Conselcor™
Project Profiles
The following is
a brief list of locations where StableCrete™
has been applied. Contact us for more information.
| Project |
Launch
Pad 39B Restoration, Kennedy Space Center, Florida |
| Owner |
N.A.S.A.,
United Space Alliance, Reynolds Smith & Hills, Inc. |
| Contractor |
Iveys
Construction/H.I.S. Painting, Dave Heyne (321) 385-9155 |
| Use |
 StableCrete
chosen as the migrating, corrosion-inhibiting coating for concrete
surfaces of crawler way, catacomb roof and Launch pad.
These surfaces had
been exposed to hydrochloric acid which is a by-product of
propellant exhaust and water from the noise suppression system.
Moisture had carried calcium a depth of four plus feet to the
catacomb roof below and stalactites were being formed on the roof
surfaces creating a hazard for workmen in the area
Sherwin-Williams
Hi-Mil Sher-Tar Epoxy applied to crawler way surface after StableCrete
application. |
| Project |
Veterans
Administration Hospital, Port Charlotte, Florida |
| Owner |
Dooley
& Mack Contractors, Richard Jones (914) 921-4636 |
| Contractor |
Harvard
Jolly Clees Toppe, St. Petersburg, Florida |
| Use |
Application
to entire concrete slab floor at cool down stage of hydration to prevent
ground water vapor from transfer through slab prior to installation
of a rubber floor system on completion of job. 80,000 square feet
in initial pour without a single crack, followed by flooring
installation after ASTM 2170 confirmed a relative humidity of less
than 70% in the concrete matrix.
 |
| Project |
Multi-Story
Parking Garage for the Lynx North and South |
| Owner |
Ponce
Lighthouse Properties, Inc. |
| Contractor |
Rivermar
Contacting Co., James Monahan, P.E. (386) 767-1313 |
| Use |
Stable
Crete applied to top surfaces of two newly constructed parking garages
to waterproof and stop chloride contamination from occurring due to
constant exposure to wind driven sea water mist settling on these
structures. Without waterproofing, these surfaces absorb salts and
corrosion cells are formed on steel within months of a structure
being put in service. A structure as this that is not protected from
moisture/contaminate intrusion will experience spalling at the Top
mat of steal which is affected first and will require at least a
surface repair, usually followed by a more extensive thru repair at
a later date. Once chloride thresholds exceed a certain level, more
aggressive measures must be undertaken if an owner expects to stop
corrosion and protect the assets. This principal of early protection
applies to any concrete surface in any environment. |
| Project |
Cinnamon
Beach Condominium, Palm Coast, Florida |
| Owner |
Centex
Destination Properties |
| Contractor |
Ralph
Smith Architect for Centex Homes |
| Use |
Application
to green concrete in construction of eleven six-story oceanfront buildings.
On direct oceanfront buildings, StableCrete was applied as a water
proofer and corrosion inhibitor. Application was made by concrete
sub-contractor approximately 24 hours after pour was completed. The
product reaction inside the concrete matrix left no film formed on
the surface and also served as a evaporation retarder allowing for a
more complete interior hydration of the concrete. Several hundred
thousand square feet of concrete floors with negligible shrinkage
cracking have been poured to date. In addition to preventing
intrusion of chlorides from ocean borne salt mist the pH of the
concrete surrounding the reinforcing steel is kept high preserving
the passivating layer on the steel.
 |
| Project |
Fleming
Island WWTP, Clay County, FL |
| Owner |
Clay
County Utilities, David Bolam, P.E. |
| Contractor |
North
Beach Engineers. Jacksonville, Heather Baxter, P.E. |
| Use |
Application
to influent structure and chlorine contact chambers after restoration.
Treatment of new concrete on aeration tank, clarifier tank and chlorine
contact chambers after construction.
 |
| Project |
Phoenix
Towers Condominium, Singer Island, Florida |
| Owner |
Old
Port Cove Management, Dianne Fordering (561) 626-3100 |
| Contractor |
A.T.
Designs, Tim Marshall, P.E. (561) 881-7280 |
| Use |
Applied
to a poured concrete roof deck after concrete restoration was completed.
Totally waterproofed a 25 year old deck area used as tennis courts
above the parking garage below. Chlorides were detected throughout
the entire structure and the decision to apply StableCrete to the
top surface and repairs accomplished during this repair was made in
order to slow the corrosion process that had already begun.
Waterproofing the top surface at this stage did stop further water
intrusion however future repairs will be needed as the active
corrosion cells continue to compromise the already salt laden
concrete matrix. (Project was re-inspected five plus years later in
November of 2006 with positive testing for a waterproof surface and
minor surface spall repair needed. Thru repairs were under way and
included bottom mat as well as vertical support columns which were
then failing due to continued corrosion. (Owner advised at this time
to consider installation of an impressed cathodic system in order to
salvage the structure.)
 |
| Project |
Champs
Sporting Goods, Westshore Mall, Tampa, Florida |
| Owner |
S.A.
Kennedy Contractors, Atlanta, Georgia |
| Contractor |
Harvard,
Jolly, Clees, & Toppe, St. Petersburg, Florida |
| Use |
Application
to floor slab to retard moisture vapor emission prior to installation
of floor coverings. |
| Project |
Ocean
Hammock Condominium. Palm Coast, Florida |
| Owner |
Centex
Homes (407) 661-2212 |
| Contractor |
Ralph
Smith |
| Use |
Application
to all concrete surfaces being constructed for 116-unit oceanfront
project. Product specified as corrosion inhibitor and waterproofing
sealer to stop chloride penetration and carbonation of new concrete.
All subsequent floor covering, paint and tile installations were
accomplished with no further preparation of these surfaces except a
mild detergent wash to remove surface contaminates from construction
activities.
 |
| Project |
Grant
Street WWTP, Melbourne, FL |
| Owner |
City
of Melbourne |
| Contractor |
Mr.
George Varall |
| Use |
Re-inspection
of clarifier, two and one-half years after StableCrete application
prior to coal tar coating. Coating "still looks brand new".
No degradation of shotcrete which has come in contact with effluent
due to pinholes/construction damage to coating and excellent adhesion of coal tar product
to the treated surface.
 |
| Project |
Compatibility
and adhesion testing |
| Owner |
Freudenberg
Building Systems, Lawrence, Maine |
| Contractor |
Guenther
Kerscher, Technical Director |
| Use |
Test
of several adhesives used in conjunction with Nora Rubber Flooring
installations. Excellent test results and approved for use by corporate
offices for use with all flooring system products manufactured by
this company. Company endorses use of ASTM 2170 as a test protocol
for water vapor emissions prior to installation of it's products. |
| Project |
David
B. Lee WWTP, City of Melbourne, Florida |
| Owner |
Wharton
Smith, Inc., Jupiter, Florida (561) 745-9277 |
| Contractor |
Hazen
Sawyer, Hollywood, Florida Shajan Joykutty, P.E. |
| Use |
Application
as water, vapor and acid proofing material above and below grade.
Structures include clarifiers, reuse filters, headworks, aeration
tanks and effluent pump stations. Emphasis placed on wire wound pre
stressed tank surfaces which after backfilling would be subject to
ground water intrusion at the exterior surface. Protection of wire
by maintaining high pH on the steel and prevention of water borne
contaminates from entering the Shotcrete were considerations.
Shotcrete surfaces demonstrated exceptional waterproofing qualities
and a high absorption rate of the StableCrete product into the
matrix. High absorption rate (150 square feet per gallon or less) is
due to high % of Portland Cement in the matrix and a more aggressive
reaction of the product. No micro-cracking or alligatoring of
treated surfaces was noted prior to backfill operation.
  |
| Project |
Test
for Compatibility with Impressed Cathodic Protection |
| Owner |
J.E.
Bennett Consults, Inc. (440) 286-672 |
| Contractor |
Jack
E. Bennett |
| Use |
Bondex
used as a patch material and StableCrete used as a bonding agent in
conjunction with impressed current cathodic protection revealed that
both products are acceptable for this use. Application of StableCrete
produced little or no change in the electrical resistance of the
concrete. Resistance to current flow in concrete is a major
consideration to proper installation of impressed cathodic systems.
Photocopies of this report may be obtained from Concelcor, Inc. upon
request. Application of StableCrete in conjunction with a cathodic
install waterproofs the host concrete keeping the resistance stable
at pre-prescribed levels. Maintaining acceptable resistance levels
by excluding moisture prevents premature consumption of anodes known
as Hot Spots. |
| Project |
Remodel/Restoration
of Freezer Warehouse, Cape Canaveral Air Force Base |
| Owner |
Whitley
Construction, Don Bray (321) 784-2374 |
| Contractor |
Technical
Engineering & Spacelift Services, Russ Hamilton (321) 853-0962 |
| Use |
StableCrete
used as curing agent for new concrete pours, to waterproof concrete
at thermal breaks and to waterproof finished floor in re-designed
freezer. Waterproofing of concrete prevents freeze thaw damage and
moisture from penetrating into surrounding areas as moisture may
condense on surfaces with temperature differential. |
| Project |
Lake
Washington Water Treatment Plant Expansion, Melbourne, Florida |
| Owner |
Poole
& Kent Company, Mike Caulfield (321) 751-1580 |
| Contractor |
CH2M
Hill, Allen Bigelow (321) 254-2190 |
| Use |
StableCrete
specified as waterproofing material on the exterior surface of a CT/Blending
station built below water table approximately 28' deep. Product applied
after a film forming curing compound was sandblasted from the surface.
Positive test for waterproofing and acid resistance. No water penetration
when de-watering pumps removed and area backfilled.
 |
| Project |
Balcony
Deck Replacement, Sunrise Condominiums, New Smyrna Beach,
Florida |
| Owner |
Southeast
Restoration, Inc., Bill Kiper (386) 304-4200 |
| Contractor |
Concorr,
Inc., Ali SohanghpurwalaBill Scannell (703) 729-7955 |
| Use |
Use
of Stable Crete as a curing agent/evaporation retarder on new poured
4000 psi concrete elevated decks. Far superior cure of new concrete,
now totally waterproofed as well as preventing introduction of contaminates
and loss of pH at reinforcing steel.
 |
| Project |
Repair
to Cruise Terminals and Piers, Port Canaveral, Florida |
| Owner |
Canaveral
Port Authority, Ed Callahan (321) 783-7832 |
| Contractor |
Gee
& Jensen, Guillaune Lucci, P.E. (321) 799-1236 |
| Use |
Test
and use of StableCrete "Bondex" as repair material on existing
damaged concrete expansion joints, transition strips and wear surfaces
exposed to large tonnage fork lift and steel wheel traffic. Bondex
selected over all other products as previous attempts at repairs
using other cementitious products have failed Piers are 35 years
plus old and have suffered the affects of a harsh saltwater
environment. Surface scaling, popouts, Alkali Silica Reaction and
physical abuse had taken a toll. Original expansion joints had been
chipped away at the top corners and a repair using angle iron bolted
to the concrete to form new corners was employed. Heavy traffic on
the joints transferred shock to the attach bolts resulting in
another failure. Angle steel was removed, surfaces treated with
StableCrete and "Bondex" was utilized as a patch material to reform
pier expansion joints back to original shape. Joints were protected
by 1/2 inch steel plates for 48 hours then normal traffic was
allowed to the repaired areas. Over a period of several years this
repair being successful has been repeated a number of times here and
similar locations worldwide.
  |
| Project |
Adhesion
and Compatibility Testing of StableCrete |
| Owner |
Tenemec
Company, Inc., Kansas City, Missouri (816) 474-3400, ext. 4322 |
| Contractor |
Research
& Development of Tenemec Co., Mike Krosen |
| Use |
Testing
of adhesion characteristics and compatibility of concrete surfaces
treated with StableCrete to Tenemec Co. products utilized in Water
and Waste Water Treatment facilities. Complete line of products approved
and far superior adhesion was demonstrated as well as better coverage. |
| Project |
Grant
Street Waste Water Plant, Melbourne, Florida |
| Owner |
Water
Processing Company, Johnathon Belloit, President (904) 268-0099 |
| Contractor |
Gee
& Jensen, Gary Ledford, P.E. (321) 799-1236 |
| Use |
500K
gallon clarifier, new construction with efflorescence commencing in
one week, StableCrete application to entire surface after removing
efflorescence and prior to Tenemec Company coating application. StableCrete
prevented ettringite conditions as well.
 |
| Project |
Oceanfront
Seawall Reconstruction, New Smyrna Beach, Florida |
| Owner |
AAA
Bobcat, Inc., Shawn Buchanan, President (407) 282-5340 |
| Contractor |
United
Engineering Consultants, Robert Fitzpatrick, P.E. (407) 788-8050 |
| Use |
Reconstruction of a oceanfront seawall failure during a storm.
Entire seawall (600 feet) required replacement after severe
corrosion in the Splash Zone Area caused a catastrophic collapse
after tides breached the cap. 5’ X 20’ panels cast on site were
treated with StableCrete prior to jetting into the sand. New
waterproof seawall does not permit moisture and chlorides to enter
the matrix causing corrosion cells to be formed. Splash Zone is most
vulnerable due to the constant wet-dry cycle on concrete causing
more aggressive corrosion on the steel. Use of StableCrete, an EPA
Approved penetrating sealer also allowed a colored coating to be
applied that has not burned off with alkali migrating out of the
concrete compromising the bond of the coating.
 |
| Project |
Lake Washington SWTP Phase #2 , Melbourne , Florida |
| Owner |
City of Melbourne Utilities |
| Contractor |
Wharton-Smith, Inc. CH2MHill Engineering, Hazen and Sawyer Engineers |
| Use |
Phase 2 of this project for surface water improvements involves
construction of a raw water intake, Ozone contactors, Ozone
generator building and associated structures. Most of these
structures have been built below grade and all will be exposed to
the deleterious affects of O3 (Ozone) in the water treatment
process. Type IV Concrete (5500 psi) has received an application of
Red Tinted StableCrete upon removal of form work. The application is
designed to waterproof all concrete structures and to prevent the
harmful effects of exposure to Ozone to the concrete surfaces. The
exterior application was required to prevent ground water
penetration into the matrix causing corrosion of the steel
re-enforcing.
 |
| Project |
Protection of aged concrete of
chlorine Contact Chambers Chlorine Contact |
| Owner |
Clay County Utilities, Clay County,
Florida |
| Contractor |
North Florida Construction, Inc.
Gee and Jensen Engineering |
| Use |
Red Tinted StableCrete used to treat interior rehabilitated concrete
surfaces of several chlorine contact chambers approximately 20 years
old. Testing with water and acid is a common practice to demonstrate
proper application and absorption into the concrete. This photo is a
close up of the top surface of one wall. Toward the bottom, an arc
is visible that is StableCete that was applied to a small area of
the top surface as well as the sides in the tank. The Red color is
beginning to fade out as is normal after exposure to the sun for
about ten days. Notice two drops of liquid in the treated area and
two above the treated area. These were placed using an eye dropper
at the same time. The untreated area above has a drop of water on
the left and a drop of Hydrochloric acid to the right. It is
apparent that the water is being readily absorbed into the concrete.
The acid is producing fumes, bubbling and consuming the lime in the
concrete that is typical of acid introduced to an untreated surface.
The two drops within the arc on the bottom show no penetration into
the concrete and no reactivity to the acid. Structures received a
coating 48 hours later and will enjoy many more years of service
even after the coating begins to deteriorate with age.
 |
| Project |
New Recycle Facility Floor Application ( 70,000 square feet) |
| Owner |
Schupan & Sons, Inc. Kalamazoo, MI |
| Contractor |
Brivar Construction Company, Brighton MI. |
| Use |
Company has several recycling plants in operation. All plants are
experiencing degradation of the concrete floors in the intake and
transfer areas of their plants. Problem is acidic products in
recycled containers leak onto the concrete surfaces dissolving the
lime that binds the aggregate in the cement paste creating scaling,
ruts and dusting throughout plant. StableCrete applied to a 70,000
sq. ft. area 24 hours after concrete pour. Concrete subcontractors
completed a wash of the surface and applied StableCrete using a
squeegee and heavy knap rollers. Temperature remained above 32
degrees for 24 hours allowing a cure of the product, promoting
moisture retention in the slab to provide for better internal
hydration and cure of the entire floor. If a coating is later
applied (not required) for esthetic purpose there will be no
adhesion/ compatibility issues with the coating or a bond.
|
StableCrete@att.com
321-795-7438
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