Mobile Ready Mix Among New Techniques for Today’s Contractor
Imagine finding a way to capture a bit more control in your business, while at the same time reducing costs. Impossible? Not with the advent of mobile ready mix. Learn how one CFA member has implemented such a process change and the overwhelming results.
The benefit is obvious – cost savings on concrete, no lost man-hours waiting for delivery, and elimination of concrete waste from ordering too much of the material – all a result of purchasing mobile mixing concrete trucks.
Modern Foundations — a residential service provider specializing in excavation, foundation, and flatwork services in the Baltimore and Washington D.C areas — implemented mobile ready mix in late July, beginning with four trucks and the production of about 80 to 130 yards of concrete a day. According to Bruce Neale, president of the $10 million company headquartered in Woodbine, Maryland, the idea stems from a single-family home project in Pennsylvania completed in the late 1980s.
“Mobile ready mix allows for the production only of what is needed and the concrete is always fresh,” said Neale. “Typically, we would have to wait for the inspector to approve the job, and then call the concrete company. Obviously, that scenario involves a lot of wasted time. With our own trucks, we are there waiting for the inspector to arrive. As soon as our work is approved, we can get started pouring concrete.”
To date, the mobile ready mix venture has been a success for Modern Foundations. Neale said they are currently producing 40 percent of their own concrete with the goal of producing 55 to 60 percent by next summer. It has been a profitable experience and they noticed results immediately.
“This has proven to me that we can successfully batch our own concrete and maximize our equipment usage,” said Neale. “We are able to send trucks out earlier and can adjust the slump as needed.”
However, as with any new operation, Neale’s team experienced some challenges initially. For example, the flatwork department had problems with the concrete creating a bleed order from setting too rapidly. Modern Foundations quickly determined that this problem was based on the type of cement they were using. After the cement was changed, this challenge was alleviated.
Neale anticipates that this winter will produce a new set of challenges for his team. “Our trucks do not have the opportunity to generate heat within the concrete like traditional barrel trucks do,” said Neale. “We are in the process of installing hot water heaters on the trucks and we will use different admixtures to help curb this problem.”
Recognizing the opportunities gained from this venture, Neale encourages other CFA members to determine if this would be a good fit for their company. He recommends ordering the concrete from someone who uses mobile trucks and investigating the maintenance of the truck from other users. Also, he explains that it is necessary to have a driver who is committed to the job, because the driver is the key to good concrete. Neale adds that for mobile ready mix to be profitable, 25 yards of concrete per day must be produced.
In addition to mobile ready mix, Modern Foundations has also implemented stone placement with truck-mounted conveyers. Referred to as ‘stone slinging,’ the new method entails the delivery of 20 tons of stone by a truck with a mounted conveyor. The process gets stone into the basement quicker, before the house is backfilled.
“We have been able to save on material losses, because every bit of stone gets in the basement and jobs can be completed quicker,” said Neale.
This zeal for innovation and technology is sure to be a benefit to CFA in 2003. As incoming President, Neale would like to strengthen CFA’s position as the voice of authority in the industry, to include participation and appearance by CFA members at code bodies. He also would like to grow the membership.
“I want to gain more quality contractors for the Association,” said Neale. “CFA should be a reliable source for builders, architects and engineers for information on residential concrete foundations. I want to use this knowledge and experience of members to help get proper codes in place.”
For more information about Modern Foundations, a CFA member since 1985, visit www.modernfoundations.com or contact Bruce Neale at 410-795-8877.
CFA Board of Directors Update
The CFA Committees and Board of Directors met for a full day on October 17 in Richmond, Virginia. Below is a summary of some of the more important discussions and actions from the meetings.
Structural Task Group
The board authorized the establishment of a Structural Task Group to research, study, and review current trends toward more conservative designs and to propose analysis, testing, and other actions that might help establish adequacy of the designs and construction methods that have proven effective for the past several decades. The plan of action, as identified by Executive Director Ed Sauter, would be to 1) Determine the extend and nature of current basement wall failures; 2) Research what testing and engineering has already been performed; 3) Determine design assumptions and perform engineering analysis on existing and new designs; and, 4) Propose testing, if necessary, to validate or confirm design assumptions and calculations.
Several engineers and contractors have agreed to serve on this task group. A survey of CFA members regarding their experience of failures will be the first task.
Codes and Standards
The CFA Standard, under development for the past two years, was approved with minor comment from the board. Following an editorial review, the document will be ready for publication. The format of the document follows the format of the IRC for easy correlation of the two documents. Copies will mailed out before the World of Concrete and the WOC will be the official unveiling of the document.
World of Concrete
The CFA and Concrete Homes Council will again share booth space, #2537, this year at the World of Concrete show in Las Vegas. The CFA, CHC and the Tilt-Up Concrete Association will share a 20’x 30’ island booth – the largest amount of space ever occupied since the show has been held. Voting for the “Basement of the Year” will again be held in the booth. A seating area for members to visit will also be featured.
Education
The Board gave a top priority rating to the CFA Education initiative for 2003. Management will begin the development of a series of educational modules based on the Foundation Fundamentals seminars that can be used for inhouse training, formal presentations, or self study. The modules will be on a CD basis and will include video footage, text, and multi-media presentations. The first step is to have a transcript made of the seminar. A script will be developed once the transcript has been made.
Concrete Homes Magazine
The CFA directory was recently published in Concrete Homes Magazine along with several articles about the CFA, CHC and concrete homes and basements. CFA has plenty of copies left. If you need additional copies, contact the CFA.
Summer Meetings
The summer meeting at Mount Hood was reviewed. It was thought to be an excellent program but there were suggestions for improvement. Most of the sessions were too short with too little time for questions or interaction. Next summer will feature longer lecture periods. Topics suggested included another presentation on mold (perhaps mold mitigation – and litigation), a management presentation by Doug Staebler, and a presentation on technology or the CFA Standard.
The round table format used for several years was also suggested as a means of delivery for one of the days. The smaller sessions make questions and participation easier. Some form of smaller sessions will be included in next summer’s meeting. Topics suggested for the round tables included safety programs, concrete decks, insulation systems for concrete walls, accountability, material and equipment acquisition, and job change orders.
The half day of education on above grade homes was very well attended. It will be retained for next year’s program.
A bus trip to the concrete beach homes under construction by CFA member Curt Fields will be scheduled for next summer’s meeting if possible.
Note: Any member of the CFA is welcome to participate in the CFA committee meetings. The committee meetings are where ideas, initiatives, and actions are developed to present to the board. The committees typically meet the morning of the board meetings. Plenty of networking also occurs during these meetings. Contact Ed Sauter or Jim Baty at CFA if you are interested.
Basement Contractors Oklahoma City, Oklahoma
Education and innovation the keys to success for building a market
“Constantly strive to obtain more knowledge,” may be the mantra for Mike Hancock of Basement Contractors, but “willingness to take a chance” are certainly the words most would use to describe the firm that has successfully built a basement market from scratch in Oklahoma.
With beginnings as a branch of Hancock Building and Design Inc., a residential construction company established to build homes with basements, Mike Hancock brings 30-plus years of foundation and excavation experience to Basement Contractors. When he moved his family to Oklahoma, he was amazed to find no basement market in the area. The perception was that basements were not feasible due to the rough terrain. Out to prove otherwise, Hancock began building homes with basements and Basement Contractors was born 20 custom homes later. Basement Contractors primarily services the Oklahoma City area and the company has officially installed basements for the past three years. They currently have a staff of about 15 employees and serve a wide area of the state — including Oklahoma City, Edmond, Norman, Yukon, Mustang, as well as Tulsa and Muskogee – and average approximately two basements per week. Although predominantly a residential company, Basement Contractors has experience with commercial work, such as a full service car wash as well as lube and tire centers. Typical home projects range in size from 1,500 to 3,000-square-feet, but they recently completed a project that used 700 yards of concrete with an 11-foot radius wall and a two-foot thick footing.
The unique challenge of building acceptance for a basement market truly sets Basement Contractors apart. Basements are atypical in Oklahoma due to the local fear of groundwater, clay and a stereotypical myth that all basements leak. However, despite these factors Basement Contractors saw basements as an opportunity and began to build the market with their own unique approach.
“Many do not realize the diverse terrain in Oklahoma,” said Hancock, “which presents interesting challenges to building a slab home. However, we recognized the opportunity to build homes by installing walkout basements.”
This determination has met many challenges, however. For example, the lot on a recent project had a slope of approximately 25 to 30 feet. To combat the terrain, Basement Contractors built a basement under a basement — essentially turning the home into a three-story house. They also have been innovative in their construction of basements under garage floors with the use of the ICF product “Lite Deck” to support the garage floor above.
The gumption and innovation of Basement Contractors has been successful – so successful that other area builders soon began to show interest in learning the necessary steps to build homes with basements. While many would have run from the thought of educating the competition, Basement Contractors once again embraced the learning process and took the initiative to lead seminars teaching other builders about basement construction.
“By educating others, our business gained a consulting edge, which increased our credibility with both builders and homeowners,” said Hancock. “Our efforts have helped build a strong market and acceptance of basements in the area as more and more builders are constructing homes with basements.”
Hancock added that developers also have gained a tremendous economic advantage to the new basement market as they are now able to build on a wide variety of terrains, which would otherwise be sold as less expensive lots – allowing formerly inexpensive lots to now serve as prime building sites.
Joining the CFA seemed like the next logical step for the Basement Contractors. “We decided to join the CFA because of the broad-based foundation knowledge in the membership,” Hancock said. “Further, we believe that CFA membership will set us apart from other companies by adding another level of credibility to our efforts.”
As a licensed engineer, Hancock appreciates the importance of education in business and as one of CFA’s newest members, he looks forward to the wealth of experience of the other members. For more information about the Basement Contractors, contact Mike Hancock at 405-359-0269.
Coastal Homes with Staying Power Coming to the Carolina Coast
Uniquely Disaster-Resistant Cast-in-place concrete homes promise to be the home of the future
Topsail Island, a prized vacation and living destination on North Carolina’s Treasure Coast, will now feature a cluster of innovative homes of the future built to endure the region’s hurricane season with unparalleled luxury and comfort.
Security Building Group (SBG) has six upscale town homes under construction that will be built entirely of cutting edge cast-in-place removable form concrete construction technology. This will provide homebuyers a powerful investment opportunity that will pay lifelong dividends through uniquely rock solid construction designed to weather storms and last for generations.
Concrete, the time-proven material of choice for commercial and residential building foundations, has now moved “above grade” to take center stage in the construction of residential homes with the highest investment protection in areas subject to catastrophic weather. Homes built using new cast-in-place concrete construction technologies bring significant cost savings because they are uniquely energy efficient, disaster resistant and low maintenance. Homeowners can expect a solid return on investment with a cast-in-place concrete home while enjoying the flexibility to choose any exterior and interior style they desire.
SBG is partnering with the Institute for Business & Home Safety (IBHS) to add even more disaster-resistant materials and techniques to these homes, as part of the award-winning “Fortified…for safer living” program. “We chose to partner with Security Building Group because they are an experienced leader with a great track record of building safe and solid homes for the future,” said Chuck Vance, IBHS Fortified Program Manager. IBHS, a national nonprofit disaster safety group headquartered in Tampa, Florida launched the “Fortified” program in Florida in 2000.
“The number one concern of homebuyers considering a coastal purchase is, ‘Can this house survive most hurricanes and weather events?’” said Dave Pfanmiller, partner of Security Building Group in Raleigh. “The best answer available anywhere is: Yes it will. Not only will your house be standing tall season after season, but you will save money along the way. You can’t find a more comfortable, secure, money-saving residential investment than one of our cast-in-place concrete homes.”
In addition to consuming at least 30 percent less energy than a stick-frame home, cast-in-place concrete homes bring the outstanding benefit of significantly lower home insurance premiums thanks to their unique resistance to fire, termites, rot, and ability to withstand impact damage not found in stickframe construction.
“Fortified” features added protection against wind-borne debris for windows and doors. And through the program’s inspection process, the home is certified upon completion as a “Fortified…for safer living” home. The following “Fortified” features are part of the Topsail Island homes:
• Reinforced continuous piles that elevate the home and critical utilities a minimum of two feet above the Base Flood Elevation (BFE) and ground level walls and stairs that can break away from the main structure.
• From the peak of the roof to the foot of the reinforced piles the home is connected to form a continuous load path capable of withstanding 130 mph winds.
• The windows, doors and other openings are protected by tested products that can withstand the impact of windborne debris without penetration of wind and water.
• An engineered roof truss system with an enhanced minimum 110 mph wind rated covering and a secondary moisture barrier, plus, twice the required underlayment, and a thicker plywood deck sheathing with a stronger holding nail and nailing pattern.
• Verification by a certified inspector that all required “Fortified” products and materials are installed correctly in accordance with manufacturer’s specifications or Fortified…for safer living requirements.
• The home and property is also verified to be a low risk hazard for exposure to wildfire.
Security Building Group, LLC (SBG) is a collaboration of experienced residential builders and concrete contractors in Raleigh whose mission is to build disaster-resistant homes in North Carolina. SBG is committed to concrete construction not only for its safety and security qualities, but because it is an energy-efficient, quiet, and environmentally responsible way to build better homes.
For more information, about Security Building Group and cast-in-place removable form concrete construction contact Dave Pfanmiller at 919-782-6789.
North Topsail Beach Town home Specifications:
• 3976 – 3966 Island Drive, North Topsail Beach, NC 28460
• Two-Story Town homes
• 45’ underground concrete pilings
• All concrete steel-reinforced construction
• Private Concrete Porch on first and second floors
• Stucco Exterior and Bahama Shutters
• Three bedrooms, 2.5 Baths, Kitchen, Living Room, and Dining Room
Bartley Receives Sawyer Award
Robert “Buck” Bartley of The Bartley Corporation was awarded the Robert D. Sawyer Distinguished Service Award at the CFA annual awards luncheon August 2 at The Resort at the Mountain in Welches, Oregon.
Buck, co-founder of The Bartley Corporation of Ashton, Maryland, is recognized for his devotion to the industry over several decades. He and his late wife Marcia and brother Tom formed The Bartley Corporation in 1970 and have been instrumental in introducing residential concrete foundation construction to the Mid-Atlantic region. Their industry efforts are mirrored by their own business success, their company now employs approximately 80 full-time employees in a multi-million dollar firm. CFA executive director Ed Sauter credits The Bartley Corporation with the dedication to implement new technologies that increase efficiency, as well as the willingness to share these innovations with others.
As one of the first members of the Concrete Foundations Association, Buck has been an active member and supporter since 1977 and has served on multiple committees for the organization. The only residential foundation concrete contractor on the ACI-332 (Residential Concrete) Committee until recent years, Buck has provided valuable input from a contractor’s perspective to the committee’s efforts don’t stop with ACI committee work. He is also active on the CFA Codes and Standards committee and is always at the forefront in bringing new ideas and technology to the mainstream for foundation construction.
The Robert D. Sawyer Award is named on behalf of Bob Sawyer, the first Executive Director of the CFA, and it is presented occasionally to a member of the concrete foundation industry whose contributions to the industry merit recognition. The award recognizes individuals who give tirelessly of their time and resources to serve the industry, as Bob Sawyer did for the association through its formative years. Bob is currently president of Wall Guard Corp., a manufacturer of foundation waterproofing systems, located in Oak Creek, Wisconsin.
“The Robert D. Sawyer Award is the highest honor given to any CFA member and Buck Bartley is very deserving of this award,” said Ed Sauter.
Other presentations were also made at the luncheon, including recognizing CFA members with long-standing memberships (5, 10, 15, 20, and 25 years). The coveted “basement of the year” award plaque was accepted by Mike Klingert on behalf of Erwin “Buck” Sweet of Perma-Structo, Inc., Sturtevant, Wisconsin. Buck is suffering from cancer and was unable to make the trip. The Basement of the Year award is voted on by members of the CFA in the CFA booth at the World of Concrete each year.
Finally, a plaque was presented to Ron Colvin as outgoing CFA president and certificates of appreciation for board service were presented to Barry Herbert, Mike Klingert, and Steve Rhinehart. Their service has been greatly appreciated and we hope they will continue to serve the association through committee work and networking.
Poured Walls Achieve Thermal Performance Equal to ICFs (with half the insulation)
The Concrete Foundations Association (CFA) participated in a Portland Cement Association (PCA) research project this past year studying the dynamic behavior of multiple wall systems. The conclusions from this report, PCA Residential Construction Energy Study For PCA R&D Serial No. 2518, are very beneficial for the contractors that are represented by our association. This article highlights that key pieces of information that can benefit the marketing of poured concrete walls particularly those above grade.
Study:
The PCA study was conducted at Construction Technology Laboratories in Skokie, IL and consisted of thermal computer modeling eleven different wall constructions typically seen in today’s housing market. These wall systems included standard wood frame walls, steel framed walls, AAC block walls, CMU walls, ICF walls and poured concrete walls with interior, exterior and internal (sandwich) insulation. It is important to note from this study that all of these constructions were based on their individual “typical” construction design. No attempt was made at increasing or improving the thermal efficiency of the constructions to balance the effective R-value of the individual systems. It is also important to note that these studies were conducted with an identical house model for all eleven wall systems. The majority of these studies were conducted with and identical house model for all eleven wall systems. The majority of this study was conducted without adjustments for air infiltration variation. This is an important characteristic to consider as other studies have shown the advantage of poured concrete walls over both block and framed walls in reducing air infiltration.
Results:
The following table shows the relationship of the major wall types in cost of HVAC for a typical climate year for three climates in the study. The table also shows the relationship of each major wall type to that of a wall constructed to the code required R-value. The three climates are a good representation of the extremes and means of the 25 climates studied in the research project.
8-in. poured concrete sandwich panel engineered so that both layers of concrete are identical in thickness without increasing the overall thickness of the constructed wall. A “typical” sandwich panel was also studied having a thicker layer of concrete on the interior and a thinner exterior layer. The “typical” wall shows a slight improvement over the “engineered” sandwich due to a thicker layer of concrete on the interior.
From the information above we can see that the study is concluding that the presence of concrete mass significantly lowers the cost of heating and cooling a home without considering air infiltration. In addition, we can clearly see that the performance of and ICF wall does not have any significant advantage over a properly insulated poured concrete wall despite it having roughly twice the material R-value.
The researchers then conducted a series of evaluations that added the affects of typical air-infiltration values for the various constructions. Three selected climates were studied for all wall systems. The following table show the relationship of the concrete wall specimens to wood-framed walls of various insulation ratings. This is done in order to develop a relationship between material R-value and “true” thermal performance, which incorporates thermal mass.
From this table, we can see that both the ICF walls and the insulated poured concrete walls perform better than wood frame walls insulated to an R-38. It is not economically feasible to construct a house from 2×10 or 2×12 walls insulated R-30 or R-38. From this study we can conclude that traditional methods used to construct poured concrete walls having insulation either on the interior, exterior or in the center of the wall produces a wall construction that betters the performance of these two framed walls. At the same time, the poured concrete walls maintain economic feasibility in addition to their aesthetic continuity.
A study of the comparison between the “traditional” poured concrete walls and the ICF walls shows little relative significance between the five wall types in terms of HVAC operation costs. This study, as stated previously, was conducted using traditional construction design for all of the wall types. This means that the ICF walls consisted of 4-in. of insulation for the “flat panel” system. In all three “traditional” poured concrete walls, only 2-in. of insulation was used. Therefore we see that the minimal benefit of the ICF wall over the poured wall is due to the construction having roughly twice the initial R-value.
Conclusion:
This study shows that significant benefits are achieved by constructing homes with massive concrete walls. The combination of insulation value with reduced air-infiltration is then bolstered by the fly-wheel or temperature dampening effect of thermal mass to produce HVAC energy costs that are significantly lower than other “traditional” methods of construction as well as the code minimum values throughout the country. This study further suggests that the highest advantage is given to walls that combine a higher initial R-value with concrete mass as well as those that combine continuous insulation with a larger mass body on the interior side of the insulation. The location of a majority of the concrete mass adjacent to an interior space results in the highest percentage increase of performance when compared to the material insulation alone that is placed into it. This means that poured concrete walls with insulation placed on the outside or placed internally so that there is a significant amount of concrete adjacent to the interior space achieves the greatest amount of thermal performance per insulation value. Although ICF’s performed with the lowest utility bills by a small margin, their higher initial R-value combined with thermal mass is not as significant an increase as with the poured walls.
For more information on this information on this study or to receive a copy contact Jim Baty, Technical Director for the Concrete Foundation Association at 319-895-6940.
Easton Receives Lifetime Achievement Award
The CFA presented Jack Easton, owner and co-founder of Durand Forms, Inc. of Durand, Michigan its first Lifetime Achievement Award at the CFA Summer Meeting luncheon in Niagara Falls, Canada last July. Easton was recognized as a leader in the concrete and aluminum forms industry.
The award was presented by long-time Durand salesman and former CFA Executive Director Bob Sawyer. Sawyer said that through Jack’s many years of hard work and dedication he not only put Durand on the map, he also helped thousands of contractors build their businesses.
The Lifetime Achievement Award was created by the CFA to recognize individuals who have devoted a great part of their life to improving the concrete foundation business. Jack is certainly deserving of this recognition.
CFA Directors Elected
Two new directors were elected and two incumbents were reelected at the CFA Annual meeting held in conjunction with the Summer Meeting in Niagara Falls, Ontario. Reelected to three year terms were Arie Van Wyk, Van Wyk’s, Inc. of Waldo, Wisconsin and Gary Moore of Moore & Cormier Construction, Ltd., Dartmouth, Nova Scotia.
Elected to their first 3 year terms were Richard Crosby of Crosby’s NE Foundation Company, Branford, Connecticut and Jim Bartley of The Bartley Corporation, Ashton, Maryland. The CFA wants to welcome the new directors.
The associates council also elected two representatives to the board. Steve Rhinehart of Wall Ties and Forms and J. Kevin Van Gilder of Koch Waterproofing Solutions are serving alternating 2-year terms.
The CFA would also like to thank outgoing directors Kirby Justesen of Formco Foundation, West Jordan, Utah and Bill Mulready of C & B Foundations, Bethlehem, Connecticut for their contributions over the past years. Service on the CFA board is costly in terms of time and money and their efforts have helped make the association stronger.
Understanding Fabric Formwork
The use of fabric to form concrete is a very new technology. In fact, one of the first articles published on this method appeared in the October 1998 issue of “Concrete Facts”. Since that article appeared, considerable progress has been made, and fabric forming is finding various economic applications throughout North America.
This article will examine fabric forming, the progress made over the last two years, where fabric has an economic advantage, and what future it’s future will be.
Understanding Fabric Forming
Rigid materials such as dimensional lumber, plywood, or aluminum are conventionally used to restrain the fluid forces of concrete. In order to restrain these forces, the form will have tension forces on one surface, compressive forces on the other surface, and a neutral plane between the two surfaces.
Fabric, however, can only operate in tension and as a result can be an extremely efficient method of forming concrete. Fabric weighs approximately 1/300th that of dimensional lumber. However, in the world of concrete, nothing is “free”. Pressure is pressure, and pressure in fabric results in bulging or deflection. This means that fabric can only be used where the bulging is not detrimental to the finished concrete.
Using Fabric to Form Footings
To use fabric to form footings, the two edges of the fabric are supported with 2x4s or #5 rebar using a bracing system (called Fast-Yokes), and the concrete is placed into the fabric. In this case, the bulging of the fabric is not a disadvantage, and indeed the ability of the fabric to deform to the uneven ground becomes an advantage compared with rigid forming materials. The diagram below shows the shape the footing fabric takes when under the concrete pressure.
Advantages of Fabric in Forming Footings
- Less weight – fabric weights approximately 1/300th that of a conventional rigid form
- Less expensive – fabric is approximately 1/25th the cost of dimensional lumber. This may make the use of fabric a viable option, especially when the cost of moving the lumber from job to job is taken into consideration
- Stay in place form – As the fabric is left in place, the cost of stripping the forming lumber is eliminated.
- Waterproofing membrane – the fabric prevents the wicking of water up into the footing (testing of this factor has not been completed).
- Adaptable to uneven ground conditions – the weight of the concrete on the fabric ensures that the footing forms conform perfectly with uneven ground conditions. This makes the system ideal for use on uneven ground.
- Improves the quality of concrete – in the summer, the fabric prevents the rapid drying of the concrete, and in the winter, the fabric prevents the contamination of the concrete with mud and excess water.
- Stakeless system – as the concrete pressures are held by the fabric and the Fast-Yokes, there is no requirement for stakes to hold the concrete pressure. Small stakes are only required to locate the Fast-Yokes.
Where is Fabric Forming of Footings Competitive
- Deeper footings – With deeper footings, the cost of lumber and labor to install and strip the forms increases significantly. With fabric, the weight of the fabric and the labor to install remain constant, regardless of the footing height. Footing heights of up to 30″ are achieved with fabric.
- Uneven ground – Using lumber to conform to uneven ground is expensive, both from a lumber and labor standpoint. fabric adapts perfectly to uneven ground with minimal labor and inexpensive fabric. As well, the Fast-Yokes are easily adjusted both vertically and horizontally.
- Rocky ground – Driving stakes in rocky ground is extremely difficult, and sometimes impossible. Fastfoot is a stakeless system, and in rocky conditions can save thousands of dollars.
- Accuracy – The Fast-Yokes are easily adjusted and enable a high degree of footing accuracy.
- Curved footings – #5 or # rebar is bent to the desired radius, and placed in the Fast-Yokes. The Fastfabric is attached to the rebar by wrapping around the bar, and stitching with a 3″ nail. Fabric forming is about 1/3 the cost of conventional methods.
- Footing pads – Fastbags are an economic solution to forming footing pads, as they replace short lengths of lumber which are normally wasted on the jobsite
Where Fabric Forming of Footings is NOT Competitive
- Shallow footings with level excavations – The contractor will not experience significant savings if his footings are shallow, and he can reuse his 2x4s or 2x6s on the jobsite. Form-A-Drain is an excellent product for this situation.
- Trenched footings – Fabric forming is not suitable in this situation.
- Production forming – If a contractor has already invested in conventional footing forms, he may be reluctant to invest in the Fast-Yoke bracing system.
The Future of Fabric Forming
The following items provide some indication as to the future on fabric forming in the concrete industry:
- Carbon reinforced fabric – carbon fibers woven into the fabric will eliminate the need for steel reinforcing in the concrete. As the strength of the reinforcing is directly proportional to the square of the distance from the neutral plane, the fabric becomes an excellent location for the concrete reinforcement.
- Fastfabric DPM – Using the fabric as a damp proof membrane (DPM) that ‘blankets’ the footing and prevents water from wicking into the concrete will become an important feature of footing forming design in the future; this will allow builders to construct drier, healthier concrete structures and interior spaces.
- Fabwall – This wall forming system uses a waterproof fabric on the outside, and rigid insulation on the inside. A drop stitch in the fabric acts as the tie. This fabric based wall form has significant advantages:
- The thickness of EPS or XPS is determined by insulation requirements, not concrete pressure (i.e., the tie spacing can be reduced to accommodate concrete pressure)
- The form can be shipped flat, minimizing storage and shipping costs
- The form is pre-manufactured – no labor is needed to install ties on the job site
- The form panel size is not limited (in sizes up to 10′ high and 4′ wide), further reducing labor costs
- No stripping, as the forms are left in place
- No damp proofing, as the fabric is a damp proofing membrane.
CFA Announces Foundation Fundamentals Venues
The Concrete Foundations Association announced the venues for the next two Foundation Fundamentals Seminars. The fall seminar will be held on Saturday, October 19, 2002 at the Richmond Marriott West, located at 4240 Dominion Blvd. Glen Allen, Virginia. The seminar will have a slightly different twist than previous seminars in that the noon luncheon will be extended by 30 minutes and will be held in conjunction with a mini trade show from area vendors.
The CFA committees and board of directors will meet the day prior the seminar and will be feature a 2 hours management seminar. The CFA is always looking for additional committee volunteers. If you have some time to give, plan to attend the management seminar and sit in on the committee meetings.
The spring Foundation Fundamentals seminar will be held on Saturday, April 12, 2003 at the Embassy Suites Hotel, Denver, South at the Denver Tech Center, 10250 E. Costilla Avenue, Englewood, Colorado. The CFA committees and board of directors will meet on Friday before the seminar.
Look for registration forms for both events in future newsletters and on-line at www.cfawalls.org beginning around 3 months before the event. Flyers will also be mailed to all CFA members.
