ACIFC Conference · PDF fileACIFC Conference 2014 . ... - Suspended floors - Basements - Precast ... Replacement ground floor slab Bespoke design

ACIFC Conference 2014

Thursday 25 September

#ACIFCConf


Welcome and Introduction

Colin Shephard

ACIFC Chairman


Concrete Flooring for the Future

Colin Dowds, Lafarge Tarmac

Steve Crompton, Cemex

Jasen Gauld, Hanson



Colin Dowds, Lafarge Tarmac


Extensia Low shrink concrete

Created by/Date

Extensia Low Shrink Concrete

With 110 production plants and 17 dedicated

regional support teams, Lafarge Tarmac Readymix

Concrete is the UK’s leading supplier of innovative

concrete solutions.

Extensia – Why?

Drive from our international customers for a concrete with ….

Reduced Shrinkage

Drying Shrinkage

All concrete shrinks as the water in the concrete evaporates.

After 3 months the slab may have only undergone 30% of its long term drying

shrinkage.

For a well designed/manufactured concrete, long term shrinkage strains are in

the range of 400 to 600μm/m, this can be in excess of 800μm/m for poorly

designed concrete.

Meaning for a 6m x 6m slab this is equivalent to an overall unrestrained

shortening of 2.4 to 3.6mm, mitigated by restraint and creep to

approximately half these values.

Concrete drying shrinkage

Water

Cement paste

Curling

Results from differential shrinkage between

the top and bottom of the slab.

Moisture loss from the slab is primarily in

one direction towards the surface,

resulting in a moisture gradient that

causes the slab to curl.

Low Shrink Concrete Objective

Designed for use in commercial, industrial and retail floors

Design alternative to steel mesh and fibre reinforced floors

Designed to meet the following target criteria:

Flexural Strength 6N/mm2

Shrinkage value < 250μm/m

Shrinkage cracks with a width no greater than 0.25mm at 20oC @

60%RH

Saw cut at 20x20m sections (400m2)

No crack control steel

TR34 Concrete Specification Recommendation

To reduce shrinkage

Do not Specify Higher Strength than required

Do not Exceed W/C ratio of 0.55

Consider water-reducing admixtures

Specify the largest appropriate size of coarse aggregate (usually 20mm)

Do not specify a high minimum cement content

Optimum overall aggregate grading

Do not use aggregates that high levels drying shrinkage

TR34 Recommendations

TR34 Recommendations Extensia Performance

All concrete shrinks as the water in the concrete evaporates

to the atmosphere. The prediction of drying shrinkage is

complicated (see Hobbs and Parrot). (Pg 43)

One of the key modelling tools developed in the R&D

phase of Extensia enables us to fully understand the

drying process and therefore fully understand the

level of shrinkage we can expect Cement and water contents should be as low as possible,

consistent with the specified maximum free water/cement

ratio and the practicalities of placing and finishing. The

maximum water/cement ratio should be 0.55.

Extensia is produced with W/C ratio’s < 0.4

Although the cement paste is usually the only component of

the concrete that undergoes significant shrinkage, some

aggregates are known to have high levels of drying

shrinkage.

Understanding the pastes performance through

extensive R&D allows us to produce a concrete with

a shrinkage value of 250µm/m - 300µm/m. Only

aggregates that comply are used in the production of

Extensia. The combined grading of the coarse and fine aggregate

should be adjusted to minimise the water demand.

Aggregate content should be maximised by using an overall

grading that provides optimum packing and the minimum

effective surface area.

Extensia fine and coarse grading are controlled

through the batching process to optimise the

aggregate packing within the mix design. Both

shape and absorbsion rates are checked prior to

selection of any aggregates package for Extensia.

The main factors influencing drying shrinkage are volume of

cement paste and its water content.

Due to the specific design criteria and methodology

behind Extensia, paste volumes are carefully

calculated to ensure dimensional stability

Sub-base Preparation and Curing

Sub-Base preparation is critical so work must meet recommendations as laid

out in TR34 and BS 8204.

Although curing is of great importance in achieving a durable concrete floor, it

does not reduce drying shrinkage

However curing has a significantly beneficial effect on tensile strain capacity,

it is for this reason effective curing may reduce the risk of cracking.

Concepts Validation – Instrumented Panels

Final Validation

Drying Shrinkage

Drying Shrinkage Performance Comparison Graph

Extensia v Standard Concrete

-900.0

-800.0

-700.0

-600.0

-500.0

-400.0

-300.0

-200.0

-100.0

0.0

0.0 50.0 100.0 150.0 200.0 250.0 300.0Time (days)

µm

/m

Ext ensia

C 50 High

Perf o rmance

C 3 0

St andard

Extensia strength gain

Extensia Strength Gain Profile

0

10

20

30

40

50

60

70

80

90

1 2 3 5 7 14 21 28 56

Days

N/m

m2

Min

N/mm2

Max

N/mm2

Average

Slab Performance

Slab Performance

Request for Design Chemical Class (DC4) – Aggressive environments

Achieved through the addition of GGBS

Our design CIII/A + SR (36 – 65%) – 38%

Minimum W/C – 0.35

Lower W/C + Increased GGBS content = Adjust workability

Waste Industry

Charts & diagrams - if you need lots of space do not display the LT logo.

TITLE


Steve Crompton, Cemex


Developments in Concrete Technology for

Flooring Applications

Steve Crompton

Technical Director

Developments in Concrete Technology for

Flooring Applications

• Evolution - Self Compacting Concrete

• Microtech - High Abrasion Concrete

• Promptis - Rapid Hardening Concrete

• Sustainable Solutions

Ease of handling & placement

Self-flowing

Excellent early strength

Key benefits: Key benefits: Key benefits: Key benefits:

Ease of compaction

Ease of handling &

placement

Ease of finish

Gives a good even set

High strength

Self-compacting

Good surface-finish

Good pumpability

Tailored specifically designed mix

Comprehensive Technical support

Very easy to place

- Domestic foundations

- Mass commercial

- Trench Fill

- Commercial/Industrial

groundfloor slabs

- Domestic groundfloors

- Specials: Bridges, tunnels

- Congested/complex formwork

- Innovative/bespoke designs

- Structural Frames / walls

- Suspended floors

- Basements

- Precast

‘Building’ applications ‘Construction’ applications

High performance concrete

Typical applications: Typical applications: Typical applications: Typical applications:

INTRODUCING THE EVOLUTION RANGE

Evolution Flooring

Easily placed and economical

Self-levelling

Reduced labour

Smooth Finish

Enhanced consistence

Excellent strength

No vibration necessary

Reduced noise

Meets BS and EN Standards

Meets NHBC requirements

Domestic floors

Basements

Commercial floor slabs

Industrial floor slabs

29Copyright © 2011 CEMEX Research Group, AG

Easily Spread with Minimal Equipment


Dapple Bar in Use


Minimal Labour


Final Finishing


Compressive strength C32/40

Early strength > 30N/mm2 at 24

Hours

Flexural strength >5N/mm2

Consistence Class – SF1/ SF2

Setting time – comparable to

standard concrete

Cement type: Cem I or Cem II

EVOLUTION FLOORING – Properties

Ease of handling & placement

Self-flowing

Excellent early strength

Key benefits: Key benefits: Key benefits: Key benefits:

Ease of compaction

Ease of handling &

placement

Ease of finish

Gives a good even set

High strength

Self-compacting

Good surface-finish

Good pumpability

Tailored specifically designed mix

Comprehensive Technical support

Very easy to place

- Domestic foundations

- Mass commercial

- Trench Fill

- Commercial/Industrial

groundfloor slabs

- Domestic groundfloors

- Specials: Bridges, tunnels

- Congested/complex formwork

- Innovative/bespoke designs

- Structural Frames / walls

- Suspended floors

- Basements

- Precast

‘Building’ applications ‘Construction’ applications

High performance concrete

Typical applications: Typical applications: Typical applications: Typical applications:

INTRODUCING THE EVOLUTION RANGE


C32/40 SCC

40% pfa – Low heat generation

12mm poly fibres

583m3 completed in one pour

Extended working life – 200m2 area

40mm diameter reinforcement in two layers

Slab 3.3m in depth

High quality finish Exposed soffit and top face to take

waterproof system.

Evolution for Congested Reinforcement – Transfer Slab

Evolution – Strength Development

0

20

40

60

80

100

120

140

0 10 20 30 40 50 60

Age (Days)

Str

en

gth

(M

Pa

)

Flint control

Granite Control

Flint + MS

Granite + MS

LST + sand + MS

LSt + grit + Sand + MS

LST + sand + HMS

LSt + grit + Sand + HMS


• The UK’s biggest pump in full use arching over the Greenwich main road


• The final moments of the pour, with some minimal surface finishing

• The slab will now form part of the main station roof at Woolwich as

well as provide the foundation for a new shopping complex above


High impact and abrasion resistance

High compressive strength concrete

Low permeability

Increased flexural strengths

Increased cohesion

Recycling centres

Scrap yards

Chemical works

Container handling facilities

High Performance floors

Microtech – High Performance Floors

Microtech – Properties

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

RC32/40 PF SF HS S

L/st Microtech

mm

Mix

Abrasion Resistance

L/st HandFinished

L/st MouldedFace Finish

Gravel HandFinished

Gravel MouldedFace Finish

Microtech S High performance concrete for use in most

applications

Compressive strengths >60N/mm2

Early strength > 30N/mm2 at 24 Hours

Flexural strength >6N/mm2

Abrasion resistance improved by >70%

Consistence Class – S3 to SF1

Microtech HS Compressive strengths of 80N/mm2

Heavily loaded applications

Microtech SF Steel fibre reinforced

High impact

High abrasion

Improved post crack performance

Promptis – Rapid Hardening Concrete

High early strength

Up to 40N/mm2 in 24 hours

Can be loaded within 24 Hours

Bespoke mix design for specific properties

Standard cements

Consistence class S3/S4

Ideal solution for winter conditions

Handles like conventional concrete

Retains consistence for 120 minutes


Promptis – Early Strength Development

Applications

Crane bases

Access roads

Rail and road network

Repairs and Renovation


20mpa @ 20 hours

Replacement ground floor slab

Bespoke design

30m3 completed over-night

20N/mm2 reached in 15 hours

allowing project to proceed on time

Early Age Strength for Rapid Reinstatement


Early Age for Rapid Reinstatement

0

5

10

15

20

25

8 Hours 9 Hours 10 Hours 11 Hours 12 Hours 13 Hours 14 Hours 15 Hours 16 Hours 17 Hours 18 Hours

High Early Strength

Strength (N/mm2)

// CHANGES IN THE INDUSTRY – SUSTAINABILITY


ENGAGING CUSTOMERS AT DESIGN STAGE -

CARBON MODELLING

• CEMEX have developed a global tool for

measuring embodied CO2 against recognised

standards (PAS2050)

• We can now provide average CO2 data from every

location in the UK

• We can also simulate different mixes from plants to

give a very accurate picture of specific project work

• We can also work with you to design out CO2 in

concrete mixes and supply chain


LOW CARBON CONSTRUCTION IN CONCRETE

STANDARD CONCRETE MIX CEMEX SOLUTION

57kg

CO2 / tonne

+ no reinforcing

steel134kg

CO2 / tonne

IT CAN BE A REALITY


Jasen Gauld, Hanson


HANSON FastTrack and COLOURCRETE

Jasen Gauld FICT

Technical Sales Manager

Presentation Outline

What is Hanson FastTrack

Guidance for Designers

Case Study using Hanson FastTrack solutions

What is Hanson Colourcrete

Applications for Hanson Colourcrete

Case Studies using Hanson Colourcrete

Concrete‘s FastTrack Opportunity

Flexible and provides design opportunities to influence timing

properties for:

High early-strength

Potential to speed up construction

Accelerate construction sequencing

Increase productivity

FastTrack Concrete Scenarios

Powerfloat concrete floors (section 60)

Building Information Modeling – enabling the

plan in construction

Enable acceleration of critical sections on the

construction path

Enable progress and construction during rail

possession

Greater abrasive resistance from early age

trafficking

Winter concreting

Guidance For Designers

Carefully consider what it is you are trying to

achieve

Consider how you can best automate

construction processes

Speed in concrete batching, delivery,

placement, compaction & finishing is important

Correct mix design to compliment construction

processes and enable speed of production

Consider the alternatives and have standby

plans in place

Get the concrete to do its thing once placed and

cured

Permit the use of admixtures and pre validate

your mix design, examine the detail

FastTrack Case Study – Carlisle to Settle

Hanson won the British Ready-Mixed Concrete Association’s (BRMCA)

Gold Medal for excellence in customer service for 2013.

Supply to a rail viaduct repair project in Yorkshire.

Contractor Story Rail had to repair two under track slabs some 5km apart

on the historic Settle to Carlisle railway line in the Ribble Valley between

a Saturday afternoon and Sunday morning.


The concrete was delivered to a central point, pumped into rail-mounted

mixers then transported over 1.5km down the track in both directions for

onward pumping to the two locations.

Hanson’s technical services manager Terry Balmer:

“The mix design for the two 80m³ pours was critical. It had to be initially

free-flowing and capable of multi-stage pumping, then set rapidly to

enable follow on works to take place. And, to make things more difficult,

the temperature dropped below freezing during the early hours.”


Hanson’s technical services manager Terry Balmer continues:

“A critical part of the brief was to ensure the project did not over-run so

we used a mix containing steel fibres as a substitute for steel bar

reinforcing and worked through the night to ensure every load was

produced to the exact technical specification”

“The project is a good testimony to the value of Hanson FastTrack

profiling”.

Concrete‘s Colourcrete Opportunity

Flexible and provides creative design opportunities to influence visual

impact and improve the aesthetics of concrete appearance

Enables the creation of a feature

Demarked area

Sets a tone

Leave a legacy

Further applications for Hanson Colourcrete

Architectural design – create a feature or tone with the surroundings

Public buildings – e.g. museums, showrooms, schools, airports, etc

Walkways and cycle paths – brighter colours for safer pedestrians

and cyclists

Tramways – differentiate between road and tramway

Parking – delineate parking bays

Leisure – use in skate parks and sports centres

Sea defences – complement coastal areas

Industrial flooring – demarcation for safer working

Domestic – for driveways, patios and domestic use

Hanson Colourcrete – Architectural

Queen Elizabeth Olympic Park

Hanson Colourcrete – The Sainsbury Exhibitions Gallery

British Museum

Hanson Colourcrete – The Sainsbury Exhibitions Gallery

British Museum - Flooring Contractor quote:

“Working in partnership with Hanson ensured we were able to deliver a

high performance, integrally coloured concrete floor to a world-class

exhibition facility on time and in budget.

Hanson’s Colourcrete product gave excellent colour accuracy and

consistency and through an extensive mix design and validation process,

we were able to install the floor quickly and easily.”

Ed Lazenby – Managing Director

E J Lazenby Contracts Ltd

Hanson Colourcrete – Demarcation Concrete for Danger Zone

Hanson Colourcrete – Payers Park Folkestone

Hanson Colourcrete – Olympic Park Exposed Aggregate

Hanson Colourcrete – Exhibition at the Building Centre

Conclusions

Hanson FastTrack improves construction

through using innovative concretes to

accelerate the speed of build / finish on time

Hanson Colourcrete provides creativity in

concrete design, appearance and colour

Preferential treatment for low carbon concretes

and low carbon cement types

Early engagement with supply chain improves

surety of product in terms of quality and

delivery.

Coffee & Networking


#ACIFCConf

Panel Question Time

Chaired by Colin Shephard


Lunch


#ACIFCConf

The Future of Warehousing

Gwynne Richards - Apprise

Consulting Ltd


The future of

Warehousing

Gwynne Richards

Rugby

September 2014

The future

An acknowledgement that reducing warehousing and storage costs continues to be high on the agenda

E-commerce continues to grow significantly Automated stores and computerised systems make it possible to better manage

these facilities

Automation means bigger warehouses but not necessarily in terms of footprint –increasing land costs dictates higher warehouses

More regional warehouses to get closer to customers

Better logistics systems, improved supply chain integration, visibility and collaboration

‘Time compression’ reducing time consumed in business processes. Elimination of non-value-added time.

Ageing population - elder friendly warehousing

The Green agenda – BREEM regulations Replacement of thermally inefficient warehouses

Insulated warehouses with heating systems to stop ground from freezing

Robotics

Additive manufacturing

?74

BNP Paribas – Logistics at a glance 2014

The investment market has seen an incredible first half of the year with £2.1bn

transacted by the end of Q2, and twice the number of deals transacted, year-on-year.

The outlook for the remainder of the year is positive for the Big Shed logistics market.

The continued drive from online and omni-channel retailers to reconfigure their supply

chains will ensure that retailers and 3PLs dominate the take-up numbers for 2014.

Design and build to grow due to lack of available sheds

UK manufacturing has continued to rebound during 2014 seeing further demand from

the sector, particularly the automobile industry and its supply chain

Biggest deals in 2014 to date

Waitrose has pre-let 950,000 sq ft at Magna Park in Milton Keynes,

Primark has exchanged with London Metric for a 1.06m sq ft shed on their 70 acre East

Midlands site, known as Central A14.

The Range are believed to have found a home in Wiltshire to build their 750,000 sq ft Southern

Distribution Centre and should complete before year end.

Outside of the Midlands and South East, the occupational demand has been focussed on urban

logistics. These are smaller units at edge of town centres that are able to fulfil the ‘last-mile’

delivery function for many of the 3PLs.

The North West’s largest deal saw M&G let 162,116 sq ft to Mayr-Melnhof Packaging in

Deeside, whilst, in the South West, Farmfoods took 175,000 sq ft at Central Park, Severnside.

75Source: BNPPRE Research / BoE / IPD

76Source: BNPPRE Research / BoE / IPD

Mega-warehouses?

Quinn Glass Liverpool - 180 x 290 x 35 metres high

250,000 pallet capacity (Courtesy of Stocklin)

Multi-storey warehouses

CWT Commodity Hub

24 Penjuru Road

A multi-storey ramp-up logistics facility comprising a five-storey warehouse

with mezzanine office and a separate office block and a container yard

Gross floor area: 2,295,994 sq ft

78http://www.colliers.com/

AS/RS systems

79

https://www.youtube.com/watch?v=ubGEt9V09bo

https://www.youtube.com/watch?v=ubGEt9V09bo

John Lewis Milton Keynes – 62,000 m²

80

Other automation systems

Cimcorp 3D shuttle

No racks

Approximate cost: 300 sq. metres

857 stacks, 9,000 totes = €3m

https://www.youtube.com/watch?v=9emyxAwFdzQ

https://www.youtube.com/watch?v=9emyxAwFdzQ

Swisslog Autostore

82

https://www.youtube.com/watch?v=uxSca0u-9mA

https://www.youtube.com/watch?v=uxSca0u-9mA

Robo pick by Kiva

10,000 sq. metres - $4 - $6 million

https://www.youtube.com/watch?v=6zXOW6v0c8s

https://www.youtube.com/watch?v=6zXOW6v0c8s

Materials Handling Equipment

84

Jungheinrich navigation system

Seegrid AGV

Bendi Articulated truck

Jungheinrich RFID Technology – Logistics Videos – DCV-TV – DC Velocity.flv

Jungheinrich RFID Technology – Logistics Videos – DCV-TV – DC Velocity.flv

Robotics

85

Honda’s ASIMO

https://www.youtube.com/watch?v=sF4sm47cGw0

https://www.youtube.com/watch?v=sF4sm47cGw0

JCB Staffordshire

John Lewis Milton Keynes

The Green Agenda

3D printing

Will we actually need warehouses?

87

Can we 3D print the warehouse?

The future – as uncertain as it’s always been

http://www.youtube.com/watch?feature=player_embedded&v=V5XYdQrsPA8

http://www.youtube.com/watch?feature=player_embedded&v=V5XYdQrsPA8

1. Composite Concrete Slabs on Steel Decking

2. Maintenance and Repair Methods


Workshops

Thank You!


www.acifc.org


#ACIFCConf

Documents

ACIFC Conference · PDF fileACIFC Conference 2014 . ... - Suspended floors - Basements - Precast ... Replacement ground floor slab Bespoke design