NEW VERTICAL SLIP FORMING TECHNIQUE UTILIZING CEMENTS THAT WILL DOUBLE THE SLIP RATE WHILE CUTTING COST AND MANPOWER

Slip forming has been the fastest construction method for high-rise concrete structures since its invention some seventy years ago in Sweden by Bygging-Uddemann. They are now the largest in the world.
Slip forming’s other strong suite is it’s the safest method of forming since the formwork is only assembled once at ground level.

DOUBLING THE SLIP FORM RATE

Setting time of concrete depends on temperature. This can be achieved by a new type of cement used in the concrete. Seven years ago, a company in Houston Texas called Geopolymer Solutions, LLC invented this cement (binder) for concrete called Cold Fusion Cement (CFC). This company, now with its new cement for concrete, obtained a patent entitled “Method of making construction materials with a voltage.”

In order to meet passive structural steel fireproofing code requirements, there are a number of methods available.

NEW LOW VOLTAGE CFC PRONE CONCRETE

When electricity is passed through CFC the electrons are excited and the concrete cure begins. As the concrete passes the electrical input sources on the forming panels its conductivity will start to cure the mixture while seeking parts of the mix it has not cured. This heat input is assured by the second set of voltage inputs in the bottom third of the forming panels.

OTHER FACTORS THAT WILL SPEED THE SLIP

The CFC is a high slump material that will require fewer concrete placement positions. The CFC mix design will have no air entrainment or vibrating requirements, which will eliminate a few men on the production deck allowing more room for the horizontal bar rod busters to place and tie the bar.
Since the cure will start when the concrete is placed, the pressure on the slip form plates will reduce, allowing them to be moved down on the vertical yokes allowing a larger dimension between the horizontal bar and the work deck. This will allow the rod buster a larger space and time for rebar placing and tying.
The upper deck will have fewer concrete boom placement feeds, allowing better rebar and concrete management.
If the structure is designed with Basalt rebar, its lightweight and ease of handling could easily cut the rebar crew by a third, allowing for better rebar management and a faster slip.

MINIMUM MODIFICATION TO THE SLIP FORM FORMWORK

In general, the formwork will have to be modified to achieve the higher slipping rates. These few changes and adds are as follows:

  • Teflon coating on all forming plates
  • A single wire, low voltage plug-in, from the back through to the surface face so some but not all of the forming panels
  • Placing insulation on the waling’s to ensure there is no incorrect voltage flow to the facing panels. There is a wide variety of ways to accomplish the voltage installation.
  • The voltage input placement for a four-foot deep forming panel run is, a single wire adapter placed one-foot down every five feet along the top and one-foot up from the bottom, placed two and a half feet laterally starting from the inputs above.

One of the most costly challenges in the petrochemical industry today is managing corrosion under insulation (CUI) and corrosion under fireproofing (CUF). The most simplistic description of corrosion on steel is rust.

The vast majority of steel corrosion consists of an electro-chemical reaction converting the iron into an oxide. This type of corrosion is most typically prevented or controlled with the use of coatings, galvanizing, or grounding.

The second-largest type of steel corrosion is from chemical attack. This type of corrosion can be prevented or controlled with the use of coatings.

NACE (National Association of Corrosion Engineers) estimated in NACE International News, March 8, 2016, that the “global cost of corrosion at $2.5 trillion annually.” For some countries, this is a significant portion of their GDP. Energy Skeptic reported on March 26, 2016, that in the U.S.:

  • $1.4 billion annual loss due to steel corrosion in the Oil & Gas Exploration and Production Industry.
  • $3.4 billion annual loss due to steel corrosion in the Petroleum Refining Industry.
  • $1.7 billion annual loss due to steel corrosion in the Chemical, Petrochemical and Pharmaceutical Industries.
  • $6.0 billion annual loss due to steel corrosion in the Pulp and Paper Industry.

Corrosion is a real problem that costs the average American.

Industrial piping and vessels will corrode from excessive moisture or water penetration — if there’s not an effective, lasting treatment in place. Engineers mitigate these risks with protective treatments and inspections, some of which come with significant hurdles.

But there are more sustainable solutions that have been adopted to help engineers avoid (costly) mistakes and prevent corrosion under insulation and fireproofing entirely.

Side Effects of Corrosion Under Insulation and Fireproofing

Corrosion under insulation and fireproofing costs building and project owners billions of dollars every year. Many of the factors that cause corrosion, like equipment design, weather, salt spray, humidity and other factors are a challenge — if not impossible — to control. This makes consistent maintenance and frequent inspections not just necessary, but standard.

Corrosion under insulation and fireproofing are responsible for many leaks, cracks and other damage including catastrophic structural failure, and there’s pressure in the chemical, manufacturing and refining industries to find effective solutions.

Corrosion under insulation and fireproofing will continue to occur for the foreseeable future, making preventative maintenance and CUI/CUF detection methods of critical importance. Preventing corrosion under insulation and corrosion under fireproofing could save the industry from extra, unnecessary costs and energy expenditure.

Because fireproofing is a necessary part of any industrial productivity to protect workers and the public, measures must be taken to control CUF.

Strategies for Preventing Corrosion

There are a few effective strategies for preventing corrosion under insulation and fireproofing, from the materials selected to the barriers and maintenance systems in place. Many times the means utilized to discover corrosion are not timely and elements must be replaced.

But there are a number of non-invasive methods for inspection, from Eddy Current, radiography to ultrasonic thickness measurements, where sound waves help to capture data from the piping design. This data helps engineers determine instances of CUI and CUF in structural elements, and piping and vessels so that the damage can be addressed.

Expedient discovery is an important part of the strategy. When corrosion begins, the damage is most times exponential with time.

More Effective Solutions for Corrosion

However, there’s another approach to prevention: using a corrosion inhibitor. When applied, a high-quality corrosion inhibitor product provides excellent protection and damage resistance to structural elements, industrial piping and vessels.

Modern manufacturers have produced a cold fusion concrete that contains an alkali-activator largely comprised of glassy elements, resulting in a product that prevents damage like other materials can’t. The mixture contains no Portland cement, making it far more environmentally palatable to produce, and the product contains none of the inherent weaknesses of Portland.

Using an alkali-activated cement solution gives engineers more options for corrosion protection, as it’s easily produced by combining materials that are accessible throughout the world.

The inherent concrete corrosion inhibitor has been proven to prevent rusting and damage on metal substrates, even after being tested with ten thousand hours of salt spray exposure (ASTM B117). Third-party test report results indicate that using this glassy corrosion inhibitor has a higher resistance to acids, solvents, sulfates and fire than other treatments.

Solutions That Sustain

Source: Corrosion under insulation and fireproofing has been a long-standing issue for engineers. “CUI is difficult to find because of the insulation cover that masks the corrosion problem until it is too late,” wrote Michael Twomey for Inspectioneering. “It is expensive to remove the insulation.” Fireproofing is no different.

But engineers and builders have solutions for corrosion under insulation and fireproofing by using the right forms of prevention. Maintenance and inspections are a standard part of every job site, but using an effective corrosion inhibitor is the best way to prevent damage and costly repairs.
The corrosion inhibitor materials from Geopolymer Solutions have helped engineers everywhere address the demands (and cost) of better structural element, piping and vessel protection. Geopolymer Solutions’ Cold Fusion Concrete/cement’s glassy characteristic electrically insulates the substrate and doesn’t allow water or chemicals to contact steel features, eliminating the possibility of corrosion before it begins.

Your project will likely require some sort of fireproofing to protect workers and reduce economic loss during explosions or fire events. Using an economical and environmentally superior fireproofing that inhibits corrosion at the same time makes perfect sense.

The vast majority of clients are return customers, and working with Geopolymer Solutions includes comprehensive training prior to using their products.

The best way to prevent damage is by inhibiting it completely. If you’d like to find out more about Geopolymer Solutions and the high-performance products available, reach out to an expert here.

Pictures present acid resistance tests performed on Cold Fusion Concrete, with Portland Cement Concrete samples tested in the same acid and concentration. Try to guess which samples are Cold Fusion Concrete.

Pictures present a demonstration conducted at an extremely reputable coatings company using Cold Fusion Concrete FP250, and the Coating Company’s equipment.

Pictures present the construction of a Nitric Acid secondary containment using Cold Fusion Concrete A260.

Pictures present several segments of one of our many visits to Underwriter Laboratories, LLC, where our Cold Fusion FP250 material underwent extensive analysis for certification and design purposes.

Pictures present an event that occurred at Geopolymer Solutions’ plant in Conroe, Texas. An extremely reputable coatings company brought their equipment and sprayed our Cold Fusion Concrete A220 series material in a dry mix gunite application.

Environmentalists and the concrete industry are looking to Geopolymer Solutions and what we offer: an economical, more durable and environmentally friendly concrete with a 90% reduction

INTRO

Geopolymer Solutions, LLC (GPS) has developed Cold Fusion Concrete ® (CFC) FP250 Series Spray Applied Fireproofing for use where extreme durability and chemical resistance is desired. This UL listed (Design X860) 42 to 48 pounds per cubic foot (pcf) density material contains fire resistant microfiber to resist cracking during seismic events or shipping and handling of coated members. This fiber, combined with an early and final compressive strength greater than that in any other cementitious fireproofing material, makes FP250 the material of choice, especially for shop applications. FP250 contains no Portland cement and has none of the weaknesses of conventional cementitious fireproofing materials. FP250 has elevated resistance to acids, solvents, chlorides and sulfates. Due to the reduced permeability of FP250, harsh environmental conditions including extreme heat and cold, and salt water spray have no detrimental effect.
Cold Fusion Concrete ® FP250 contains 80 – 90% recycled content and can be helpful in obtaining LEED certification.

Geopolymer Solutions, LLC (GPS) has developed Cold Fusion Concrete ® (CFC) FP250 Series Spray Applied Fireproofing for use where extreme durability and chemical resistance is desired. This UL listed (

SUBSTANTIAL

Geopolymer Solutions, LLC (GPS) has developed Cold Fusion Concrete ® (CFC) FP250 Series Spray Applied Fireproofing for use where extreme durability and chemical resistance is desired. This UL listed (Design X860) 42 to 48 pounds per cubic foot (pcf) density material contains fire resistant microfiber to resist cracking during seismic events or shipping and handling of coated members. This fiber, combined with an early and final compressive strength greater than that in any other cementitious

fireproofing material, makes FP250 the material of choice, especially for shop applications. FP250 contains no Portland cement and has none of the weaknesses of conventional cementitious fireproofing materials. FP250 has elevated resistance to acids, solvents, chlorides and sulfates.

INTRO

fireproofing material, makes FP250 the material of choice, especially for shop applications. FP250 contains no Portland cement and has none of the weaknesses of conventional cementitious fireproofing materials. FP250 has elevated resistance to acids, solvents, chlorides and sulfates.