All the signs, glass and store front has come together and is complete, with the exception of the feature wall. Sidewalk will be complete soon.
Inside at the food service area, the ceramic tile is almost complete. The projects are beginning to come together and we are seeing more definition due to the completed work.
As mentioned previously, the food service areas are getting more defined by the finishing touches such as the ceramic tile shown above.
In addition to the front food service areas, the areas behind-the-scenes, such as the cooler and freezers, also had tile installed.
Glass has been installed in the office areas up front. The sheetrock and mud are almost complete and will be ready for the painters soon.
Steady work continues on the offsite roadway improvements. Electric crews have almost completed the transfer to the new pole locations.
Crews have been placing fill on the west side of the steel arches to build the future roadway up. There is still another 8’-10’ of fill to go in here.
Wall crews continue to progress with the segmental portion of the retaining wall. They have installed nearly 1,000 sf of block in the past 3 days.
The channel defining process began with the crews staking out the new channel and started to install the rock vain on the downstream side of the arches.
Rock vein is installed and the crew is working on the riffle section going under the arch. There will be 13 of these structures to be installed in the new channel.
Over 2,000 linear feet of concrete curbs was poured by the Curb crews. There is around 800 linear feet left to pour in the parking lot and will be finished next week.
Fine grade crews are working to get parking lot grades cut and stone placed. This is the main drive on the east side of the parking lot.
The Storefront is coming along nicely. Glass is being installed, as well as some of the sidewalk signs.
We are finishing up our sidewalk prep work with lights, tree grates and bollard sleeves.
We have also started our tile installation. Once all the pieces have been cut out for columns and sprinklers the tile will go up fast.
In the Food Ave area sheet rock is up, mud is being applied and paint will soon follow.
Crews worked all week prepping subgrade and getting the north main drive ready for stone. Some areas required an undercut after not passing proof roll initially.
Stone was used to spread the roads around the site to bring to grade. A motorgrader was used to spread the stone. The crews used water to assist in making sure that the optimum density is achieved.
A roller was used in the final step to compact the stone. The density requirement for the stone is 100% per AASHTO T99 standards.
Site crews have worked to get the last lifts of fill in the parking lot area so that concrete curb and gutter can be poured. The crews will fine-grade the parking lot for stone after the curb and gutter is done.
The crews installed a 55 foot wide raft that the basket walls sit on. The white fabric is a high strength geotextile material that wraps the raft.
Landscape crew installed the topsoil mix for the planter boxes in the front of the building. There is 3’ of topsoil over a 12” layer of stone. The fabric that covers the stone is for filtration purposes only. It acts as a barrier between the stone and topsoil.
Bailing material was placed in the center of the arches by a larger excavator as a mini-excavator placed it for compaction. This is a very slow process, but with the two crews working together it is progressing nicely.
Sidewalks are beginning to take shape and the crews are slated to start the pours this week. Preparation was completed last Friday.
Backer rods and colored caulk was completed on the outside of the building and as they finish, the painters are right behind them priming the walls.
Paint crews began priming the outside walls of the building and as of last Friday had completed 3 sides. The painting will begin this week as they finalize the last wall.
Blocking and framework has been completed in entrance and guest services area. Drywall was started and is on track to finish on schedule.
Storm crews installing storm pipe through the basket wall, which when complete will discharge drainage from nearby areas and to the relocated Duhart’s Creek.
Crews finishing up the truck turn around concrete paving; this area will allow full access to the load dock for delivery to the building as it is now completed.
Our crews have placed curb on the North side of the building and in the eastern side of the parking lot including completing almost 3,000 linear feet in one day.
Crews are excavating for the raft foot to support the basket wall. This leg of the wall runs to approximately where the trucks are sitting in the picture. At that point the wall changes to a concrete-covered soil nail wall.
The construction of bridge and wall backfill areas are shown above as crews perform their various assigned tasks.
The blade tower and front entrance is nearing completion. EIFS was finished last week and now the crews are working on the metal studding for the façade and over the entrance area.
The rear and side elevations were finished and the fine grading near completion around the building. There is still a lot of work to be done, but Gastonia takes one more step towards completion each day.
There are two long “islands” that were prepped for curb pouring. These islands will separate the two parking lots at Gastonia.
The relocation by AT&T of the utility service will have to be completed before the widening of Cox Road and new sidewalk construction can be completed.
Crews used an excavator with a 60’ long reach to place the fill material between the 78’ wide arches. The photo above shows the various materials and the need for some of the work to be done by hand.
The raft footing that started last week has 4’ of washed stone and 4 layers of grid inside. The 23’ high wall will be constructed on top of this footing.
Sitting on 6” of stone, the concrete slab for the truck turn around area got its first pour. This is the first of the +/-400cy of 4500psi concrete that is required for truck turn around area.
Cooler/walk-in storage has been installed and the next step includes installing quarry tile and stainless base/trim.
Metal studs were installed at the front Guest Services area. Once completed, the electrical work will begin and then the area will be finished by the sheet rock and paint crews.
Duct work in the front vestibule area was completed and wrapped. The metal stud installation shown on the right in the photo above was completed as well and sheetrock crews will be the next in this area.
The blade tower section of the building received EIFS this past week and is ongoing. This area, on the left side of the building, is where the signage will eventually be installed.
Raft Footing being installed which consist of a rip rap layer, fabric and stone to support the gabion walls.
Installation of stone layer within the raft footing. The 4’ thick raft footing will support a 22’ high gabion wall when completed.
Geogrid, a high-tensile plastic mesh, is a major component of this work. These 2 layers of basket wall will be covered once the slope grades are finished.
On the building side of things, masonry work is ongoing. As the masonry work is being completed, the entrance and feature wall of the building is prepped for paint.
The site will feature planters near the entrance area of the building. Planter 1 was poured and stone caps installed with irrigation installation started. Meanwhile, Planter 2 was prepped for the concrete pour and irrigation will follow.
The loading dock is getting closer to finishing as our crews spent the week grading the drive. Stone was placed at the Subgrade level and the civil completed for access. The actual loading dock area was pressure washed and prepped for paint.
In other areas of the site, the electrical crews neared completion of the conduit runs and tying into the main power
The SW corner slope with ECO-Flex hydro mulch held up well to the past week of storms that dropped over 3” of rain in 7 days. The mulch has seed, fertilizer, and tachafier (a type of polymer) that helps the organic mulch bond to the soil and helps reduce eroding of the slope.
The civil construction continues as the site contractor cuts out an area for the basket retaining wall. These walls once finished will measure over 40 feet; starting at the cut from the top of slope to the bottom where the wall footing will be.
The waterlines are being laid and crews are ready to tie it into the existing lines around the site. Before service can be sent to the building, the lines will have to be filled, flushed and treated with chlorine. In addition, the lines will be tested for bacteria as well.
We are using rip rap to condition and stabilize the ground under the raft style footing for the basket walls. Rip rap is the rock or other material used to strengthen structures against water and natural erosion. The basket walls will cross over each end of the double arches and hold the roadway to be constructed above.
The raft footing for the basket walls shown have 3 layers of geo grid and 2 ft of stone that is wrapped by another fabric like a “burrito”. This type of footing is used for the basket walls so that the wall is able to move and float on the marginal soils underneath without compromising the integrity of the wall itself.
The building work this week featured our crews began working on installing the membrane for the roof. In the photo above, the white area of the roof is the rubber membrane. This membrane is lightweight and allows for rain water to move more freely.
There is an inspection done weekly onsite for erosion control. Due to the heavy rain events we had there were a lot of the erosion control devices that needed to be replaced, repaired, or improved upon. Thanks to the rainout days and 2 ½” of rain, this was the focus of our site work last week.
To date, we have undercut over 15,000 cubic yards of wetlands, hauled over 60,000 cubic yards of overfill and trash, laid 340 linear feet triple run of 72” corrugated metal pipe, installed over 2,000 linear feet of 60” underground detention system pipe and installed the twin arch spans measuring 75’ long by 49’ wide by 17’ high.
During the last few weeks, we’ve seen the building work begin as the site work was winding down. The foundation is poured and the forms for the walls started on the southern wall. Brick work was began as the wall concrete pours were completed
Our crews began to unload the first loads of steel for the roof.
Other necessary structures for the roof steel will be started soon and topping out should be completed as well.
Masonry work was started throughout the building as the walls were finished out.
Concrete pours are still a vital part of Gastonia. The retaining wall in the loading dock area was poured last week. Subgrade work has started after the forms were stripped. The driveline concrete will be poured at the site by our crews soon. Progress continues with the walls up and the roof steel delivered.
During the time since our last post, multiple concrete pours were made as shown in the photos above. The process includes using a laser-guided automated screed and large ride-on power trowels. In the last photo, you can see the slab is covered with plastic to ensure that moisture is retained allowing the concrete to cure slowly, yielding the highest strength.
Site work continued with underground utilities, removal of overburden/trash and installation of the underground detention system.
The filter tanks shown above weigh nearly 90k lbs. each and have 52 filter cartridges each; these tanks will filter sediment and other environmental pollutants before storm water is discharged off-site.
A major feature of the site is the arches shown above. Crews attached the end caps to the arches and lay grouting to the keyway between the two, which bonds the structure and concrete foundation together.
The proposed location of Duhart’s Creek will run adjacent to the wall footing. The crews have finished the sheet piles that act as scour protection for the basket style wall footing.