self-consolidating · pdf file1. recognize and understand the basic technology behind...
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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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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.
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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
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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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Seminar Overview
• Historical Perspective
• Current Market Status
• SCC Technology
• Testing and Measurement
• Bottom Line Economics
• Market Impact
• Getting Started
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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
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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
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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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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
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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
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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
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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
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Case Example: Rosenthal Contemporary Art Center
Photos provided by: Master Builders, 1-800-MBT-9990, www.masterbuilders.com
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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.
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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
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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
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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
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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
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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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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
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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
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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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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
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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!
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When is Concrete SCC?
SCC
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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
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Admixture Chemistry
• Electrostatic Repulsion
– Electrical attachment to cement
– Grains repel each other
• Steric Hindrance
– Size of molecule prevents contact
– Admixture reacts longer
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Cement and Water
Graphic supplied by: W.R. Grace, 62 Whittemore Ave, Cambridge, MA, 02140 617-876-1400, www.graceconstruction.com
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Cement and Water
Graphic supplied by: W.R. Grace, 62 Whittemore Ave, Cambridge, MA, 02140 617-876-1400, www.graceconstruction.com
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Cement and Water
Graphic supplied by: W.R. Grace, 62 Whittemore Ave, Cambridge, MA, 02140 617-876-1400, www.graceconstruction.com
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Cement, Water, and Admixture
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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
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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
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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
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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
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Cement and Pozzolans
• Higher performance concrete
• Lower cost per yard
• Cannot produce HPC without
• Increase in workability
– “ball bearing effect”
• More cohesive paste
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Cement
Photo source unknown
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Class C Fly Ash
Photo provided by: Boral Material Technologies Inc., 45 Northeast Loop 410, Suite 700, San Antonio, Texas 78216
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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
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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
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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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Testing and Measurement
• Rheology Basics
• Test Methods
• QCQA Approach
– Precast
– Ready-Mix
Video provided by: Advanced Engineering Solutions, McKinney, Texas, 972-529-1951
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Rheology Definitions
• Yield stress
– Pressure necessary to make
concrete begin to move
• Viscosity
– How fast concrete moves,
once yield stress is exceeded
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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
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Rheology Basics
Sh
ea
r S
tre
ss, t
Shear Rate, g
1
Plastic viscosity,h
1
Plastic viscosity,h
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Rheology Basics
Sh
ea
r S
tre
ss, t
Shear Rate, g
Yield Stress, to
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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
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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
This concludes the American Institute of Architects
Continuing Education Systems Program.
Any Questions?