What I Learned from Talking FF/FL With 100 Testing Labs Last Year

I wanted to use a different title for this article, but I ran out of room so I had to cut it short. What I wanted to name it was something like:

4 Principles I Was Fortunate Enough to Learn by Travelling to 25 States and Talking With 100 Construction Materials Testing Managers About Floor Flatness Testing Over the Past 12 Months

That’s much too long, of course, so I had to shorten it up. Although I feel like some of the pizzazz is lost in the shorter title.. But I digress.

There’s a few key things that I’ve learned from my excursions, but they aren’t mere technical information. There’s plenty of technical things I’ve learned about testing methods, equipment, etc. Stuff you can read about in ASTM. That’s not what this article is about.

Here we’re going to talk about Principles. Fundamental truths. The things that the best labs in the world are doing (and the biggest mistakes I see labs making).

These are principles specifically around Floor Flatness (FF/FL) testing, so if you don’t know much about FF/FL or are just getting started in materials testing, I’d recommend watching this video to learn more.

But first...

Before I talk about the principles, I have to answer the one question that may be burning in your mind: Why are you talking to so many testing labs?

The easy answer is: We sell floor flatness testing equipment. CMT labs are our prospects and customers and we help them become more efficient at testing FF/FL on concrete slabs.

Because of that, I get insights and a unique perspective from talking with labs in a variety of markets, in both small and large companies, and I get to hear about all kinds of projects and processes that labs are using.

I've talked to labs from Portland, Oregon to Portland, Maine. From Boston to Austin (ah, I've always wanted to slide that into an article someplace).

Let's go over four FF/FL principles I’ve learned from my work with world-class CMT labs.

Here they are:

1. FF/FL Testing is Narrow but Deep
2. Know the Impact Your FF/FL Report Has
3. Great Labs Aren’t Winging It
4. Relationship + Communication Matter

Principle #1: FF/FL Testing is Narrow but Deep

In many cases, the FF/FL test is something that’s included in a larger project scope or is an addendum to a project that’s already underway. Because of that, I’ve been stunned to learn how many labs are so unfamiliar with the entire FF/FL testing process. So often, it’s been something that one or two technicians or project managers know about and the rest of the team is clueless.

Admittedly, Floor Flatness testing is not something that most CMT firms are staking their revenue targets on.. But it’s important to understand one thing: FF/FL testing is narrow but deep. Just because it’s an add-on service doesn’t mean it doesn’t have any impact or value.

When it’s required, it matters.

This is where so many of our customers (labs and contractors alike) have run into problems on projects. A specified FF/FL number gets copy-and-pasted by the architect from one document to the next, it’s altogether ignored by the project engineer, and the testing lab doesn’t even notice it in the fine print of their Scope of Work until the customer calls for it.

Countless times I have been visiting with labs and been shocked at the lack of understanding around a test they are being paid to perform. It's okay to not know.. But if it's something you're offering to clients, you need to make sure you're doing right by them and performing the test according to the standard.

(There’s a great example of this under Principle #3.. Keep reading.)

Action: Learn and understand ASTM E1155. Teach your technicians how to test and report on it. Watch our video on it. Research and really understand it! FF/FL testing might seem like a small inspection in the project scope, but it’s deep. And in the real world, this is a case of The Devil in the Details.

Coming off of this point is the second Principle:

Principle #2: Know the Impact Your FF/FL Report Has

Last year I worked with a lab in California who had tested a floor that didn’t meet the specified requirements. The lab technician sent out the report and promptly forgot about it. That is, until the contractor called.

He was hot under the collar and, in no uncertain terms, let the lab know where they stood. He questioned their technician, their certification, their equipment calibration, their time frame for the test.. Everything under the sun. As far as he was concerned, there was no way on God’s green earth that he poured a floor that didn’t meet the project specs.

When I arrived at the project, I finally got the chance to talk with the contractor one-on-one. He seemed nervous. After we talked for a while, he confided in me.

“I can’t afford to rip out this slab. It's 25k sq ft! We’re so far behind on money and schedule that this would darn near put us under.”

Of course the testing lab was only there to take the test, and the financial well-being of the contractor is not their responsibility. But I think this illustrates a principle that many miss:

What may be a simple PASS/FAIL to the lab might be enough to put someone else out of business.

Action: It’s absolutely critical that you and your technicians know the impact your test can have. The “out-of-business” stuff is not just me being melodramatic. Before you send off a FAIL test report, do your own checks and balances. Make sure your technician did everything by the book. Have a copy of ASTM E1155 nearby. You’re about to get a phone call.

Principle #3: Great Labs Aren’t Winging It

A few months ago, I met with a lab in California..

(Before I go any further: I have to be extremely careful with specifics of who I talk about and the case studies I share. People (understandably) get really uncomfortable when you over-share their stories and details with the rest of the world.

One thing I learned however, is that it’s a basic universal truth that California is the epicenter of all insanity. California residents are the first ones to say it! So from here on out, I’m going to refer to all my crazy, real-life stories “a lab in California” haha, love you CA!)

Back to the story.

A few months ago, I met with a lab in California. They were interested in seeing the Axiom and casually mentioned that they just found out about a FF/FL project they had coming up.

During our conversation, I learned that they didn’t currently have any floor flatness testing equipment. No one in their firm had ever performed an FF/FL test before. Worse yet, they had only found out FF/FL was in the project scope the day before when their biggest client called to schedule the test. I asked when they would be needing to perform it.

“Oh, they placed the concrete at 2:00am this morning. We’ll need to do it by this time tomorrow.”

On the inside I was shaking my head in disbelief. There are so many nuances to FF/FL testing that it’d be a sheer miracle if they could take an ASTM compliant test with 24 hours notice.

Fortunately for them, their firm had been hired as a “fourth party” consultant and were able to tag along with the other lab (their competitor) and take cues on run layout from them. But on principle, there’s no way your technicians should be learning how to perform the test on the jobsite, especially from your nearest competitor. It’s bad form and it dings your reputation in front of the owner, GC, and concrete contractor. Steer clear.

On another project, I rode the jobsite elevator to the 25th floor of a tower project (in California, of course). The contractor and I arrived at the top to find the CMT technician getting a head start on the FF/FL test.. He was so early, in fact, that his device foot pads were creating obvious indentations in the slab every 12”. Needless to say, we had to let him know that measuring a wet slab sort of defeated the purpose of the test.

It’s essential that your team knows what details to watch out for. All it takes is a little sand on the foot pad, taking a run too close to a penetration, not collecting quite enough Z values, or getting the device orientation mixed up and the scene that unfolds with the contractor will resemble Mixed Martial Arts meets Barnum and Bailey’s circus.

Action: Keep your lab up to date with training, certification, and ongoing education on ASTM 1155. Create an FF/FL checklist to complete during each test.

Principle #4: Relationship + Communication Matter

Not long ago, a contractor flew me out to their project in California (haha) because they wanted to purchase an Axiom for their own testing purposes. In many cases, our contractor clients use the device to diagnose their placement and finishing processes. Their tests aren’t necessarily ASTM compliant, but they’re doing forensics work to check curling, shrinkage, and look for ways they can improve.

I was pleasantly surprised with the third party testing lab who had been hired by the general contractor. While we were getting ready to go on-site, the project manager from the lab called my client and let him know he had just emailed over their run layout diagram for the test they were going to be performing later that day.

“We’ll be using the usual equipment. My tech should be there around 3:00pm and we’ll have the report to you tomorrow. Let me know if you have any questions.”

When he hung up, I asked if that was a typical occurrence.

“Working with this lab, yes. These guys have really gotten to know us and are proactive about getting us their pre-test plan and the final report. They’re great to work with.”

These guys got it. Even if the concrete contractor isn’t your direct customer, one of the most underestimated ways to avoid issues on floor flatness tests is to build a relationship with the contractor so there’s a level of trust. He knows you’re going to give him honest, thorough test results and in return, you aren’t going to be his whipping boy if there’s any issues. It’s much harder to cuss out a friend.

Action: Create a pre-test checklist for the project manager and testing technician to cover your bases. Enforce a pre-test meeting or phone call with the superintendent and concrete foreman before each test.

In Conclusion:

As the third party testing lab, you've been hired to tell the truth. Of the 100+ labs that I've met in the last 12 months, the best ones understand this, communicate it to their team, and stand by it to ensure the best possible finished product for the client.

As the third party testing lab, you’ve been hired to tell the truth.

Remember:

• FF/FL Testing might be Narrow but it’s Deep
• It’s critical to know the impact your FF/FL report has on the contractor and project
• Great labs aren’t flying by the seat of their pants - they stay up to date and invest time in training and education
• Relationships + proactive communication can be the difference between a great project and a recurring nightmare

Get copies of ASTM E1155 for each of your technicians, take the time to teach your teams about floor flatness testing, and build trust with the contractors you work with.

Your clients, your employees, and our industry itself will be better for it.

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Benjamin Holmgren with Axiom spends his time writing for, talking to, thinking about and meeting with contractors and testing labs all over the country to help them make more money and produce better concrete floors. When he's not doing that, he's hanging out with his wife and kiddos, drinking great coffee and trying to come up with even more dad jokes.