concrete

Structural Concrete

Core walls, columns, and structural elements for commercial buildings

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Serving Johnson County

Structural concrete construction forms the backbone of commercial buildings throughout Cleburne and Johnson County, TX, providing the columns, beams, walls, and foundations that transfer gravity and lateral loads safely to the ground. From multi-story office buildings and parking structures to distribution centers and manufacturing facilities, precision structural concrete work ensures buildings perform as engineered while meeting stringent safety codes and long-term durability requirements in North Texas's challenging climate.

Structural concrete elements are engineered per American Concrete Institute (ACI) 318 standards to resist specific load combinations including dead loads (building weight), live loads (occupancy and equipment), wind loads, and seismic forces. While Texas has minimal seismic activity, wind loads from severe thunderstorms and tornados drive structural design requirements for Johnson County buildings. Column and beam sizes, concrete strength, and reinforcement schedules are determined through structural analysis accounting for all anticipated loads with appropriate safety factors.

Commercial structural concrete in Cleburne typically specifies 4,000-6,000 PSI concrete for standard applications, with high-strength mixes up to 8,000+ PSI used for high-rise columns or long-span beams requiring maximum capacity in minimal cross-sections. Reinforcement uses Grade 60 deformed rebar in precisely engineered patterns providing tensile strength that concrete alone cannot achieve. Critical elements like moment-resisting frames and shear walls require complex rebar cages with hundreds of bars tied to exact specifications before concrete placement.

Formwork represents a significant component of structural concrete construction: temporary molds that shape and support fresh concrete until it achieves design strength. For columns and beams, we use adjustable steel or aluminum forms enabling reuse across multiple floors, reducing costs on multi-story projects. Wall forms include gang panels for large pours or hand-set panels for smaller elements. All formwork is engineered to resist concrete placement pressure and construction loads without deflection that would compromise finished dimensions.

Our structural concrete expertise encompasses foundation design and construction, column and beam forming and placement, elevated slab systems, concrete core walls for elevator shafts and stairs, architectural concrete with exposed finishes, post-tensioned concrete systems, and complex connections integrating structural steel or tilt-wall elements with cast-in-place components. Every project includes comprehensive quality control: concrete testing to verify strength, reinforcement inspection confirming bar sizes and placement, formwork inspection before concrete approval, and final inspection documenting compliance with structural engineering plans for Cleburne Building Inspections and third-party special inspectors as required by code.

Common Applications

Multi-Story Office Buildings

Cast-in-place concrete construction provides economical, fire-resistant structure for 2-6 story office buildings throughout Cleburne. Concrete columns and beams support post-tensioned or conventionally reinforced floor slabs, with concrete core walls providing lateral resistance and housing elevators and stairs. Concrete's thermal mass moderates interior temperatures reducing HVAC costs in Texas heat, while sound attenuation between floors creates quality office environments. Architectural concrete finishes on columns and walls create distinctive interiors without applied finishes.

Parking Structures

Multi-level parking structures use cast-in-place or precast concrete for superior durability under vehicle loads and weather exposure. Structural systems include flat-plate slabs on columns for economical construction, post-tensioned slabs allowing longer spans and thinner sections, or precast double-tee systems for accelerated construction. Concrete resists deterioration from vehicle fluids, road salt, and freeze-thaw cycling better than steel alternatives. Proper drainage, corrosion-resistant reinforcement, and air-entrained concrete ensure 50+ year service life in Johnson County's climate.

Distribution Center Interior Structure

Large distribution facilities often combine tilt-wall perimeter with cast-in-place interior columns supporting roof systems and mezzanine floors. Columns range from 24x24 inches to 36x36 inches depending on roof spans and loading, typically spaced 50-60 feet on center. High-strength concrete allows minimum column sizes preserving warehouse space. Columns include embedded plates connecting to roof beams and embed anchors for racking systems, material handling equipment, and building services. This structural approach provides economy and speed while accommodating the complex loading and equipment requirements of modern logistics facilities.

Manufacturing Plant Foundations & Equipment Bases

Manufacturing facilities require specialized structural concrete including heavy equipment foundations, vibration-isolated machine bases, process pits and trenches, and elevated platforms for material handling. Equipment foundations use high-strength concrete with robust reinforcement resisting dynamic loads and equipment vibrations. Anchor bolts are positioned with tight tolerances using templates provided by equipment manufacturers. Deep foundations may include drilled piers or driven piles extending through Johnson County's expansive clay to competent bearing strata. Comprehensive engineering addresses equipment loads, soil conditions, and operational requirements ensuring reliable, long-term performance.

Technical Specifications

Concrete Strength Requirements

Structural concrete strength is specified based on element type and loading. Foundations typically use 3,500-4,000 PSI. Columns range from 4,000 PSI for low-rise buildings to 8,000+ PSI for high-rise or heavily loaded elements. Beams and slabs use 3,500-5,000 PSI depending on spans and loads. All structural concrete includes minimum 4% air entrainment for freeze-thaw protection in North Texas climate. High-strength mixes use Type III cement or supplementary cementitious materials achieving design strength in reduced curing periods while improving long-term durability.

Reinforcement Standards

All reinforcing steel is Grade 60 deformed bars (ASTM A615) with mill certifications documenting compliance. Bar sizes range from #3 (3/8 inch diameter) for temperature and shrinkage reinforcement to #11 (1-3/8 inch diameter) for heavily loaded columns and beams. Minimum concrete cover is 1-1/2 inches for formed surfaces, 2 inches for weather-exposed surfaces, and 3 inches for concrete cast against earth. Rebar is tied at all intersections using steel wire, with chairs, bolsters, and supports maintaining proper position during concrete placement per ACI 301 standards.

Formwork Engineering

All formwork is designed for concrete placement pressure (150 lb per cubic foot), 50 PSF construction live load, and impact factors per ACI 347 formwork standards. Column forms use steel or aluminum adjustable systems allowing reuse across multiple floors. Wall forms include gang panels for large areas or hand-set panels for complex geometry. Elevated slab formwork uses engineered shoring systems (typically 5,000-6,000 PSF capacity), horizontal stringers and joists, and plywood decking. Form ties resist concrete pressure while maintaining proper wall thickness. All formwork is inspected for adequacy, tight joints, and alignment before concrete placement approval.

Placement & Consolidation

Concrete placement follows ACI 304 procedures ensuring quality and structural integrity. Maximum free-fall height is 5 feet to prevent segregation. Concrete is placed in lifts not exceeding 24 inches with internal vibration consolidating each lift before the next is placed. For columns and walls, placement occurs continuously without cold joints that compromise strength. Slabs are placed, screeded, and finished to proper elevation and surface texture. Placement rate is controlled preventing excessive formwork pressure while maintaining crew efficiency. All placements are monitored by qualified technicians with authority to stop operations if quality is compromised.

Quality Control Testing

Comprehensive testing program ensures structural concrete meets specifications. Slump testing on every truck load verifies workability (typically 4-6 inches). Air content testing confirms freeze-thaw protection (4-7%). Compressive strength cylinders are cast per ACI 301: minimum one set (three cylinders) per 100 cubic yards, per day's pour, or per 5,000 SF of slab area. Cylinders cure under controlled conditions (60-80°F), then undergo compression testing at 7 and 28 days by certified testing labs. Test results meeting 100% of specified strength at 28 days and averaging 115%+ across all tests demonstrate compliance.

Curing Requirements

Proper curing maintains moisture and temperature allowing complete cement hydration and strength development. We apply liquid membrane-forming curing compounds meeting ASTM C309 immediately after finishing, supplemented by wet-curing (soaker hoses or wet burlap) for critical elements or high-strength mixes. In Cleburne's summer heat exceeding 95°F, evaporation retarders during finishing and aggressive curing prevent plastic shrinkage cracking. Winter concreting uses insulated blankets maintaining minimum 50°F concrete temperature if ambient temperatures drop below 40°F. Minimum curing duration is 7 days, extended for high-strength mixes or cold weather.

Special Inspection Requirements

Cleburne Building Inspections requires third-party special inspectors for structural concrete per International Building Code. Special inspectors verify reinforcement placement including bar sizes, spacing, cover, splices, and anchorage. They observe concrete placement confirming proper consolidation, verify formwork adequacy and alignment, review concrete test reports for compliance, and inspect curing and protection measures. Continuous inspection is required during all structural concrete placement. Inspection reports documenting compliance are submitted to Building Inspections before subsequent construction phases are approved.

Project Timeline

Foundation Excavation & Prep

Excavate for spread footings, grade beams, or mat foundations per geotechnical recommendations. For Johnson County's expansive clays, excavation extends to competent bearing strata with overexcavation and select fill as needed. Install forms for below-grade elements, place and tie reinforcement per structural plans, install anchor bolts or dowels connecting to superstructure columns. Third-party inspection verifies excavation depth, bearing surface, reinforcement placement, and embedments before concrete approval.

1-3 weeks depending on foundation complexity

Foundation Concrete Placement

Place foundation concrete using continuous pours to avoid cold joints in structural elements. Concrete is consolidated with internal vibrators ensuring complete placement around reinforcement and embedments. Surface is screeded and floated to proper elevation for column placement. Curing begins immediately using curing compounds or wet-curing methods. Anchor bolts and dowels are verified for position and plumbness before concrete sets. Cylinders are cast for strength verification.

1-3 days for typical building foundation

Column & Wall Formwork

Erect column forms at locations established by survey, verifying position and plumbness. Walls receive gang forms or hand-set panels creating cavity for concrete placement. All formwork is braced adequately resisting concrete pressure and construction loads. Forms are cleaned, coated with release agents, and inspected for tight joints preventing grout leakage. Embedded items like sleeves, plates, and block-outs are positioned per plans and secured against displacement during concrete placement.

3-7 days per floor level

Vertical Element Rebar Installation

Place and tie column and wall reinforcement per structural bar schedules. Rebar cages for columns may be pre-assembled on ground then lifted into forms, or tied in place for smaller elements. Wall reinforcement uses horizontal and vertical bars tied at intersections with proper spacing maintained by rebar chairs. Lap splices, development lengths, and concrete cover are verified against structural drawings. Third-party special inspection confirms all reinforcement before concrete placement approval.

2-5 days per floor level concurrent with formwork

Elevated Slab Formwork & Rebar

Install shoring systems supporting slab formwork at proper elevation. Beam forms (if applicable) are positioned and braced. Plywood decking creates smooth slab soffit. Reinforcement is placed per structural plans, typically two-way mats of rebar with additional bars at columns and openings. Electrical conduits, sleeves, and embedments are coordinated. Edge forms contain slab perimeter. Complete inspection verifies shoring capacity, deck elevation, reinforcement compliance, and embedded items before concrete approval.

5-10 days per floor level

Vertical & Horizontal Concrete Pours

Columns, walls, beams, and slabs are poured in sequence (sometimes same day for structural continuity). Concrete is placed in lifts with vibration ensuring complete consolidation, avoiding segregation or cold joints. Slabs are screeded to proper elevation, floated, and finished to specified surface. Temperature is monitored, and curing begins immediately. Quality control testing (slump, air, strength cylinders) occurs per ACI standards. Pour continues without interruption until structural elements are complete.

1 day per floor level for most buildings

Curing & Form Removal

Concrete cures under protection from rapid moisture loss, achieving strength for form removal and construction loading. Column and wall forms strip after 12-24 hours (minimum 1,500 PSI). Elevated slab formwork and shoring remain until concrete achieves 75% design strength, typically 7-14 days. Cylinders are tested verifying adequate strength before form removal and loading. Removed forms are cleaned and moved to next level, while curing continues for elements remaining in forms.

7-14 days for complete floor cycle

Connections & Integration

After structural concrete achieves design strength, connections integrate steel elements, mechanical and electrical rough-ins, and finishes. Dowels and embed plates welded or bolted to steel framing transfer loads per engineering details. Core-drilled penetrations (if needed) for MEP systems are located avoiding reinforcement. Post-installed anchors for equipment, handrails, or finishes are installed using engineering-approved systems. Final inspection verifies all structural work complies with approved plans before building systems installation proceeds.

Ongoing throughout building completion

Cleburne & Johnson County Considerations

Expansive Soil Foundation Design: Structural concrete foundations in Johnson County must address expansive Eagle Ford clay soils that exert significant uplift forces during wet cycles and shrink during dry periods. Conventional spread footings on grade are often inadequate, requiring drilled pier foundations extending 10-20 feet to competent bearing below active soil zone, grade beams spanning between piers elevated above grade allowing soil movement without inducing structural stress, or structural mat slabs designed to bridge over differential soil movements. Geotechnical engineering determines appropriate foundation system based on site-specific soil testing including plasticity index, swell potential, and bearing capacity. Foundation designs must account for both downward gravity loads and upward swell forces that can exceed 5,000 PSF in highly plastic clays.

Wind Load Design Requirements: While Texas has minimal seismic activity, wind loads from severe thunderstorms and tornadoes drive lateral force design for Johnson County buildings. Building codes specify 115-120 MPH design wind speeds (3-second gust, Exposure C) creating substantial lateral forces on building frames. Structural concrete shear walls, moment-resisting frames, or braced frames resist these lateral loads, with connections engineered to transfer forces through the structure to foundations. Taller buildings or buildings with large roof areas experience increased wind loads requiring robust lateral force-resisting systems. All structural designs are reviewed by licensed professional engineers and submitted to Cleburne Building Inspections for plan review and approval before construction permits are issued.

Local Concrete Supply & Logistics: Johnson County is well-served by ready-mix concrete suppliers in Cleburne, Burleson, and surrounding communities, providing reliable high-quality concrete for structural applications. However, large structural pours requiring 100+ cubic yards of continuous placement demand advance coordination with suppliers ensuring adequate capacity, backup plants for emergencies, and proper truck cycling maintaining optimal placement rates. We maintain relationships with multiple suppliers enabling competitive pricing and reliable service. Local aggregates from North Texas limestone quarries produce quality concrete meeting structural specifications while minimizing transportation costs. Summer heat requires discussing concrete cooling if placement temperatures exceed 90°F, while winter work may need Type III cement or accelerators for cold-weather concreting.

Frequently Asked Questions

Service Areas

We provide structural concrete throughout Cleburne and Johnson County:

Cleburne, TX Burleson, TX Joshua, TX Keene, TX Alvarado, TX Godley, TX Grandview, TX Rio Vista, TX

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