Is it possible to design a new concrete casting methodology, leveraging the precision and freedom of industrial robots? That was the question posed by Form Found Design when Joseph Sarafian and Ron Culver began their Fabric Forms research. They quickly determined that a fabric sleeve, when positioned by robots, could act as an adjustable formwork to realize innumerable geometric possibilities. By sending digital 3D designs to these robots, an innovative digital concrete fabrication method was created.
When Amazon asked them to build the thirteen-foot-tall pavilion at the company’s MARS conference, Joseph and Ron knew they needed a solution for reinforcing. Since all 70 components are unique, conventional rebar would have proven too labor intensive. After searching the market for applicable reinforcement solutions, Helix Steel Twisted Steel Micro Rebar was a perfect fit for this application. “Its capacity to provide homogeneous reinforcement throughout the concrete eliminated the time and labor associated with building 70 unique rebar lattices,” said Joseph Sarafian, CEO and Co-Founder of FFD.
Needing a cementitious mix design that provided a low carbon footprint and high structural strength, FFD selected Rapid Set Cement All from CTS. The combination of Helix Steel and CTS enabled FFD to meet their unique needs.
“CTS is well-known for the innovative technology we bring to design and construction. We were honored to be a part of this groundbreaking project that is taking innovation to the next level,” said Ken Vallens, President at CTS.
The MARS Pavilion will be on display at the A+D Museum in LA, starting in July 2017. Come have a look and see for yourself where the future of construction is heading.
About Form Found Design (www.formfounddesign.com)
Form Found Design is a collaborative design studio based in Los Angeles with a belief that design must be derived from the geometry found in nature using the most advanced digital tools available. This fusion of nature and robotics is a motif explored in all of their projects, most recently the MARS Pavilion for Amazon’s MARS Conference in Palm Springs.
About Helix Steel (www.helixsteel.com)
Helix Steel, a Pensmore company, is the manufacturer of Twisted Steel Micro Rebar (“TSMR”), the leading proactive concrete reinforcement technology in the world. Helix Steel is leveraged across a variety of markets including commercial, industrial, precast, residential, underground and infrastructure and in applications ranging from structural, temperature and shrinkage to crack, seismic, impact and blast resistance.
About CTS (www.ctscement.com)
CTS Cement Manufacturing Corporation manufactures Rapid Set® professional-grade cement products for concrete repairs, restoration, and new construction projects. Construction professionals choose Rapid Set when superior durability is required, results need to be structurally sound and aesthetically pleasing, and to save time and money.
Helix Steel has been reinforcing concrete with Twisted Steel Micro Rebar (TSMR), globally, for over 16 years. In that time, we have accumulated a vast amount of knowledge on the various aspects pertaining to reinforcing a concrete structure. This information has been assimilated into training modules and published online for our partners and end users.
The aspects covered in the modules include:
- Helix Steel Design Methodology
- Calculating a Helix Steel Dosage Rate
- Analysis of concrete mix design
- Dosing concrete with Helix Steel
- Mixing Helix Steel with concrete
- Pouring Helix Steel reinforced concrete
- Finishing Helix Steel reinforced concrete
- Cutting Joints in Helix Steel reinforced concrete
Upon completion of each online training course, a certificate of attendance will be provided. While the best practices for Helix Steel are nearly identical to the best practices for ordinary concrete application, the training modules review these practices with a particular focus on Helix Steel reinforced concrete. Those interested in enrolling in the training program can do so at: https://www.helixsteel.com/resources/premium/online-training/
“We are excited by the opportunity this presents to add even more value to our partners and end customers,” said Luke Pinkerton, Founder and CTO of Helix Steel. “With the ever-increasing use of Helix Steel TSMR, we have been proactively educating our clients on our best practices. The Online Training Platform provides a medium for Helix Steel to educate in a more efficient manner.”
About Helix Steel (www.helixsteel.com)
Helix Steel, a Pensmore company, is the manufacturer of Twisted Steel Micro Rebar (“TSMR”), the leading proactive concrete reinforcement technology in the world. Helix Steel is leveraged across a variety of markets including commercial, industrial, precast, residential, underground and infrastructure and in applications ranging from structural, temperature and shrinkage, crack, seismic, impact and blast resistance.
The American Journal of Testing and Evaluation recently published “The Measurement of Average Tensile Force for Individual Steel Fiber using New Direct Tension Test”. An integral part of this publication is the acceptance of the groundbreaking methodology of Direct Tension testing for concrete, which was developed by Helix Steel.
Ashley Capital selected Helix Steel as the primary concrete reinforcement technology for its’ new Findlay Commerce Center (FCC), located in Findlay Township, PA. The FCC is a 316,000 sq. ft. state-of-the-art, distribution/light industrial facility that can accommodate up to four tenants of varying sizes.
Although originally designed with welded wire mesh and fiber mesh reinforcement, Helix Steel provided a design that 3 dimensionally reinforced the slab of the facility with Twisted Steel Micro Reinforcement (TSMR), removed all welded wire mesh and fiber mesh and promises to deliver an increase in shear strength, ductility, modulus of rupture and toughness, reduced carbon footprint and shortened the total project timeline.
“Helix Steel’s code approved technology removed all labor associated with chairing, laying and tying welded wire mesh and enabled our contractor to pour in a more efficient manner, which in turn shaved time off of our delivery schedule.”, said Kevin Hegg, Vice President with Ashley Capital. “As a developer, we are always looking for ways to shorten the construction schedule and to provide a better potential value to our tenants. Helix Steel TSMR is designed to help offer those benefits.”
“The goal with each of our customer’s projects, is to provide a more structurally sound, longer lasting concrete application and to deliver quantifiable value in terms of time savings and sustainability. This resonates within the Owner/Builder community in terms of project financing, delivery dates, realized rental or lease revenue and green initiatives.” said Helix Steel VP of Sales, David Stephens.
Helix Steel is exhibiting at the 2017 World of Concrete in Las Vegas next week, booth N3005.
#WOC2017
About Ashley Capital (www.ashleycapital.com)
Founded in 1984, Ashley Capital has become one of the largest privately-held real estate investment companies in the United States. Based in New York, the firm has offices in Atlanta, Chicago, Detroit, Grand Rapids, Nashville and Norfolk, VA. Ashley’s current portfolio stands at approximately 22 million sq. ft.
About Helix Steel (www.helixsteel.com)
Helix Steel, a Pensmore company, is the manufacturer of Twisted Steel Micro Rebar (“TSMR”), the leading proactive concrete reinforcement technology in the world. Helix Steel is leveraged across a variety of markets including Commercial, Industrial, Precast, Residential, Underground and Infrastructure and in applications ranging from structural, temperature and shrinkage, seismic and impact and blast resistance.
Pensmore has been the leading investor in Helix Steel since 2012. On the strength of those investments Helix Steel has been able to increase capacity, expand sales and drive market penetration. In an effort to further increase Helix Steel’s global expansion, Pensmore Reinforcement Technologies, a Pensmore Company, has acquired Helix Steel.
“Helix Steel’s products are disruptive technologies for reinforcing concrete, adding both strength and durability. Pensmore is proud to acquire this unique technology and committed to its global success,” said Steven T. Huff, General Manager of Pensmore. “Building durable, resilient and safe infrastructure is of utmost importance to the Pensmore mission, and Helix Steel is a key component enabling structures to standup to both natural and manmade disasters such as tornadoes, earthquakes, and blasts. The infrastructure of the future will be remarkably safer and more durable with Helix Steel.”
“We are excited about this acquisition and the added growth and expansion it affords Helix Steel. Continued successful market penetration and innovation will provide a solid platform from which to grow our company,” said Helix Steel CEO, Chris Doran.
About Pensmore (www.pensmore.com)
Pensmore advances leading infrastructure technologies with durability, energy efficiency and safety in mind. Pensmore identifies and develops unique cost effective innovations that will lead to a safer and cleaner environment for generations to come.
About Helix Steel (www.helixsteel.com)
Helix Steel is the manufacturer of Twisted Steel Micro Rebar (“TSMR”), the leading proactive concrete reinforcement technology in the world. Helix Steel is leveraged across a variety of markets including Commercial, Industrial, Precast, Residential, Underground and Infrastructure and in applications ranging from structural, temperature and shrinkage, seismic and impact and blast resistance.
IAPMO ES has updated the Helix Steel 5-25 Evaluation Report (ER-279) to specifically address both above and below grade walls built in accordance with the IBC, IRC, ACI 318 and ACI 332.
IAPMO ES has updated the Helix Steel 5-25 Evaluation Report (ER-279) to specifically address both above and below grade walls built in accordance with the IBC, IRC, ACI 318 and ACI 332. The ISO/IEC 17065:2012 compliant ER-279 provides engineers, contractors, code officials and owners assurance of Helix Steel code compliance and design, installation and field quality assurance instruction.
UES Technical Director Brian Gerber, PE, SE, explains: “Helix Steel can reference its ER-279 on Helix 5- 25 Micro-Rebar to ensure that code officials quickly have the information, from a trusted third-party source, necessary for their quick decision on approval.”
In the past 15 years, Helix Steel has been used in over 10,000 structures, successfully replacing rebar in vertical applications including above and below grade, cast in place walls, tilt walls, insulated wall panels, stay in place cement board form walls and ICF walls. In addition to allowing for reduction or elimination of rebar, Helix Steel adds seismic, tornado, hurricane and impact and blast resistance. Success stories are broad and global, ranging from single-family home basements in Ohio, USA to high-rise buildings in Melbourne, Australia.
Luke Pinkerton, CTO of Helix Steel states, “Science has proven that Helix Steel changes concrete’s state from brittle to one more ductile. This has enabled our customers to build more durable structures, while saving valuable schedule time and reducing carbon footprint.” The ER-279 also provides International Accreditations in over 90 countries. “The updated ER-279 further validates our technology and its’ use worldwide.” For more details on our projects, click the link below:
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About IAPMO (www.iapmoes.org)
Uniform ES offers manufacturers and building officials another, we believe better, option as an evaluator of building products. Since 1926, IAPMO has been a leader in codes and standards development and its’ Uniform Evaluation Services is built upon an 88-year-old foundation of experience, expertise and quality.
About Helix Steel (www.helixsteel.com)
Helix Steel is the manufacturer of Twisted Steel Micro Rebar (“TSMR”), the leading proactive concrete reinforcement technology in the world. Helix Steel is leveraged across a variety of markets including Commercial, Industrial, Precast, Residential, Underground and Infrastructure and in applications ranging from structural, temperature and shrinkage, seismic and impact and blast resistance.
Frontier Kemper Constructors Inc., a Tutor Perini subsidiary, selects Helix Steel as the concrete reinforcement technology provider for the Metro Transit Authority’s East Side Access Project. The MTA’s East Side Access project, the nation’s largest public transportation project and the first expansion of the Long Island Rail Road in more than 100 years, will connect the rail line via underground tunnels to Grand Central Terminal in Manhattan.
Frontier Kemper’s portion of the project includes work on a permanent structural concrete lining, interior structures, and fit-out for previously excavated tunnels north of Grand Central. Helix Steel is providing Twisted Steel Micro Rebar solutions for cast-in-place tunnel final lining and shotcrete applications.
According to Leon “Lonnie” Jacobs, from Frontier Kemper, “Helix Steel has been able to meet both the concrete reinforcement specification for the MTA’s East Side Access project and deliver on the demanding supply schedule that Frontier-Kemper requires in order to keep the project on schedule. We are glad to have HELIX on the construction team.”
These solutions, Helix 8-50 and Helix 5-25 respectively, provide industry leading shear strength, ductility and durability. With a factory in Grand Rapids, MI, Helix Steel is Made in America using 100% USA sourced materials and therefore compliant with the Buy American project requirements. Buy America Compliant product is available on request.
“Helix Steel is proud to be selected by Frontier Kemper as part of the MTA’s East Side Access project,” said Helix Steel CEO, Chris Doran. “Our technology has value across a variety of markets and the tunneling world is no exception. We look forward to working with Frontier Kemper and delivering American Made value to the MTA”
About Frontier Kemper (http://www.frontier-kemper.com/)
Frontier-Kemper Constructors, Inc. (FKCI) is widely recognized as a leader in underground and heavy civil construction. With more than $2.5 billion in projects successfully completed throughout the Americas, FKCI is known for their expertise in the engineering and construction of deep shafts and tunnels of all sizes and complexity.
About Helix Steel (www.helixsteel.com)
Helix Steel is the manufacturer of Twisted Steel Micro Rebar (“TSMR”), the leading proactive concrete reinforcement technology in the world. Helix Steel’s technology lowers the tensile response of the modulus of elasticity in plain concrete thus increasing its strain capacity, ductility and flexibility. Helix Steel proudly manufactures TSMR in Grand Rapids, Michigan.
Helix Steel, the leading provider of proactive concrete reinforcement technology, today announced the general availability of its Helix 8-50 product line. Helix Steel’s unique design of Twisted Steel Micro Rebar (TSMR) allows for efficient tensile stress redistribution within concrete prior to the concrete cracking. The result is a significant increase in concrete’s strain capacity and pre-crack properties. Unlike rebar and other forms of reinforcement, TSMR provides proactive reinforcement which engages the concrete before large cracks form.
Helix 8-50 has a nominal length of 2 inches (50mm) and an equivalent diameter of 0.30 inches (0.8mm) which meets specification ASTM A820 – Type I. “Today’s launch of Helix 8-50 combines our proactive concrete reinforcement technology with a longer length that provides superior post-crack behavior. These qualities make Helix 8-50 ideal for the Tunneling and Industrial flooring markets,” says Jeff Novak, VP of Engineering at Helix Steel. “The performance efficiency gained when using Helix 8-50 allows use of dosages quantifiably lower than hooked steel fibers, thus reducing carbon footprint while increasing overall reinforcement capability.”
Helix Steel’s patented anchorage technology uses a continuous deformation along the length of the shaft in the form of twisted ribs rather than a smooth shaft with hooks at each end. This provides a continuous anchorage in concrete and stable pre- and post-crack behavior as opposed to smooth steel fibers that rely on small end hooks. In addition, the proactive nature of Helix 8-50 redistributes forces before cracks occur unlike macro plastic fibers that depend on the concrete cracking before they can provide any tensile resistance.
The Helix 8-50 data sheet can be found at: http://www.helixsteel.com/technical/helix-data-sheet Helix Steel is proudly made in the USA. Based on project specifications, American steel mill certification is available.
About Helix Steel (www.helixsteel.com)
Helix Steel is the manufacturer of Twisted Steel Micro Rebar (“TSMR”), the leading proactive concrete reinforcement technology in the world. Helix Steel first entered the market with its’ flagship product Helix 5-25 in 2003. Since then, Helix 5-25 has been reinforcing concrete in Commercial, Industrial, Transportation, Underground, Tunneling and Precast markets. In 2013, Helix 5-25 received a Uniform-ES ER-0279 Code Approved evaluation report, which certifies that Helix 5-25 can be used in concrete reinforcement for structural applications, as defined by ACI-318. Helix Steel proudly manufactures TSMR in Grand Rapids, Michigan.
Helix Steel recently earned IAPMO’s Uniform Evaluation Service (UES) Evaluation Report ER-279 on Helix 5-25 Micro-Rebar. This report accredits Helix Micro-Rebar 5-25 and its design method under ISO Guide 65 for use as an alternative to conventional rebar and wire mesh in concrete. Helix Micro-Rebar 5-25 is the only discontinuous concrete reinforcement product in the world that now has a ISO certified design manual that can be followed to design vertical applications (such as walls) with Helix as the primary concrete reinforcement.
ER-279 opens up more than 99 countries worldwide for the immediate use and design with Helix due to the MLA/MRA agreements in place under IAF (International Accreditation Forum). It recognizes Helix 5-25 Micro-Rebar under the 2009 and 2012 revisions of the International Building Code® (IBC), International Residential Code® (IRC) and 2011 ACI 318 concrete code. ER-279 documents the substantiating data provided as evidence that Helix 5-25 Micro-Rebar satisfies applicable code requirements. This allows for the specification of Helix 5-25 Micro-Rebar by architects, contractors, and designers, and approval of installations by code officials. It also provides code officials with a concise summary of the product’s attributes and documentation of code compliance.
“With ER-279, building code officials have peace of mind that Helix 5-25 has been fully reviewed as an acceptable alternative to traditional reinforcement in concrete design; this accreditation is great validation for Helix, and a significant advantage for the market,” said Luke Pinkerton, Helix president. “Helix is a cost-effective, durable and easy-to-use alternative to conventional rebar and wire mesh. Having ER-279 assures engineers, code officials and others that they can rely on Helix for their concrete structures.”
Products recognized under UES have successfully undergone evaluation based on applicable requirements within the International Family of Codes, as well as codes published by other entities. UES staff thoroughly examined Helix 5-25 Micro-Rebar product information, test reports, calculations, quality control methods and other factors to ensure the product was code compliant.
The UES program is built upon IAPMO’s more than 70 years of experience in evaluating products for code compliance. Accredited by the American National Standards Institute (ANSI), the program operates under ISO/IEC Guide 65, “General Requirements for Bodies Operating Product Certification Systems.”
UES technical director Brian Gerber, PE, SE, explained why Uniform Evaluation Reports are so valuable: “Helix can now reference its ER-279 on Helix 5-25 Micro-Rebar to ensure that code officials quickly have the information, from a trusted third-party source, necessary for their quick decision on approval.”
About Helix Steel
Based in Ann Arbor, Mich., Helix Steel’s Micro-Rebar product is a cost-effective and durable replacement for traditional rebar. In any application, including structural foundations, slabs, suspended structural concrete, and paving, Helix Micro-Rebar is proven to increase the strength and durability of concrete. For more information, visit helixsteel.com.