Vibco Concrete Handbook.1 - Bertda Services

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Vibco Concrete Handbook.1 - Bertda Services

ENGINEERING DATA& APPLICATIONSCONCRETE WALLSPROBLEM:SOLUTION:RESULT:CAST-IN-PLACE WALL SECTIONSWall sections were being cast between precast columns. It was impossible to reach the mixso internal vibrator could not be used.Model US-1600 electric vibrators were used with wood form brackets (page 10 of Concrete Handbook),2 x 4 wood planks were placed on the Symons form at 4’ intervals and the vibrator wasclamped to the wood.The concrete consolidated properly and an excellent almost architectural surface finish wasobtained by using the high frequency vibrators.Symons form using Model US-1600 with clamp-onbracket (page 11) made to clamp on to 2 x 4.Wood form bracket (page 10) on 2 x 4. Straddledbetween two 2 x 4’s.EQUIPMENT USED:MODEL US-1600115 Volt - 1 Phase5 amps - 9000VPMMODEL UC-2Clamp-On Bracket(Page 11 & 16 ConcreteHandbook)1-800-633-0032ALTERNATIVEPNEUMATICEQUIPMENT:MODEL CCF-2000or SVRFS-4000BRACKET CCFC-3(Page 10 & 14 Concrete Handbook)3


ENGINEERING DATA& APPLICATIONSCONCRETE WALLSWASTE WATER TANKS – LAWRENCE, MAEFCO-Ready radius forms were used to cast32’ high wastewater tanks. The very closesteel reinforcement rods made it impossibleto use internal vibrators. 12 Model SVRFS-4000 Vibco pneumatic vibrators were usedand staggered on form starting 2’ from bottomto insure that concrete flowed aroundreinforcement bars – next vibrator 4’ higheron next form panel. Required density wasachieved and contractor saved several daysusing external vibrators.Wall section to be cast – notice the tight reinforcing rods.Special vibrator bracket was designed toclamp on to form stiffener.Close up of Vibrator SpacingEQUIPMENT USEDPNEUMATIC:MODEL SVRFS-400012000 VPM40 CFM & 85 dBSpecial Bracket designed by VIBCOBracket speciallymade byVIBCO!4(Page 14 Concrete Handbook)1-800-633-0032


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ENGINEERING DATA& APPLICATIONSCONCRETE WALLSIO MODEL US-1600 ELECTRIC VIBRATORSON 20’ HIGH WOODEN FORM SYSTEMPROBLEM: Workers handling 20’ long internalvibrators when standing on ladders,became a safety concern, and contractordecided to use external vibrators.SOLUTION: Working with VIBCO’s engineersa special bracket was designed thatcould easily be attached and removed fromthe form when using Model US-1600 vibrators(page 4 of Concrete Handbook). Vibratorswere placed 8’ apart and staggered on 4’levels. Vibrators were started when concretereached them and they ran until pourreached next level of vibrators. Then turnedoff and moved 4’ above top row ofvibrators.COMMENTS: Finish came outperfect. Contractor was verypleased and now committed touse external vibrators on his wallforms because of safety, ease ofhandling and product finish.EQUIPMENT USED:UWF-1 BracketMODEL US-1600115 Volt - 1 Phase5 Amps - 9000 VPMALTERNATIVEPNEUMATICEQUIPMENT:MODEL CCW-2000or SVRWS-40006(Page 5 & 16Concrete Handbook)(Page 2 ConcreteHandbook)1-800-633-0032


ENGINEERING DATA& APPLICATIONSCONCRETE WALLSTHE BIG DIG IN BOSTON – MODEL SVRLS-4000USED ON FORM FOR VENTILATING SHAFTThe exterior walls of concrete were to be as free from as many blemishes and bug holes as possible. Form was made upof aluminum stiffeners mounted against a plywood face. For a smooth architectural finish model SVRLS-4000 PneumaticVibrator with 15000 vibrations per minute at 100 PSI was recommended. A special bracket was designed to grip the aluminumform stiffeners. Vibrators were placed on 6’ centers and 6’ between rows. The contractor marked the vibrationlocations with spray paint prior to the pour to eliminate any confusion where to place vibrators once the pour was started.Vibrators were started when concrete reached the first row and continued until concrete reached the next row ofvibrators. These were then started. By tapping against the wall with a 2 x 4 the contractor could determine how high upin the form the concrete was. The finished wall came out over expectations. No patching necessary.Special Bracket designed by Vibcowith Lug-Bracket for vibrator allowingvibrator to be moved frombracket to bracket.EQUIPMENT USEDPNEUMATIC:MODEL SVRLS-400015000 VPM at 100 PSI50 CFM & 85 dBSpecial Bracket designed by VIBCOBracket speciallymade byVIBCO!(Page 6 Concrete Handbook)81-800-633-0032


ENGINEERING DATA& APPLICATIONS C O L U M N SMODEL SVRFS-4000 PNEUMATIC VIBRATORSON BRIDGE COLUMN FOR BRIDGE BETWEENSOMERSET & FALL RIVER, MA (Summer 2000)Columns had a large amount of steel reinforcements.The first pour with internal vibratorscame out with large voids and honeycombs.Model SVRFS-4000 high frequencypneumatic vibrators were recommendedinstead of internals. The same portable bracketthat was designed for the Efco-Forms page13 was used and straddled 2 form stiffeners.They were easily moved up the form as thepour progressed. Vibrators were placed on 6’centers around form and next row 6’ higher.Vibrating procedure and time followedinstructions on page 14. The honeycombsdisappeared, the finish was excellent withoutany patching.Vibrators placed on 6’ centers around form.Next higher row 6’ up.Special Bracket straddling twoform stiffeners.EQUIPMENT USEDPNEUMATIC:MODEL SVRFS-400011500 VPM at 80 PSI40 CFM & 80 dB(Page 14 in Concrete Handbook)Bracket speciallymade byVIBCO!1-800-633-00329


ENGINEERING DATA& APPLICATIONS C O L U M N SPROBLEM:Internal re-bars made it difficultto use internal vibrators andthe form was also too tall forinternal vibrators to reach bottom.The columns came outwith large voids and unvibratedsurfaces.SOLUTION:Contractor had large compressoron job site and 2 pneumaticmodel SVRLS 4000 high frequencyvibrators were recommendedmounted on a clamponbracket with a lug bracket(page 6 of Concrete Handbook).Lug-bracket was chosen so thatcontractor could move thesame vibrators to other permanentlymounted lug brackets onhis wall forms. Vibrators weremounted 2’ from bottom and 7’from bottom then moved 5’each time. Vibrators were startedwhen concrete reachedthem and stopped when concretereached the oppositehigher vibrator which then wasstarted.RESULT:Excellent surface finish wasachieved without any rework.Concrete completelyconsolidated.10EQUIPMENT USEDPNEUMATIC:MODEL SVRLS-400012000 VPM40 CFM & 80 dBwith Clamp-On Bracket(Page 6 Concrete Handbook)1-800-633-0032ALTERNATIVEELECTRICEQUIPMENT:MODEL US-1600115 Volt - 1 Phase5 amps - 9000 VPMMODEL UC-2Clamp-On Bracket(Page 11 Concrete Handbook)


ENGINEERING DATA& APPLICATIONS C O L U M N SJOB SITE: Sea-Train Office Bldg.PROBLEM: To assure placement of dense concrete witharchitectural finish in 18” square x 28 foot tall supportingpiers.Overall view of job site . . .EQUIPMENT: Concrete, 2” slump supplied by transit-mixtruck, to be placed into Symons forms. VIBCO US-900electric external vibrators fitted with bolt-on brackets.Power available: 115 volt, AC, from field generators.SOLUTION: The Symons forms had angle L-iron stiffeningframes to which US-900 bolt-on adapters could beattached. Vibrators mounted to forms in a staggered manneron opposite sides at the 2’, 7’, 12’, 17’, 22’, and 27’levels. They were operated in succession for about oneminute each until concrete reached about 6” above eachvibrator. Vibrators were moved to next higher position aspour progressed.RESULT: No honeycombs! No unsightly holes! No patchingup! A good-looking job done quickly and efficiently!CONTRACTOR COMMENT: The best equipment purchasethey ever made!Testing one US-900 on piling.Men feeling to see if vibration is carried to allfour sides...it is.Close-up of US-900 on inside pier.EQUIPMENT USEDELECTRIC:MODEL US-900115 Volt - 1 Phase - 10000 VPMMODEL UC-1Clamp-On Bracket(Page 11, 16 & 17 Concrete Handbook)1-800-633-0032ALTERNATIVEPNEUMATICEQUIPMENT:MODEL CCF-20006000 VPM - 35 CFMCCFC-3 Clamp-On Bracket(Page 14 & 15 Concrete Handbook)11


ENGINEERING DATA& APPLICATIONS C O L U M N SROUND COLUMN FOR BRIDGE SUPPORTA round column form was used for casting support columns for elevated highway thruBridgeport, Connecticut. Internal vibrators could not be used due to closeness of hightension electrical wires, and close spacing of steel reinforcing rods. Vibco’s ModelSVRFS-4000 Pneumatic Vibrators were used with clamp-on brackets. They were placedon 4’ centers around the form. Next row 4’ up and 45° off first row. Vibrators were startedwhen concrete reached them and continued to vibrate until concrete reached nextrow. These were then started and the lower row vibrators were moved to next higherposition.Contractor was excited about the ease of using external vibrators and the finishachieved. In his own words: “The column looks just like marble, no patching wasnecessary.”12EQUIPMENT USEDPNEUMATIC:MODEL SVRFS-400011500 VPM at 80 PSI40 CFM & 80 dBCCFC-3 CLAMP-ON BRACKET(Page 14 in Concrete Handbook)1-800-633-0032ALTERNATIVEPNEUMATICEQUIPMENT:MODEL CCF-40007000 VPM40 CFM & 75 dBCCFC-3 Clamp-On Bracket(Page 14 Concrete Handbook)


ENGINEERING DATA& APPLICATIONS C O L U M N SEFCO-FORMS WITH SVRLS-4000HIGH FREQUENCY VIBRATORSJOB SITE: Renovation of bridge columns onRt. 95 Conn.PROBLEM: Internal vibrators would not reach bottomof column due to reinforcement bars.SOLUTION: Model SVRLS-4000 (page 6 of Concrete Handbook)was recommended. VIBCO designed a special bracketto be attached to the EFCO form and fit between twohorizontal stiffeners. When loosening the clampingbolts it could be removed and moved up the form asthe pour progressed. A total of 8 vibrators were used –one on each side. Vibrators were started when the concretereached them and continued until it reached thenext group of vibrators 6’ up. They were then stoppedand moved 6’ above top row of vibrators. Vibrationtime approx. 5 min. Concrete was trucked in from localready mixed plant. (6” slump)RESULT: Columns came out perfect. The customersword was - “They look just like marble...”EQUIPMENT USEDPNEUMATIC:MODEL SVRLS-400012000 VPM40 CFM & 85 dBSpecial Bracket designed by VIBCO(Page 6 Concrete Handbook)ALTERNATIVEPNEUMATICEQUIPMENT:CCL-40006000 VPM35 CFM & 78 dB1-800-633-003213


General Rules for Selecting, Sizingand Placing External VibratorsFor the successful use of external vibrators you must determine:1. VIBRATION PENETRATION2. EFFECTIVE VIBRATION AREA3. SIZING AND PLACING OF VIBRATORS4. VIBRATION PROCEDURE & VIBRATION TIME1. VIBRATION PENETRATION: As a general rule, when the thickness ofthe concrete in the form exceeds 6 inches, use vibrators (staggered) on bothsides of the form. In columns the reinforcement steel will aid in vibration transferto the center of the column.2. EFFECTIVE VIBRATION AREA: The sinusoidal vibration waves arestrongest at the vibrator and as they move away in a circular pattern (like thewaves when a stone is thrown into water) and reach a 3-5 foot radius. Generallyfigure a 3 foot radius from the vibrator as an effective vibration area. Someof the vibration will travel to a 5 foot radius. At the 5 foot radius the vibrationfrom the next vibrator should overlap the first.3. SIZING AND PLACING OF VIBRATORS(A) SIZING: There are many ways to select and size vibrators. Not tomake the selection confusing, we will list the most common ones(for other selections consult a VIBCO applications engineer)ELECTRIC VIBRATORS:Model US-900:Model US-1600:115 volt single phase - 4.5 amps10,000 vibrations per minute115 volt single phase - 5 amps9,000 vibrations per minutePNEUMATIC VIBRATORS:(Both can be run off field generators.)Model CCF, CCWor CCL-2000:Model CCF, CCWor CCL-4000:80-100 PSI - 40 CFM6,000 vibrations per minute80-100 PSI - 45 CFM7,000 vibrations per minute141-800-633-0032


GENERAL RULES FOR SELECTING, SIZING & PLACINGEXTERNAL VIBRATORS, cont’d.3. SIZING AND PLACING OF VIBRATORS (cont’d.)PNEUMATIC VIBRATORS cont’d:Model SVRLS,SVRFS-4000,SVRWS-4000:80-100 PSI - 40-50 CFM11,500 to 15,000 vibrations per minute(For architectural finish)(B)COMPARABLE VIBRATORS:US-900 & CCF, CCL, CCW-2000’s: Used on smaller forms, low productionwith effective vibration area of 2.5 to 3’ radiusUS 1600 & CCF, CCL, CCW-4000’s & SVRL, SVRF, SVRW-4000: Used onhigh production, larger forms with an effective vibration area of 3’ plus.PLACING OF VIBRATORS:STEP 1. For walls, make a dimensional drawing of the form, if 6 inch thickconcrete, draw up front only. If over 6 inches, make a drawing of both sides(see Figure 1 A & B). For columns, make a drawing of all 4 sidessee Figure 2 A & B).STEP 2. Draw in circles of 3’ radius and 5’ radius.The 5’ radius shouldoverlap, one circle for each vibrator position. (see Figure 2 A & B)TIP: A good idea is to start first row of vibrators 2’ up the form from thebottom. Since all the form weight is resting here and some of the vibrationshould also travel under the form.You can make your own decisions where to place the vibrators on the form –just remember the simple rule that the effective vibration area is on a 3’ radiusand that the 5’ radius is the maximum and the adjacent vibrator’s area shouldoverlap.When you have drawn up your form and placed the vibrators, you will knowhow many vibration positions you have. Now you will have to decide howmany vibrators you need. A good rule of thumb is to have enough for the firstrow of vibrators. Remember the bottom row of vibrators must be moved to thenext row up and started when the concrete reaches that row. If this is too muchclimbing and rushing while the pour is going on , you might want to getadditional vibrators.Another consideration when using the electric is that the US-900 and US-1600high frequency vibrators have a 50% duty cycle – in an hour you can use them30 minutes. These 30 minutes can be 30 minutes continuous running or 1, 2, 3,etc. minimum minutes “on” with the same or longer “off” time – but notexceeding a total running time of 30 minutes in one hour. The pneumatic unitshave a 100% duty cycle and can be operated continuously.1-800-633-003215


GENERAL RULES FOR SELECTING, SIZING & PLACINGEXTERNAL VIBRATORS, cont’d.6'6'2'6'6'2'WALL 6" THICK 18' HIGHFigure 1A3'Bx6'Fx6'FxBx30'BxFxFxBxBx18'WALL 6” THICK: It is only necessaryto vibrate one side. Front sidewill have the best finish. If oppositeside also has to have a better finish,stagger vibrators on both sides.Shown in Figure (1B).FxBxFxBxFxWall 6" thick - 18' HighWALL 8" THICK 18' HIGH – BOTH SIDES NEED TO BE VIBRATED IN STAGGERED ROWS.Figure 1B FRONT BACKx x xxxx x xx6'x x xxx x xxxx x x xxx x xx3' 6'6'6' 6'161-800-633-0032


GENERAL RULES FOR SELECTING, SIZING & PLACINGEXTERNAL VIBRATORS, cont’d.3. SIZING AND PLACING OF VIBRATORS (cont’d.)(C)BRACKETRY: The bracketry to be selected can be one of the standardbrackets shown on the preceding applications or you can design your ownin conjunction with VIBCO’s application engineers.4. VIBRATION PROCEDURE AND VIBRATION TIME(A)(B)VIBRATION PROCEDURE: Place vibrators to be used in their lowestposition. It’s a good idea to pre-mark the vibrator positions using a paintspray can. Do not start vibrators until the concrete reaches them or isabout 6”above them.TIP: If internal vibrators are used, do not start the external ones until theinternals have stopped or moved to a higher position. The reason is,internal vibrators throw air bubbles away from the vibrator head againstform side leaving air holes and pockets on surface. External vibrators throwair bubbles into the mix, up and out, leaving surface against form smoothand blemish free.HOW LONG TO VIBRATE: The time you need to vibrate varies dependingon concrete slump, additives, stiffness of form, vibrator force, etc.To determine the vibration time needed, it is advisable to make a test run;for example: On a column, take the time from the start of the vibrators towhen the concrete reaches the 1/2 way mark to the next higher row, look atthe concrete surface (use a flashlight if column is high). When no moreair bubbles are breaking on the surface, and a glistening surface appears ontop of the concrete, you have vibrated enough. The time this took is yourvibration time for the vibrators in each position for all the columns of that size.If you do not want to measure the time, you will have to watch the concretesurface for bubbles breaking and the glistening slick surface each time,before moving the vibrators.NOTE: If the walls or columns are too high to determine the vibration timeby observing air bubbles breaking on the surface – the contractors on page8 and 13 elected to run the vibrators until the concrete reached the next higherrow. The lower vibrators were then stopped, moved up and restarted. “Overvibration”was a concern, but the tight rebars and the weight of the vibratedconcrete prevented any segregation. It was the opinion that the concrete cameout more homogenous with a better finish and strength. Caution should betaken if the concrete mix has a high slump with large aggregates.TIP: “Over-vibration” is something every contractor is afraid of (when theaggregate and sand separate and all the aggregate ends up in lumps or at thebottom of the form). The concern is well founded, but it takes a long vibrationtime and a lot of vibration force to reach this point. Our experience has beento see “under-vibration” rather than “over-vibration,” too little vibration timeor force to get a homogenous mix free of air bubbles.181-800-633-0032


GENERAL RULES FOR SELECTING, SIZING & PLACINGEXTERNAL VIBRATORS, cont’d.5. HELPFUL HINTS AND CORRECTIONS AFTER THE FORM ISSTRIPPED(A) Bleeding of cement and water: tighten seals in form or use less wateror lower slump concrete.(B)Honeycomb: often from bleeding, but if not, increase vibration time.If honeycombing on lower surface, move vibrators close tobottom of form.(C) Small pin holes in finish: difficult to determine cause. Usually fromtoo wet mix; additives or form oil; air entraining when form wall tooflexible and flexes too much during vibration, sucking in air. Large pinholes: if all over, try to reduce water content, vibrate longer after pour,add additional vibrators or re-vibrate before initial set.(D) Separation of aggregates: vibration time too long or too muchwater in mix.IF YOU HAVE ANY QUESTIONSCALL AND ASK FOR ASSISTANCEFROM A VIBCOAPPLICATIONS ENGINEER:1-800-633-0032


Let us send you free copies of our catalogsand discover all the VIBCO products designedto help you work smart.HANDBOOK &EQUIPMENTGUIDEEXTERNALCONCRETEVIBRATION■ How-To-Booklet■ 71 ApplicationPhotos■ Selection &Locating Guide■ Catalog #8401GENERALCATALOG■ Pneumatic Vibrators■ Electric Vibrators■ Hydraulic Vibrators■ Catalog #900112 VOLT DCVIBRATORS■ Dump body vibrators■ Salt & sandspreaders, etc.■ 20 to 3500 lbs. force■ Catalog #9112PLATECOMPACTORS &ROLLERS■■12” to 24” platesReversible and singledirectional plates■ Rollers 12” and 36”sizes available■ Catalog #9808We’re the ^INTERNALCONCRETEVIBRATORS■ Electric 1-3/8” to2-1/2” Head Size■ Pneumatic 1-3/8” to 3”■ Interchangeable headand shaft■ Catalog #9123SILENTVibrator Guys!SAND & GRAVELVIBRATORS■ 60 Application Photos■ Selection & SizingGuide■ Pneumatic Electric &Hydraulic■ Catalog #9803VIBCO, INC.75 Stilson Road, P.O. Box 8Wyoming, RI 02898E-Mail: vibrators@vibco.comPhone: (401) 539-2392 / (800) 633-0032FAX: (401) 539-2584http://www.VIBCO.comWest Coast:Phoenix, Arizona 85254Phone: (480) 596-1809(800) 633-0032FAX: (480) 596-1614SEE US AT www.VIBCO.comCanada:2215 Dunwin DriveMississauga, Ont.L5L 1X1Phone: (905) 828-4191(800) 465-9709FAX: (905) 828-5015CATALOG 0103

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