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Concrete Division
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Concrete’s history dates back to the Roman Empire, and while the basic of concrete have largely remained the same, technological advances of today have made this product into one of the most versatile and used building materials available throughout the world.
The words “concrete” and “cement” are often confused. Cement is the gray powder that, when mixed with water, binds the sand and rock together to create concrete. Concrete is the world’s most prolific building material. This “liquid stone” can be shaped to make roads, bridges, dams, hospitals, and homes. It is extremely strong and durable. The longevity of concrete means less maintenance and replacement when compared to other building products. These properties contribute to the environmental value of concrete versus most any other building material available today.
Concrete consists of a mixture of aggregate (sand and gravel), cement and water. Concrete can be cast in almost any shape desired and once hardened it becomes a structural element. “Ready-mix” concrete is a prescribed mix of aggregate, cement, water and often other admixtures and products that enhance the properties and characteristics of concrete.
Ready Mix Concrete is sold by volume, not weight. The measurement standard for Ready Mix Concrete is the cubic yard. A ready mix plant makes concrete with a computerized batching system. As the ready mix plant weighs the dry materials (aggregate and cement), it begins to meter in the liquid materials (water and admixtures) into the mixer. Once the system achieves the correct weights for the dry materials, the plant discharges the dry materials into the mixer where they are blended with the liquid ingredients into a homogenous mix.
Ready Mix Concrete is typically delivered from a plant to the construction location with a specialty vehicle called a mixer truck. The most noticeable feature of a mixer truck is the large drum that houses the concrete. The inside of these drums are fitted with spiral blades. When the drum is rotated in one direction, the concrete is pushed deeper into the drum, agitating the mix and keeping it in its plastic state. When the drum rotates in the other direction, blades force the concrete out of the drum. Chutes are often used to guide the viscous concrete into place. A Mixer truck typically weights approximately 30,000 pounds and can carry roughly 40,000 pounds of concrete (10 cubic yards)
Here at Ferndale Ready Mix & Gravel, we have three primary concrete divisions:
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Common Flatwork Questions
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DELAMINATION
Delaminations are similar to blisters. Delaminated areas result from water and air getting trapped between a prematurely closed surface. Delaminations are very difficult to detect during finishing and become apparent after the concrete surface has dried and the delaminated area is crushed under traffic. The primary cause of delamination is finishing the surface before the bleeding of water and air has occurred |
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SCALING
Scaling is the general loss of surface mortar due to freezing and thawing. The aggregate is usually clearly exposed and often stands out from the concrete. Scaling is primarily a physical action caused by pressure from water freezing within the concrete. |
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SPALLING
Spalling is a deeper surface defect than scaling, often appearing as circular or oval depressions on surfaces or as elongated cavities along joints. Spalls are caused by pressure or expansion with the concrete, bond failure in two-course construction, impact loads, fire or weathering.
Improperly constructed joints and corroded reinforcing steel are two common causes of spalling | |
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DISCOLORATION
Factors found to influence discoloration are calcium-chloride admixtures, cement alkalies, Hard-troweled surfaces, inadequate or inappropriate curing, variation of the water cement ratio at the surface, and changes in the concrete mix. Weather can have a large effect on discoloration. Humidity, cloud cover, and temperature can affect the color of the cured concrete. Uneven or equally place subgrade material may affect the color. Shadows from adjacent buildings or trees often affect the color. Often discoloration from these causes appears soon after placing the concrete. | |
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CRACKING
There are several reasons why cracking can occur, listed below are the main types of cracking and their causes:
- PLASTIC SHRINKAGE CRACKING – Plastic shrinkage cracks are caused by a rapid loss of water from the surface of concrete before it has set. The critical condition exists when the rate of evaporation of surface moisture exceeds the rate at which rising bleed water can replace it.
- SUB-GRADE SETTLEMENT – Insufficiently compacted subgrades and soils susceptible to frost heave or swells, producing cracks in slabs.
- CRAZING – Crazing, a network pattern of fine cracks that do not penetrate much below the surface, is caused by minor surface shrinkage. Crazing is not structurally serious and does not ordinarily indicate the start of future deterioration. Low humidity, high air temperature, hot sun or drying wind, either separately or in any combination, can cause rapid surface drying that encourages crazing.
POPOUTS
A popout is a conical fragment that breaks out of the surface of the concrete leaving a hole that may vary in size. Popouts usually occur when a piece of porous rock absorbs moisture or freezes under moist conditions. The rock’s swelling creates internal pressure sufficient enough to rupture the concrete surface. Most popouts appears within the first year after placement. Popouts are considered a cosmetic detraction and generally do not affect the service life of the concrete
CURLING
Curling is the distortion (rising up) of a slab’s corners and edges due to differences in moisture content or temperature between the top and bottom of a slab.
DUSTING
Dusting is the development of a fine powdery material that easily rubs off the surface of hardened concrete. Dusting is the result of a thin, weak layer called laitance, composed of water, cement, and fine particles. Dusting is caused by 1) floating and troweling concrete with bleed water on the surface, 2) water applied during finishing, 3) exposure to rainfall during finishing, 4) spreading dry cement over the surface to accelerate finishing, 5) a low cement content, 6) too wet a mix, 7) lack or proper curing, 8) carbonation during winter concreting caused by unvented heaters, 9) freezing of the surface, and 10) dirty aggregate.
BLISTERS
Blisters are bumps, or varying size, which appear when bubbles of entrapped air or water rise through the unhardened concrete and get trapped under an already sealed, airtight surface. Blistering is commonly caused by an excessive amount of entrapped air held within the concrete, insufficient vibration during compaction, overuse of vibration, or finishing when the concrete is still spongy. |
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Industrial/Commercial Concrete
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FERNDALE
Ready Mix & Gravel, Inc.
Phone: 360-354-1400
144 River Road Lynden, WA 98264
Fax: 360-354-0486 | |
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Industrial/Commercial Concrete
Ferndale Ready Mix & Gravel continues to be the primary supplier of the industrial/commercial concrete needs within Whatcom County. Our three batch plants are strategically located to provide quick service throughout Whatcom County. From 200 yd3 to 25,000 yd3, we have the capability to meet the needs of any industrial or commercial project located throughout our service area. Each of the major industrial complexes in Whatcom County have mix designs approved from Ferndale Ready Mix & Gravel to use as foundations, slabs, fireproofing, pilings, or any other miscellaneous usage at their facilities. Our concrete has proven to be consistent, durable, and of high strength.
The 3,000 p.s.i. to 6,000 p.s.i. non-air entrained industrial concrete mix designs we have developed have achieved a Standard Deviation of 308 while our air entrained mix designs have achieved a Standard Deviation of 417. All our industrial/commercial mix designs meet the requirements for ASTM, ACI and the IBC. We have mix designs ranging from 100 p.s.i. CDF (flowable fill) to a 10,000 p.s.i. for special high strength needs. |
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THINGS TO CONSIDER WHEN SELECTING YOUR CONCRETE:
ADMIXTURES
When considering what type of concrete your project will require, the use of admixtures to increase the flowability and workability of the concrete mixes are often necessary to produce a high quality product. Water Reducers and Superplasticizers contribute immensely towards providing the contractor with a good flowing, workable mix. Admixture such as a Set-Delay Retarder or a Non-Chloride Accelerator can produce for the contractor a predictable concrete set time and improve their time management of their crew. Specialty admixtures like a Non-Shrink additive or a Water Proof Concrete admixture can also be achieved simply by asking our staff what the requirements are to produce these special mixes.
FIBER-REINFORCED CONCRETE
Synthetic Fibers such as Fibermesh 300 (Regular) when added to concrete may eliminate the need for a welded wire reinforcement. Fibermesh 150 (Stealth) helps control plastic shrinkage cracking that can occur during the concrete curing process. Both of these products reduce the square foot cost of your area compared to traditional welded wire fabric reinforcement. Synthetic Fibers also provide better impact resistance, abrasion resistance, reduces cracking, and provides an increase in flexural strength.
Steel Fibers such as Novocon or Novomesh are fast becoming the way for engineers and contractors to attain the structural reinforcement they need; yet save time, money, and work related injury claims. Steel fibers may reduce the square foot cost of your area compared to traditional rebar reinforcement or welded wire fabric reinforcement. Ferndale Ready Mix & Gravel has replaced over 1,000,000 square feet of traditional steel reinforcement with steel fibers. Traditional steel reinforcement as dense as a #4 rebar at 12 inch on center mat has been completely replaced with steel fiber. The blend of steel fibers along with synthetic fibers, as found in Novomesh, compliment each other by providing the structural reinforcement that is required while improving impact resistance, abrasion resistance, reduction of plastic shrinkage cracking, and providing an increase in flexural strength.
If you are in need of a potential concrete finisher or heavy foundation contractor, please feel free to contact us for a recommendation or reference. Check our common flatwork questions page to provide answers and information on frequent concrete flatwork questions.
If you have questions concerning our mix designs, you may contact us at 360-354-1400, or by email at concretesales@ferndalermg.com |
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Residential Concrete
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Ferndale Ready Mix & Gravel continues to be an innovative leader in residential concrete. No matter what your concrete needs are, we have the mix designs which can provide you with a warm, attractive, and inviting home. There are a number of local concrete contractors we can recommend to provide you excellent workmanship and a beautifully finished product.
THINGS TO CONSIDER WHEN SELECTING YOUR CONCRETE: |
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Integral Colored Concrete is used for hard landscaping and floors. Our line of Davis concrete colors gives you the opportunity to blend your concrete with your home’s surroundings providing a warm and attractive environment. Integral Colored Concrete is often looked at as a way to extend the living space of your home and increase its value. Outside the home, slopes, curves and changes in the grade can be readily accommodated by cast-in-place concrete. Inside the home, entryways, hallways, utility areas, kitchens, recreation areas all can be enhanced and complimented by an Integrally Colored Concrete. Easy to care for and maintain, Integral Colored Concrete is a wise investment for any residential use.
The popular Cascade Pea exposed mix creates a beautiful surface for patios, sidewalks, walls, or driveways. Slopes, curves and changes in the grade can be readily accommodated. A Cascade Pea mix along with a black concrete color brings out the beauty of the rock, especially with the contrasting white rock found in the Cascade Pea. With the annual application of an acrylic sealer, the beauty and depth of the Cascade Pea mix will continue to give value and warmth around your home. | |
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Stamped Concrete is yet another option that gives your home a very attractive appearance and gives you the look of a laid in place stone. The use of Integral Colors is very common with Stamped Concrete and can tie in your exterior landscaping décor. This hard landscaping technique can set apart your home from others and increase its value significantly with its warm appeal. As with other concrete, the annual application of an acrylic sealer will retain the beauty and depth of the Stamped Concrete and will continue to give value and warmth around your home.
 
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Synthetic Fibers such as Fibermesh 300 (Regular) when added to concrete can eliminate the need for wire mesh. Fibermesh 150 (Stealth) helps controls plastic shrinkage cracking that can occur during the concrete curing process. Both of these products reduce the square foot cost of your area compared to traditional welded wire fabric reinforcement. Synthetic Fibers also provide better impact resistance, abrasion resistance, reduces cracking, and provides an increase in flexural strength.
Our concrete has proven to be consistent, durable, and of high strength and we would encourage you to contact us to see what can be done to give your home that warm and attractive appearance when you drive in. For those who are in an area where impervious restrictions are keeping you from having a permanent driving surface, check out the possibility of using Pervious Concrete as a way to create a permanent driveway or sidewalk.
If you are in needed of a potential concrete finisher or concrete foundation contractor, please feel free to contact us for a recommendation or references. Check our common flatwork questions page to provide answers and information on frequent concrete flatwork questions.
If you have questions concerning our mix designs, you may contract us at 360-354-1400, or by e-mail at concretesales@ferndalermg.com.
 
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Specialty Concrete
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Ferndale Ready Mix & Gravel continues to meet the demands of the marketplace by providing mix designs specifically designed for unique or unusual needs. Whether you are looking for an economical and fast fill material (CDF), lightweight concrete, pervious concrete, SCC, waterproof concrete or LEED approved mix design, our quality control team has the resources to provide you with the appropriate mix for your situation. |
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PERVIOUS CONCRETE
Pervious Concrete is a cement based concrete with 15% to 25% void space. The voids are produced through the elimination of the fine aggregate generally found in typical concrete mixes. It is placed with standard paving equipment and compacted with rollers and it is recommended that a qualified Pervious Concrete Installer is used when placing it. Because of its low impact on the environment, Pervious Concrete can contribute toward LEED certification points. Pervious concrete driveways and parking lots allow rainwater back into the ground. Property owners and developers can also reduce runoff fees and enhance their bottom line by using pervious concrete because less site infracture is needed to handle rainwater runoff. Visit www.concreteparking.org for more information on how Pervious Concrete can work for you on your project. |
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LIGHTWEIGHT CONCRETE
Structural Lightweight Concrete is primarily used to reduce the weight or load of a concrete structure. Typical concrete weighs approximately 145 Lbs./Cu.Ft. while most of the Lightweight Concrete produced by Ferndale Ready Mix & Gravel will weigh 115 Lbs./Cu.Ft. Lightweight Concrete is produced by using a special manufactured aggregate that reduces the concrete’s overall weight. The overall strength of Lightweight Concrete is comparable to normal-weight concrete and requirements of 3,000 p.s.i. to 5,000 p.s.i. are very attainable. Lightweight Concrete in buildings also provides an increase fire rating safety and a higher R-value for improved insulation. |
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SCC (SELF CONSOLIDATING CONCRETE)
Self Consolidating Concrete (SCC) is a highly flowable, non-segregating concrete that can spread into place, filling the formwork and encapsulate reinforcement without any mechanical consolidation. Using a SCC mix allows for a faster placement rate and more uniform architectural surface finish as no mechanical vibration is needed. With a spread (slump flow) typically ranging from 26 to 30 inches, SCC mixes improve pumpability, consolidation around reinforcement and bond with the reinforcement. The high flowability of SCC is attained by using high-range water-reducing admixtures and not by adding extra water. |
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LEED CERTIFIED MIX DESIGNS
If your upcoming project is achieving a LEED Certification, we have a variety of mix designs that meet LEED requirements to assist your project in achieving the points you need for a potential certified, silver, gold, or even platinum rating. Through the use of recycled materials such as fly ash and ground granulated blast furnace slag, Ferndale Ready Mix & Gravel has the capability to design mixes that meet the specifications of your particular project while meeting the demands of LEED as established by the United States Green Building Council. To learn more about building green with concrete, the Portland Cement Association has developed a website at http://www.concretethinker.com/ where you can interact with and learn how concrete construction contributes positively towards keeping our environment protected while meeting the growing needs and demands of our society. |
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WATERPROOF CONCRETE
Waterproof Concrete has been a continual rise in use as engineers, architects, and contractors are requiring its use. Specially designed mixes along with a waterproofing admixture transforms porous concrete into a permanent, water-resistant barrier. By eliminiating the need for external waterproofing membranes, the Waterproof Concrete system saves construction time and costs. It provides maximum flexibility and can be used any time before, during or after the construction process. The admixture uses advance integral crystralines waterproofing technology to provide a powerful, guaranteed defense against water damage and the corrosion of steel reinforcements. When combined with water and concrete the waterproof admixture reacts with unhydrated cement particles to form millions of needle-like crystals. Over a period of weeks and months, these crystals grow, filling the naturally occurring pores and voids in concrete, and permanently blocking the pathways for water and waterborne contaminants. Later, if cracks form due to settling or shrinkage, incoming water triggers the crystallization process and additional crystals begin to grow, filling cracks and ensuring that the structure's waterproofing barrier is maintained and protected. Joints between walls and slabs can become completely sealed from water with the use of the appropriate grout and slurry compounds. When following the correct procedures and construction practices, a 25 year warranty may be achieved. To learn more about Waterproof Concrete, contact us at 360-354-1400, or by e-mail at concretesales@ferndalermg.com.
CDF (CONTROLLED DENSITY FILL or FLOWABLE FILL)
CDF is a low strength fill that hardens and develops into an excellent load-bearing soil. It is usually comprised of combinations of cement, water, fine aggregate and fly ash. CDF mixtures have numerous applications including bedding and backfill for utility trenches, paving sub-base, bridge abutment, and retaining wall backfill. It is also used in other void-filling applications such as abandoned tanks, tunnels, and sewer or water lines. |
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