Progress On All Fronts

Crews started the soil nail wall this week. This is the first part of the wall, and provides structure for the concrete that will be poured later.

Crews continue to cover subgrade with stone.

The off-site mitigation work is looking good. All the grading is complete with 75% of the small plantings in place. The larger plantings will be done next week.

Crews started the demolition of the concrete median for the offsite roadway improvements.  The crew will have to work closely with the NCDOT and the resurface contract, to be completed at the same time.

Stone crews yield way to paving crews as the first lift of asphalt is put down in the parking lot.

Gastonia Moving Closer To Finish Inside and Out

 

Front View of Building

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.

 

Ceramic tile installation

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.

 

Finished ceramic tile work

As mentioned previously, the food service areas are getting more defined by the finishing touches such as the ceramic tile shown above.

 

Cooler & Freezer area

In addition to the front food service areas, the areas behind-the-scenes, such as the cooler and freezers, also had tile installed.

 

Front Offices of building

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.

 

Pole relocation process

Steady work continues on the offsite roadway improvements. Electric crews have almost completed the transfer to the new pole locations.

Civil Crews placing fill

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.

 

Retaining Wall

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.

Gastonia Channels Forward

New channel staked

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 installation

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.

 

Curb crews pouring concrete

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.

 

Main Drive of Parking Lot

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.

 

Glass installation shown

The Storefront is coming along nicely. Glass is being installed, as well as some of the sidewalk signs.

 

Sidewalk for front of building

We are finishing up our sidewalk prep work with lights, tree grates and bollard sleeves.

 

Ceiling Tile Installation

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.

 

Food Area Sheet Rock installed

In the Food Ave area sheet rock is up, mud is being applied and paint will soon follow.

 

 

 

 

More basket wall work and paint is the norm at Gastonia.

Basket wall crew at work

Crews have been working 7 days a week to get the basket walls up and over the arches. This is the first basket layer over the top. There is +/-8’ more fill and baskets yet to place.

 

Flooring beneath the arches

Crews are flooring in the arches so that the new stream alignment can begin. The grading crews will establish a rough elevation for the stream crew to work from. The stream crew will define the channel and splash pools for the new location of the stream.

 

Site of off-site stream mitigation before clearing

Stream Mitigation Site after Clearing

The off-site stream mitigation clearing was started and the new location staked. You can see the existing stream to the left. The new stream location will meander along beside the existing channel.

 

Electric Crews starting on line & pole work

Electric crews have been working between storms to get the pole switched over so that the road widening can start soon.

Primer and Paint sprayed on sales floor

The painters have begun their work inside on the sales floor with primer and are following with wall paint. The ceiling grid was started this past week as well.

Sanding of drywall installed last week

Sanding of the walls is almost complete in the guest services area. Painting is expected to start this week with the ceiling grid starting shortly afterwards.

Drywall sanded & primed ready for paint.

In another part of the building, the offices are also near completion and are will be ready for paint by the end of the month.

 

Preparation for signs going up

Storefront crew working on one of the entrances to building

The exterior of the building is also taking shape. The sidewalks are almost complete, exterior cosmetic work is ongoing, as signs are ready to be hung.

 

 

Paint & Paving at Gastonia

 

Loader spreading stone before paving

North driveway getting the binder asphalt placed.

Stone crews did the final grading and compacting for the north driveway. The drive is tested and once it passes, the asphalt binder is placed.

Service drive after paving

A view of the north driveway from the loading dock

Crews placed the asphalt binder along the north service roads towards the loading dock. In addition, paving was done along the areas near the main entrances.

Concrete crews working on sidewalks

After the weather event last week, concrete crews were able to make pours for the front sidewalk areas. Despite the weather being stubborn, the crews have made great progress.

Loading Docks Shown here

The back area of the building is nearing completion as well. All areas have been primed and painted. In addition, the concrete crews have finished the back side walk pours.

Arches and basket wall shown

Crews are up to the top of the arches with the basket walls.  They have 8 more feet to the top of the wall.

Wiring for ceiling grid shown.

The interior work is progressing as well. Ceiling grid wires have been started and we plan to continue with ceiling grid installation on 5/18/11.

Drywall on sales floor shown taped and bedded.

Walls shown after mudding and tape process

The interior walls were taped and mudded after metal studs were completed last week. Here the walls are shown after this process; ready for final sanding and primer.

 

Grading Stones and sidewalks started at Gastonia

 

Crews prepping subgrade

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.

 

Motorgrader spreading stone

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.

 

Roller used to compact the stone

A roller was used in the final step to compact the stone. The density requirement for the stone is 100% per AASHTO T99 standards.

 

Crews working on last bits of parking lot area

Crews working on last bits of parking lot area

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.

 

Crews relaying material to center of arches

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.

 

Top Soil installation in planters

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.

Crews relaying material to center of arches

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.

 

Crews working on sidewalk forms

Sidewalk forms for rear of building

Sidewalks are beginning to take shape and the crews are slated to start the pours this week. Preparation was completed last Friday.

 

Crews finishing walls for painters

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 Crew Priming Wall

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.

 

Framework for guest services area

Blocking and framework has been completed in entrance and guest services area. Drywall was started and is on track to finish on schedule.

 

 

Concrete and Metal Installed at Gastonia

 

Crews installing concrete pipe

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.

 

Truck turnaround area and loading dock shown

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.

 

Curbing Crews Working on north side of site

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.

 

Excavation for raft footing

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.

 

Site Overview of Civil Operations

The construction of bridge and wall backfill areas are shown above as crews perform their various assigned tasks.

 

Entrance and Blade Tower

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.

 

Left side and rear of building

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.

Progress in all areas of Gastonia

 

Area shown is one of two islands in the parking lot

There are two long “islands” that were prepped for curb pouring. These islands will separate the two parking lots at Gastonia.

 

New utility poles shown before lines are relocated.

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.

 

Excavator placing fill material

 

Fill Material Shown here

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.

 

A top view of the raft footing at the south side of the arches

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.

 

Crews prep for a pour near the loading dock

First pour of concrete for Truck Turn Around Area.

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.

 

Walk-in Storage Cooler installed

Cooler/walk-in storage has been installed and the next step includes installing quarry tile and stainless base/trim.

 

Metal Stud Installation

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 Installed

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.

 

EIFS work shown on external of building

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.

Civil & Building Improvements Continue

Fabric installed by civil crew

Raft Footing being installed which consist of a rip rap layer, fabric and stone to support the gabion walls.

 

Spreading rock in footing area

Installation of stone layer within the raft footing. The 4’ thick raft footing will support a 22’ high gabion wall when completed.

 

Crew members laying geogrid material

Footing area after geogrid installation

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.

 

Masonry work going up

Prep and Paint of front entrance

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.

 

Planter 1 poured and irrigation installation shown

Planter 2 prep work before pour

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.

 

Stone laid of Subgrade for drive to loading dock

Loading dock area after pressure washing & paint prep

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.

 

Conduit Installation on site

In other areas of the site, the electrical crews neared completion of the conduit runs and tying into the main power

 

 

 

The Three Rs in Gastonia: Raft footing, Rip Rap and Rubber Membranes

Hydromulch on corner section of site

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.

Basket wall construction

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.

Waterlines progress around site

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.

Rip rap spread amongst the footing

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.

Crews complete the raft footing after the rip rap install

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.

Roofing crews installing membrane

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.