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Concrete Casting News from the Hill and Griffith Company

Prestressed Concrete Pressure Pipe & Concrete Steel Pressure Pipe, Review of AWWA Standard for Potable Water

Posted by Hill and Griffith Company on May 24, 2019 10:06:05 PM

"The forms shall be cleaned thoroughly and coated with a form-release agent before each use."

Concrete Pressure Pipr 101

There are two types of prestressed concrete steel-cylinder pipe:

(1) the lined-cylinder type, with a core composed of a steel cylinder lined with concrete and subsequently wire-wrapped directly on the steel cylinder and coated with mortar; and

(2) the embedded-cylinder type, with a core composed of a steel cylinder encased in concrete and subsequently wire-wrapped on the exterior concrete surface and coated with cement mortar.

(Image from PUBLIC WORKS Magazine.)

I. Introduction

I.A. Background

 

The lined-cylinder type, which was first used in the United States in 1942, is furnished in sizes from 16 in. (410 mm) to 60 in. (1,520 mm). The embedded-cylinder type, which was developed later and first installed in 1953, is most commonly manufactured in sizes 48 in. (1,220 mm) and larger. Both types are designed for the specific combination of internal pressure and external load required for the project in accordance with the procedures outlined in ANSI/AWWA C304, Standard for Design of Prestressed Concrete Cylinder Pipe. Prestressed concrete steel-cylinder pipe is used for transmission mains, distribution feeder mains, pressure siphons (including river crossings), penstocks, industrial pressure lines, water intake lines, and other applications. In the manufacture of lined-cylinder pipe, the first step is to fabricate and hydrostatically test the steel cylinder with joint rings attached. The cylinder is then lined with concrete to form the core. The concrete is placed either centrifugally, by vertical casting, or by a radial compaction method. The concrete lining is cured and high-tensile wire is wrapped around the core directly on the steel cylinder. For a selected wire size, the tension and spacing of the wire are controlled to produce a predetermined residual compression in the core to meet design requirements. The wrapped core is then covered with a dense premixed mortar coating applied by a mechanical impact method. In the manufacture of embedded-cylinder pipe, the cylinder and joint rings are constructed and tested in the same manner as lined-cylinder pipe. The cylinder is encased in concrete by vertical casting and mechanical vibration to constitute the core. After curing, the wire reinforcement is wound under tension in one or more layers around the outside of the concrete core containing the cylinder, instead of directly on the cylinder. The exterior coating of premixed mortar is placed by impaction. 

Concrete Pressure Pipe Basics

(Image from PUBLIC WORKS Magazine.)

4.6.5 Concrete for pipe core.

4.6.5.1 General. The concrete in the cores may be placed by the centrifugal method, by the vertical casting method, or by other approved methods.

4.6.5.10 Placing concrete by vertical casting method. The concrete lining or core shall be cast on-end on a cast-iron or steel base ring with rigid steel collapsible forms for the concrete surfaces. The forms shall be designed to ensure that they will have smooth contact surfaces, tight joints, and that they will be firmly and accurately held in proper position without distortion during the placing of the concrete. The forms shall be designed to allow the pipe core to be removed without damaging the surfaces of the concrete. The forms shall be cleaned thoroughly and coated with a form-release agent before each use.

(Remember that any concrete form release used for potable water needs to be NSF approved, like Grifcote LV-50 Plus.)

The transporting and placing of concrete shall be carried out by methods that will not cause the separation of concrete materials or the displacement of the steel cylinder or forms from their proper positions. Adequate methods of mechanical vibration shall be used to compact the concrete in the forms and to ensure satisfactory surfaces. 


Precast Concrete In The Google and NPCA News:

Precast Products - National Precast Concrete Association

Precast Concrete Pipe - National Precast Concrete Association

Precast Concrete Pipe Durability - American Concrete Pipe Association


Hill and Griffith Customer Service

We're known for our hands on approach. Let us visit your plant and recommend concrete release agents, packerhead concrete form releases, concrete form seasoning, potable water concrete form release, non-petroleum concrete form release, biodegradable concrete form release, rust inhibitors, NSF potable water concrete release agents and concrete dissolver products that suit your needs.

Hill and Griffith Samples

Product Samples

We are pleased to provide samples in quantities large enough to allow you to "try before you buy."
Contact Us »

 

Hill and Griffith Customer Service

Technical Services & Support

On-site casting defect investigations, product testing, machine start-ups and much more. Also, lab facilities are available to provide testing upon request.
Contact Us »

 

Bulletins and Technical Papers for Concrete Casting Products

 

Tags: Concrete Form Release Agents, Concrete Release Agents, Concrete Forms, Concrete Casting Supplies, Concrete Form Release, NSF Potable Water Concrete Release Agents, Grifcote LV-50 Plus, Prestressed Concrete Pressure Pipe, Concrete Steel Pressure Pipe, AWWA

ACPA Education Review: "Concrete Pipe – Pre & Post Pour Inspections"

Posted by Hill and Griffith Company on Apr 18, 2019 3:21:42 PM

The American Concrete Pipe Association's PPT, "Pre & Post Pour Inspections" contains information on Documentation, Pre-Pour Inspection of Equipment & Reinforcement, and Post-Pour Inspection of Stripping, Handling, Visual & Dimensions 

This is an excellent presentation of all the steps involved in producing high-quality concrete pipe. 

Concrete Pipe Pre Pour Documentation
Go to this link to download the PowerPoint.

Download a PDF.


Concrete Pipe Pre Pour Form Release

Concrete Pipe Manufacturing Pre-Pour Inspection - Form Release: Application methods, brush, spray; How much is enough??, Too Little, Too Much, Affects concrete finish, may affect curing

 

Concrete Pipe Pre Pour Barrier Form Release

Concrete Pipe Manufacturing Pre-Pour Inspection - Form Release: Barrier (non-reactive); Examples, Petroleum-based diesel, heating oils, used crankcase oil;

Advantages, Creates a physical barrier between form and fresh concrete;

Disadvantages, Need heavy application for easy release (200-400 ft2/gal), Can cause staining and bugholes, May not meet VOC requirements, Can cause buildup on forms

Concrete Pipe Pre Pour Chemically Reactive Form Release

Concrete Pipe Manufacturing Pre-Pour Inspection - Form Release: Chemically Reactive; Examples, Fatty acids (vegetable and mineral oils) are chemically reactive agents that combine with calcium in fresh cement paste to produce a soap-like film between the concrete and the form;

Advantages, Prevents bonding of concrete to form, Ultra-thin Layer (Approximately 0.005”), Reduce bugholes, stains, dusting, Typically meets VOC requirements (verify)

Disadvantages, Typically more costly per gallon

Concrete Pipe Pre Pour Seasoning

Concrete Pipe Manufacturing Pre-Pour Inspection - Seasoning

1. Remove protective coating to prevent staining, sticking, poor finish

  • Wear off during production
  • Solvents
  • Grind
  • Blast

2. Apply high fatty acid concentrate release agent; Let it react (forms metallic soap barrier). If using a barrier agent, use it for seasoning.

3. Ideally allow 24-hr sit-time

4. Apply release agent

5. Put into use

Concrete Pipe Post Pour Bug Holes

The American Concrete Pipe Association was originally conceived in 1907 by a small group of concrete farm drain tile manufacturers as the Interstate Cement Tile Manufacturers Association in Ames, Iowa.

The group needed some means of exchanging ideas and establishing a high quality, standardized products. In 1914, the organization was renamed the American Concrete Pipe Association. Throughout the 20th century, the concrete pipe industry has experienced tremendous growth. As more and more people moved from farms to cities, it created increased demand for concrete sewer and drainage products. The introduction of the automobile and subsequent highway development extended the uses of concrete pipe storm drains and culverts. There are currently over 400 plants operated by ACPA members in the United States and Canada. Over 40 countries are represented in the membership of the American Concrete Pipe Association. ACPA’s international headquarters are located in Irving, Texas USA.


Precast Concrete Manufacturing Resources from the American Concrete Pipe Association

14 Reasons to Choose Concrete Pipe

Concrete Pipe Design Manual

Concrete Pipe Specifications


Hill and Griffith Customer Service

We're known for our hands-on approach. Let us visit your plant and recommend concrete release agents, packerhead concrete form releases, concrete form seasoning, potable water and non-petroleum concrete form release, biodegradable releases, rust inhibitors and concrete dissolver products that suit your needs.

Hill and Griffith Samples

Product Samples

We are pleased to provide samples in quantities large enough to allow you to "try before you buy."
Contact Us »

 

Hill and Griffith Customer Service

Technical Services & Support

On-site casting defect investigations, product testing, machine start-ups and much more. Also, lab facilities are available to provide testing upon request.
Contact Us »

 

Bulletins and Technical Papers for Concrete Casting Products 

Tags: Concrete Form Release Agents, Concrete Release Agents, Concrete Forms, Concrete Casting Supplies, Concrete Form Release, American Concrete Pipe Association

Article Review: "Concrete Pipe – Health and Safety  in Severe Weather Conditions"

Posted by Hill and Griffith Company on Apr 11, 2019 4:48:45 PM

After more than 175 years, concrete pipe continues to be a product of choice for specifiers, contractors, and design engineers.

Throughout its 111-year history, the American Concrete Pipe Association and its members have met the demands of infrastructure owners while improving the quality and performance of concrete drainage and collection systems through advancements in product design, plant production, and concrete mixes. Contemporary de-signs of production plants in automated and robotic facilities ensure quality of products, health and safety, especially built to overcome severe weather conditions.

Concrete Pipe Health & Safety

 

Article by Russell Tripp, P.E., President, American Concrete Pipe Association, USA, and published in CPI - Concrete Plant international May 2018. To read the entire article go to the introductory page at American Concrete Pipe Association's web site.

The U.S. has sustained 230 weather and climate disasters since 1980 where overall damages/costs reached or exceeded $1 billion (including Consumer Price Index adjustment to 2018). The total cost of these 230 events exceeded $1.5 trillion (www.ncdc.noaa.gov/billions). As of April 6, 2018, there have been 3 weather and climate disaster events with losses exceeding $1 billion each across the United States. [1]  The California wildfires, which burned more than 9.8 million acres in 2017, destroyed over 15,000 homes and businesses, caused 44 deaths, and racked up a cost of $18 billion. [2] 

Following disaster events, news reports documented pipeline systems and culverts that were irreparably damaged. Failed thermoplastic or corrugated metal drainage systems, from the wild fires in California to the hurricane damage in Texas and Florida, were identified as the primary cause of many road failures.

Unlike concrete, thermoplastic pipes will melt and burn. Based on recent fires in California, damage to a thermoplastic drainage system has extended far beyond the damaged pipe itself to include sidewalks, roadway, gas/oil pipelines, drinking water systems and nearby structures. Thermoplastic pipe materials installed close to the surface or where there is an ex-posed pipeline inlet or outlet run the risk of being damaged or destroyed by fire regardless of the use of special end treatments. Fires in concrete pipeline systems generally don’t affect structural strength or flow capacity; the two fundamental requirements of a gravity pipeline drainage or collection system. The repair or replacement of infrastructure is incredibly expensive, and the community impacts include the interruption of service, localize flooding and damaged roadways that severely disrupt traffic based on damaged thermoplastic or metal pipelines found in, or adjacent to road rights of way. Thermoplastic pipe culvert failures have been documented recently where access by emergency service vehicles were blocked resulting in loss of property and more threats to health and safety.

Concrete Pipe Advantages
Before and after burn. Using the QR-Code you can see the ACPA Comparative Flammability Demonstration October 21, 2015 on www.youtube.com/watch?v=FoXuyWnaJm4

Concrete pipe production facilities produce one of the world’s most enduring products for storm drainage and sewage collection systems. The long-lasting performance of precast concrete pipe and box drainage systems is well documented in severe weather conditions. Compared to thermo-plastic drainage systems, concrete pipe has always been and will continue to be rigid, rugged, and resilient.

Russell Tripp, P.E., Clemson University alumnus, earned his Bachelor of Science degree in Civil Engineering in 1982. He spent the first 21 years of his professional career working in the natural gas industry. He then served three years in the PVC sheet pile industry and four years in the plastic drainage industry before joining the ACPA.


 

Precast Concrete Manufacturing Resources from the American Concrete Pipe Association

14 Reasons to Choose Concrete Pipe

Concrete Pipe Design Manual

Concrete Pipe Specifications


Hill and Griffith Customer Service

We're known for our hands-on approach. Let us visit your plant and recommend concrete release agents, packerhead concrete form releases, concrete form seasoning, potable water and non-petroleum concrete form release, biodegradable releases, rust inhibitors and concrete dissolver products that suit your needs.

Hill and Griffith Samples

Product Samples

We are pleased to provide samples in quantities large enough to allow you to "try before you buy."
Contact Us »

 

Hill and Griffith Customer Service

Technical Services & Support

On-site casting defect investigations, product testing, machine start-ups and much more. Also, lab facilities are available to provide testing upon request.
Contact Us »

 

Bulletins and Technical Papers for Concrete Casting Products 

Tags: Concrete Form Release Agents, Concrete Release Agents, Concrete Forms, Concrete Casting Supplies, Concrete Form Release, American Concrete Pipe Association

Quality Control and Testing of Concrete Pipe

Posted by Hill and Griffith Company on Apr 4, 2019 3:26:47 PM

The American Concrete Pipe Association is the spokesperson for the concrete pipe industry in all matters affecting the industry’s welfare.

We researched their content and found some great free resources. Their home page section on "Pipe & Box Resources" starts off with Design and "14 Reasons to Choose Concrete."

Precast Concrete Pipe Design Manual

"Concrete is the world’s most commonly used building material.

In its simplest form, concrete is a mixture of paste and aggregates. The material (paste) used to manufacture concrete pipe is composed principally of Portland cement and water, and is used to coat the surface of the fine and coarse aggregates. The Portland cement is a closely controlled chemical combination of calcium, silicon, aluminum, iron, and small amounts of other compounds, to which gypsum is added in the final grinding process to regulate the setting time of the concrete. Portland cement’s chemistry comes to life in the presence of water. Soon after the cement and water are combined, a chemical reaction called hydration occurs and the paste hardens and gains strength to form the rock-like mass known as concrete. During hydration, a node forms on the surface of each cement particle. The node grows and expands until it links up with nodes from other cement particles or adheres to adjacent aggregates. Within this process lies the key to the remarkable trait of concrete – it’s plastic and malleable when newly mixed and strong and durable when hardened. ..."

The 14th Reason is "Quality Control and Testing of Concrete Pipe."

Batching and mixing operations in the industry’s premier plants have been upgraded over the past 10 years. Characteristics of this operation of the pipe production process normally include:
• Computer controlled weighing and proportioning systems
• Computer controlled mixing systems
• Automated recording systems
• Absorption testing

Concrete PipePlant Certification

The American Concrete Pipe Association offers an on-going quality assurance program called the “Quality Cast” Plant Certification Program. (http://www.concrete-pipe.org/qcast.htm). This 124-point audit-inspection program covers the inspection of materials, finished products and handling/storage procedures, as well as performance testing and quality control documentation. Plants are certified to provide storm sewer and culvert pipe or under a combined sanitary sewer, storm sewer, and culvert pipe program.

Line Item 6.1 "Forms shall be kept clean of concrete build-up and inspected after each use."

Line Item 8.2. "Pre-Pour Visual Inspection"
For each pipe produced, visually inspect the following applicable items prior to pouring:
• Reinforcing Placement
• Handling Holes / Lifting Devices
• Tie-pin Holes
• Release Agent Application
• Form Cleanliness and Condition
• Step Holes / Plugs 

American Concrete Pipe Association

Brief History of the ACPA

The American Concrete Pipe Association was originally conceived in 1907 by a small group of concrete farm drain tile manufacturers as the Interstate Cement Tile Manufacturers Association in Ames, Iowa. The group needed some means of exchanging ideas and establishing a high quality, standardized products. In 1914, the organization was renamed the American Concrete Pipe Association. Throughout the 20th century, the concrete pipe industry has experienced tremendous growth. As more and more people moved from farms to cities, it created increased demand for concrete sewer and drainage products. The introduction of the automobile and subsequent highway development extended the uses of concrete pipe storm drains and culverts. There are currently over 400 plants operated by ACPA members in the United States and Canada. Over 40 countries are represented in the membership of the American Concrete Pipe Association. ACPA’s international headquarters are located in Irving, Texas USA.


Precast Concrete News from the American Concrete Pipe Association

2018 Camp Fire — Reminder of Need for Fire-Resilient Infrastructure

Reinforced Concrete Pipe Replaces 20-Year Old Plastic System in Florida

Become a member of ACPA by completing a membership application


Hill and Griffith Customer Service

We're known for our hands-on approach. Let us visit your plant and recommend concrete release agents, packerhead concrete form releases, concrete form seasoning, potable water and non-petroleum concrete form release, biodegradable releases, rust inhibitors and concrete dissolver products that suit your needs.

Hill and Griffith Samples

Product Samples

We are pleased to provide samples in quantities large enough to allow you to "try before you buy."
Contact Us »

 

Hill and Griffith Customer Service

Technical Services & Support

On-site casting defect investigations, product testing, machine start-ups and much more. Also, lab facilities are available to provide testing upon request.
Contact Us »

 

Bulletins and Technical Papers for Concrete Casting Products 

Tags: Concrete Form Release Agents, Concrete Release Agents, Concrete Forms, Concrete Casting Supplies, Concrete Form Release, American Concrete Pipe Association

Precast/Prestressed Concrete Institute Design Awards 2017

Posted by Hill and Griffith Company on Mar 28, 2019 9:11:36 PM

PCI recognizes groundbreaking work by owners, designers, builders, and precast concrete system manufactures across the country.

When we can't find new technical information on precast concrete release agents it's always a learning experience to look back at historically successful projects. These are from 2017.

Special Award Winners

 

The PCI Design Awards showcase the creative and innovate uses of precast and prestressed concrete in a wide variety of structures. The program demonstrates how designers are continuing to use high-performance precast, prestressed concrete to achieve sustainable, more cost-effective, aesthetically pleasing, and quickly-constructed projects.

 

Building Award Winners 

Transportation Award Winners

 

Honorable Mentions 

Higher Ground Saint Paul Higher Ground Saint Paul St. Paul MN  
Interstate 95 Interchange At SR-202 (JT Butler Boulevard) Interstate 95 Interchange At SR-202 (JT Butler Boulevard) Jacksonville FL  
Minnesota Senate Building Minnesota Senate Building St. Paul MN  
U.S. Bank Stadium U.S. Bank Stadium Minneapolis MN  

Read the host page at PCI.


About PCI
 
Founded in 1954, the Precast/Prestressed Concrete Institute (PCI) is a technical institute for the precast concrete structures industry. PCI develops, maintains, and disseminates the body of knowledge for designing, fabricating, and constructing precast structures. PCI provides technical resources, certification for companies and individuals, continuing education, as well as conducts research and development projects, conventions, conferences, awards programs, and much more. PCI members include precast concrete manufacturers, companies that provide products and services to the industry, precast concrete erectors, and individual members such as architects, consultants, contractors, developers, educators, engineers, materials suppliers, service providers, and students. To learn more, visit www.pci.org, or email Tom Bagsarian at tbagsarian@pci.org.


Precast Concrete News from the Precast Concrete Institute

Bridge Geometry Manual and Training Webinars

Find a PCI Certified Plant

PCI Design Handbook, 8th Edition


Hill and Griffith Customer Service

We're known for our hands-on approach. Let us visit your plant and recommend concrete release agents, packerhead concrete form releases, concrete form seasoning, potable water and non-petroleum concrete form release, biodegradable releases, rust inhibitors and concrete dissolver products that suit your needs.

Hill and Griffith Samples

Product Samples

We are pleased to provide samples in quantities large enough to allow you to "try before you buy."
Contact Us »

 

Hill and Griffith Customer Service

Technical Services & Support

On-site casting defect investigations, product testing, machine start-ups and much more. Also, lab facilities are available to provide testing upon request.
Contact Us »

 

Bulletins and Technical Papers for Concrete Casting Products 

Tags: Concrete Form Release Agents, Concrete Release Agents, Concrete Forms, Concrete Casting Supplies, Concrete Form Release, Precast Concrete Institute

Article Review - Selecting and Using Form Release Agents

Posted by Hill and Griffith Company on Mar 22, 2019 5:54:36 PM

Here are a few highlights of a great article by John A. Koski that was published in Concrete Construction Magazine

Enhance the quality and economy of precast products by using the right release agent

Almost every precaster has had a double tee or an architectural precast panel crack as it was being removed from a form. In some cases, an ineffective or improperly applied release agent may have been the culprit. At other times, the wrong type of release agent may have been used.

Highest quality precast concrete plant -2

Knowing how to properly use form release agents and which agent should be used for a particular application can go a long way toward preventing costly mistakes. In addition, following proper procedures and using the right agent can enhance the quality and economy of a finished precast piece.

When examining prices of comparable release agents, compare them based on their cost per square foot of coverage, not by the cost of a 5-gallon pail or 55-gallon drum. For example, two release agents may sell for the same price for a 55-gallon drum. However, one may have an estimated coverage rate of 800 square feet per gallon while the other can cover an estimated 1,100 square feet per gallon. If they are equal in performance and other attributes, than the one with the greater coverage rate is a better value.

Make sure that spray equipment is working properly. For example, a partially clogged spray nozzle can deliver a release agent in spits and spurts, allowing a too-heavy application in some areas and none in other places. Also, make sure that the spray tip is the right size for the product being applied. A tip that provides spray that is too fine or too heavy can create problems.

Biodegradable Concrete Form Release Agents 2 copy

Do not over-apply a release agent, especially when using a release agent that is chemically reactive. These release agents chemically react with the alkali in concrete to form a thin release film. Applying too much of the release agent can cause excessive surface dusting on the finished concrete.

Although these suggestions may help solve some of the problems pre-casters experience, if you continue to have problems with a release agent, call the manufacturer. Reputable manufacturers maintain technical-assistance departments designed to help solve problems and improve product quality. If a manufacturer can’t or won’t provide you with the answers or information you need in a timely fashion, consider switching to one who will.

Read the entire article here.


Precast Concrete News from Concrete Construction Magazine

Exploring the Value of BIM

Advanced Concrete Sustainability

Training Your Field Leaders

 


Hill and Griffith Customer Service

We're known for our hands-on approach. Let us visit your plant and recommend concrete release agents, packerhead concrete form releases, concrete form seasoning, potable water and non-petroleum concrete form release, biodegradable releases, rust inhibitors and concrete dissolver products that suit your needs.

Hill and Griffith Samples

Product Samples

We are pleased to provide samples in quantities large enough to allow you to "try before you buy."
Contact Us »

 

Hill and Griffith Customer Service

Technical Services & Support

On-site casting defect investigations, product testing, machine start-ups and much more. Also, lab facilities are available to provide testing upon request.
Contact Us »

 

Bulletins and Technical Papers for Concrete Casting Products 

Tags: Concrete Form Release Agents, Concrete Release Agents, Concrete Forms, Concrete Casting Supplies, Concrete Form Release, John Koski, Concrete Construction Magazine

Lightweight Precast Concrete Roof with Optimized Load-Bearing Design

Posted by Hill and Griffith Company on Mar 14, 2019 3:56:33 PM

3D Sand printing for formwork manufacturing and showing oil based precast concrete form release agent application

Researchers at ETH Zurich have fabricated an 80 m2 light­weight concrete slab at the DFAB House, making it the world's first full-scale architectural project to use 3D sand printing for its formwork. Just 20 mm thick at its thinnest point, decoratively ribbed and not even half as heavy as a conventional concrete ceiling: with "Smart Slab", the name says it all. The slab combines the structural strength of concrete with the design freedom of 3D printing.

Developed by the research group of Benjamin Dillenburger, Assistant Professor for Digital Building Technologies at ETH Zurich, Smart Slab is one of the core elements of the residen­tial unit DFAB House at Empa's and Eawag's research and in­novation platform NEST in Dubendorf. The 80 m2, 15 t ceiling consists of eleven concrete segments and connects the lower floor with the two-story timber volume above.

3D Precast Concrete Forms Release Agent 1

The Smart Slab segments being placed piece by piece on the 12 cm wide mesh mould wall.

(Thanks to CPI - Concrete Plant International May 2018)

Only as much concrete as needed

3D concrete printing is currently experiencing a boom in ar­chitecture, and entire houses have already been printed layer by layer. However, for the Smart Slab project, the researchers did not produce the building components themselves with 3D printing but rather the formwork - i.e. the mould. To achieve this, they used a large-scale 3D sand printer, which means the resulting moulds consist of a kind of artificial sand­stone. One of the advantages over the layered concrete print­ing process is that high performant fibre-reinforced concrete can be used and the structure can be fabricated in the preci­sion of millimeters.

Formwork production is the most labour-intensive step in con­crete construction, particularly for non-standardized compo­nents. Since concrete is relatively cheap and readily abundant, the temptation is for the construction industry to produce the same solid ceilings over and over again, but the disadvantage is excessive material consumption and implicitly, a big carbon footprint. Digital fabrication methods can make a key contri­bution here: components can be optimized, enabling the necessary stability with far less material. The geometric com­plexity of a component does not matter in 3D printing, nor does it cause any additional costs - the printer simply prints what it is told to.

3D Precast Concrete Forms Release Agent 7

The 3D sand printer used for the fabrication of the form work. The printer has a build volume of 8 cubic meters and a reso­lution of a fraction of a millimeter.

3D Precast Concrete Forms Release Agent 4

Post-processing of the 30 printed form work parts. Unconsol­idated sand particles are being removed from the print bed.

3D Precast Concrete Forms Release Agent 6

The formwork parts are assembled seamlessly and prepared for concreting.

Computational design coordinates parameters

Dillenburger's research group developed a new software to fabricate the formwork elements, which is able to record and coordinate all parameters relevant to produc­tion. In addition to basic data such as room dimensions, the researchers also en­tered a scan of the curved wall, accurate down to the last millimeter, which acts as the main support for the concrete ceiling. With the software, one could adapt the geometry of the slab so that at each point it was applied only as thick as structurally necessary to support the force flow. "We didn't draw the slab; we programmed it," says Mania Aghaei Meibodi, Smart Slab project lead and senior researcher in Dil­lenburger's group. "It would not have been possible to coordinate all these aspects with analogue planning, particularly with such precision."

If you look at the ceiling from below, you see an organic ornamental structure with different hierarchies. The main ribs carry the loads, while the smaller filigree ribs are mainly used for architectural expression and acoustics. Statics and ornamentation go hand-in-hand. The lighting and sprinkler systems are also integrated into the slab structure. Their size and position were similarly coordinated with the planning software. In this way, the building technology disappears elegantly into the slab to occupy very little space. This saves only a few centimeters in the DFAB House proj­ect, but in high-rises this may mean a few extra floors could be fitted into the same height.

Fabrication at the push of a button

After planning on the computer is completed, the fabrication data can then be ex­ported to the machines at the push of a button. This is where several industry part­ners came into play for Smart Slab: one produced the high-resolution, 3D-printed sand formworks, which were divided into pallet-sized sections for printing and trans­port reasons, while another fabricated the timber formwork by means of CNC laser cutting. The latter gives shape to the upper part of the Smart Slab and leaves hollow areas that reduce material and weight and at the same time create space for electrical cables.

3D Precast Concrete Forms Release Agent 3

An oil-based release agent facilitates the removal of the formwork once the concrete hardens.

The two types of formwork for the concreting were then brought together by a third company, which first sprayed the fibre-reinforced concrete onto the sand formwork to produce the finely ribbed surface of the lower concrete shell and then casted the remaining concrete into the timber formwork.

3D Precast Concrete Forms Release Agent 2

Glass-fibre reinforced concrete being sprayed on the 3D printed formwork in several consecutive layers.

Strong thanks to prestressing

After a two-week hardening process, the eleven individual concrete segments were ready for transport to the NEST. Thanks to the precise planning and prefabrication, the installation time at the construction site was reduced to a minimum: a crane hoisted the concrete elements onto the load-bearing wall, where the prestressing took place. Workers pulled steel cables lengthwise and crosswise through the concrete sup­port and into the channels already inserted in the formwork. Tensioning the cables massively increases the system's load capacity.

3D Precast Concrete Forms Release Agent 5

The hierarchical grid of structural ribs of the Smart Slab.

"It was spectacular to see on the construction site how seam­lessly our elements fitted with each other and with the existing components of the DFAB House," says Dillenburger. "We owe this in part to the outstanding interdisciplinary collaboration with our partners. The meticulous work that we had invested into planning completely paid off."

Smart Slab partners

ETH Zurich research groups: Chair for Digital Build­ing Technologies, Benjamin Dillenburger (lead); Chair for Building Materials, Robert Flatt; Chair of Structural Design, Joseph Schwartz

Industry partners: Burgin Creations; Frutiger AG; voxeljet AG; Georg Ackermann GmbH; Stahlton AG; Christenguss AG; Fischer Rista AG; Rudolf Glauser AG; Gorn International AG

See here a video about "Smart Slab."


Hill and Griffith Customer Service

We're known for our hands-on approach. Let us visit your plant and recommend concrete release agents, packerhead concrete form releases, concrete form seasoning, potable water and non-petroleum concrete form release, biodegradable releases, rust inhibitors and concrete dissolver products that suit your needs.

Hill and Griffith Samples

Product Samples

We are pleased to provide samples in quantities large enough to allow you to "try before you buy."
Contact Us »

 

Hill and Griffith Customer Service

Technical Services & Support

On-site casting defect investigations, product testing, machine start-ups and much more. Also, lab facilities are available to provide testing upon request.
Contact Us »

 

Bulletins and Technical Papers for Concrete Casting Products 

Tags: Concrete Form Release Agents, Concrete Release Agents, Concrete Forms, Concrete Casting Supplies, Concrete Form Release, Concrete Plant International Magazine

The Precast Show 2020 Fort Worth, Texas

Posted by Hill and Griffith Company on Mar 8, 2019 4:31:48 PM

Thanks to everyone who came to The Precast Show 2019 in Louisville, Ky.

The Precast Show is the largest precast-specific trade show in North America and the one place where you can find the industry’s most important suppliers and foremost equipment experts under one roof. We are looking forward to seeing you March 5-7, 2020, in Fort Worth, Tex.

Precast Show 2019 in Louisville, Ky 1b

Precast Show 2019 in Louisville, Ky 2b

Thanks to Angela Cox for posting these on LinkedIn last week during the show.

We showcased our extensive product line

  • Concrete Form Release Agents
  • Rust Inhibitors
  • Spraying Equipment
  • Seasoning Agents
  • Concrete Dissolver's

Product Categories

  • Coatings
  • Lubricants
  • Other Chemicals
  • Release Agents
  • Rust Preventive Chemicals
  • Sealants
  • Sprayers

The Precast Show is sponsored by the National Precast Concrete Association and the Precast Prestressed Concrete Institute with additional collaboration from the Canadian Precast Prestressed Concrete Institute and the Cast Stone Institute.

Our directory ad.

20181102 HG_1-2pgH_TPR-GS copy

The Perfect Release

Grifcote® and Cast-O-Magic® Concrete Form Release Agents
VOC Compliant, NSF Certified and Biodegradable Release Agents for All Concrete Applications 

Industry Leading Performance and Quality

Trained technicians are available to visit your site, determine your needs and design the right product for you.

  • Grifcote FR-50 & PR-5S VOC - Workhorse Release
  • Grifcote LV-50 Plus - NSF Certified for Potable Water Release
  • Grifcote Bio-Gold - Environmentally Friendly Release 
  • Grifcote CC-150 VOC - Premium Seasoning Agent
  • Cast-O-Magic, Con-Solver and Liquid Chisel
  • Corrosion Inhibitor for Steel Forms

Nationwide and International Distribution


Hill and Griffith Customer Service

We're known for our hands-on approach. Let us visit your plant and recommend concrete release agents, packerhead concrete form releases, concrete form seasoning, potable water and non-petroleum concrete form release, biodegradable releases, rust inhibitors and concrete dissolver products that suit your needs.

Hill and Griffith Samples

Product Samples

We are pleased to provide samples in quantities large enough to allow you to "try before you buy."
Contact Us »

 

Hill and Griffith Customer Service

Technical Services & Support

On-site casting defect investigations, product testing, machine start-ups and much more. Also, lab facilities are available to provide testing upon request.
Contact Us »

 

Bulletins and Technical Papers for Concrete Casting Products 

Tags: Concrete Form Release Agents, Concrete Release Agents, Concrete Forms, Concrete Casting Supplies, Precast Show, Concrete Form Release

Race Now to Build Your Business at The Precast Show

Posted by Hill and Griffith Company on Mar 1, 2019 10:46:42 AM

Today and tomorrow are your chances to gallop over and visit this year’s NPCA and PCI Convention in beautiful and historic Louisville, Kentucky, Feb. 28 - Mar. 2

Visit the Hill and Griffith Company's Booth 739 to learn more about application tips and performance improvements for your precast concrete release agent use.

HG 2019 Precast Show sm

From left to right: Dave Greek, Jr., Mike Lawry, Angela Cox, Bob Waterloo, Tom Dempsey and Tom Trainor.

  • Get out of the grandstand and onto the track with industry leaders and peers.
  • Discover the latest trends raising the stakes in a competitive marketplace.
  • Get the exclusive information you need to get you out of the gate and into the winner’s circle.

This year’s event kicked off with an opening welcome reception for PCI Convention attendees. Celebrating equestrian thoroughbreds with an evening reception and tour of the Kentucky Derby Museum, precast concrete thoroughbreds with our popular Design Awards, and our industry thoroughbreds with new, improved education offerings. Learn more at this PCI site page. The event is at the Kentucky International Convention Center, 221 S 4th St, Louisville, KY 40202.


The Precast Show is sponsored by the National Precast Concrete Association and the Precast Prestressed Concrete Institute with additional collaboration from the Canadian Precast Prestressed Concrete Institute and the Cast Stone Institute. The Precast Show 2019 will take place February 28 – March 2, 2019, in Louisville, Ky.

20181102 HG_1-2pgH_TPR-GS copy

The Perfect Release

Grifcote® and Cast-O-Magic® Concrete Form Release Agents
VOC Compliant, NSF Certified and Biodegradable Release Agents for All Concrete Applications 

Industry Leading Performance and Quality

Trained technicians are available to visit your site, determine your needs and design the right product for you.

  • Grifcote FR-50 & PR-5S VOC - Workhorse Release
  • Grifcote LV-50 Plus - NSF Certified for Potable Water Release
  • Grifcote Bio-Gold - Environmentally Friendly Release 
  • Grifcote CC-150 VOC - Premium Seasoning Agent
  • Cast-O-Magic, Con-Solver and Liquid Chisel
  • Corrosion Inhibitor for Steel Forms

Nationwide and International Distribution

 

The Hill and Griffith Company Booth No. 739 is easy to find. It's right-smack-dab in the middle of the show floor!

Hill and Griffith Booth 739 2019 Precast Show

We'll be showcasing our extensive product line at the show.

  • Concrete Form Release Agents
  • Rust Inhibitors
  • Spraying Equipment
  • Seasoning Agents
  • Concrete Dissolver's

Product Categories

  • Coatings
  • Lubricants
  • Other Chemicals
  • Release Agents
  • Rust Preventive Chemicals
  • Sealants
  • Sprayers

Hill and Griffith Customer Service

We're known for our hands-on approach. Let us visit your plant and recommend concrete release agents, packerhead concrete form releases, concrete form seasoning, potable water and non-petroleum concrete form release, biodegradable releases, rust inhibitors and concrete dissolver products that suit your needs.

Hill and Griffith Samples

Product Samples

We are pleased to provide samples in quantities large enough to allow you to "try before you buy."
Contact Us »

 

Hill and Griffith Customer Service

Technical Services & Support

On-site casting defect investigations, product testing, machine start-ups and much more. Also, lab facilities are available to provide testing upon request.
Contact Us »

 

Bulletins and Technical Papers for Concrete Casting Products 

Tags: Concrete Form Release Agents, Concrete Release Agents, Concrete Forms, Concrete Casting Supplies, Precast Show, Concrete Form Release

Visit Booth 739 at The Precast Show, Feb. 28 - Mar. 2

Posted by Hill and Griffith Company on Feb 21, 2019 1:50:29 PM

The Precast Show is the largest precast-specific trade show in North America and the one place where you can find the industry’s most important suppliers and foremost equipment experts under one roof.

The Precast Show is sponsored by the National Precast Concrete Association and the Precast Prestressed Concrete Institute with additional collaboration from the Canadian Precast Prestressed Concrete Institute and the Cast Stone Institute. The Precast Show 2019 will take place February 28 – March 2, 2019, in Louisville, Ky.

20181102 HG_1-2pgH_TPR-GS copy

The Perfect Release

Grifcote® and Cast-O-Magic® Concrete Form Release Agents
VOC Compliant, NSF Certified and Biodegradable Release Agents for All Concrete Applications 

Industry Leading Performance and Quality

Trained technicians are available to visit your site, determine your needs and design the right product for you.

  • Grifcote FR-50 & PR-5S VOC - Workhorse Release
  • Grifcote LV-50 Plus - NSF Certified for Potable Water Release
  • Grifcote Bio-Gold - Environmentally Friendly Release 
  • Grifcote CC-150 VOC - Premium Seasoning Agent
  • Cast-O-Magic, Con-Solver and Liquid Chisel
  • Corrosion Inhibitor for Steel Forms

Nationwide and International Distribution

 

The Hill and Griffith Company Booth No. 739 is easy to find. It's right-smack-dab in the middle of the show floor!

Hill and Griffith Booth 739 2019 Precast Show

We'll be showcasing our extensive product line at the show.

  • Concrete Form Release Agents
  • Rust Inhibitors
  • Spraying Equipment
  • Seasoning Agents
  • Concrete Dissolver's

Product Categories

  • Coatings
  • Lubricants
  • Other Chemicals
  • Release Agents
  • Rust Preventive Chemicals
  • Sealants
  • Sprayers

Hill and Griffith Customer Service

We're known for our hands-on approach. Let us visit your plant and recommend concrete release agents, packerhead concrete form releases, concrete form seasoning, potable water and non-petroleum concrete form release, biodegradable releases, rust inhibitors and concrete dissolver products that suit your needs.

Hill and Griffith Samples

Product Samples

We are pleased to provide samples in quantities large enough to allow you to "try before you buy."
Contact Us »

 

Hill and Griffith Customer Service

Technical Services & Support

On-site casting defect investigations, product testing, machine start-ups and much more. Also, lab facilities are available to provide testing upon request.
Contact Us »

 

Bulletins and Technical Papers for Concrete Casting Products 

Tags: Concrete Form Release Agents, Concrete Release Agents, Concrete Forms, Concrete Casting Supplies, Precast Show, Concrete Form Release

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