dry shrinkage of cement

SOLUTION:Shrinkage Compensating Cement

All you need to do is ADD 15% KOMPONENTto your Local Portland Cement

Portland Cement

CEMENT PRODUCTION PLANTCalcium Sulfo Aluminate Cement C4A3S

ASTM C 878

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

Types of joints and their purpose

JOINTS OVERVIEW

Tooled Joints

Saw-Cut Joints

Tooled Joints vs. Saw-Cut Joints

PROBLEM: Number of Joints

TYPICAL SLABS 210’ by 240’ 50,400 ft2

PORTLAND SLAB SLAB

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

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

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

PROBLEM: Cracks & Joints

PROBLEM: Cracks & Joints

Differential drying causes curling

Cracks (joints) form in “V” shape

Mitigates drying shrinkage cracks

Eliminates curling

SOLUTION:Shrinkage Compensating Cement

Problems / Solutions

CURLING OVERVIEW

Curling may occur at the intersections of all the joints

PROBLEM: Cracks & Joints

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

SOLUTION:Shrinkage Compensating Cement

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

Mitigates drying shrinkage cracks

Eliminates curling

SOLUTION:Shrinkage Compensating Cement

FUTURE JOINTS MAINTENANCE

COSTSPROBLEMS / SOLUTIONS

PROBLEM: Future Joint Maintenance

Typical Costly Epoxy Repair

PROBLEM: Future Joint Maintenance

Typical Spall Repair

By eliminating joints, you also eliminate the need for costly joint repair and maintenance

SOLUTION:Shrinkage Compensating Cement

NO JOINTS = NO REPAIRS

Cost Analysis

RETURN ON INVESTMENT

• 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

TYPICAL APPLICATIONS

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

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

Sofa ExpressPortland, Tennessee

April 2004

70,000 square feetMax Joint Spacing 130’

No cracks

Menards Home Improvement CentersOver a dozen locations done to date

4” slabs with 120’ by 160’ joint spacing

Floors only 4” thick

120’ by 160’

panels

No saw-cut joints!

Parking

Structures at

John Wayne Airport

John Wayne Airportwith Portland Cement and

Post-Tensioning

$1,000,000

Typical Costly Epoxy Repair

Basement moisture is the #1 cause of

mold

With Shrinkage-Compensating Cement and Post-Tensioning

Same Design, Contractor, and Ready-Mix Company.

The only difference is Shrinkage-Comp Cement.

THIS? OR THIS?

United National Foods Distribution CenterYork, Pennsylvania

675,000 sq. ft.Built in 2008

Computer and robotic aided distribution center

High-Speed, High-Capacity Food Distribution

New YorkNew Jersey

PennsylvaniaDelawareMaryland

OhioVirginia

and West Virginia

Albertsons WarehouseTolleson, Arizona

672,000 square feetJoint spacing 162’

Pallet jacks10 years old

NO REPAIRS

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

Conclusion

When You Want Concrete

Without Joints

Without Cracks

Without Curling

Without Spalling

Without Maintenance

With Lower Initial Costs

With Lower Life-Cycle Costs

Same Design, Contractor, and Ready-Mix Company.

The only difference is Shrinkage-Comp Cement.

THIS? OR THIS?

Q & A