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Learn solutions for crack-free, joint-free and maintenance-free floors.
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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
