Loads of Civil Work This Week

Initial work on the basket wall

Civil work this week involved excavating a slope for a 20 foot high gabion-style basket wall. This area will eventually feature a retaining wall for the upper site where the parking lot will be located and the lower area for the recently relocated Duhart’s Creek.

Front side of building & Parking Lot civil work

Landmarks nearing completion this week include the parking lot sub-grade and the block work on the front of the building.

Completed cut slope

On the southwest area of the site, overburden trash is almost completely gone. Nearby, a large cut slope has been seeded and mulched so that landscape efforts can get a head-start.

Grading work in mid-process

Grading work for an area on the site that will be a mitigated wetlands area began on a soil nail wall that eventually will extend vertically down over 20 feet.

Electrical crews installing conduit runs

In addition to the civil work this week, the electrical crews began installation of the conduit runs for the power feeds for the building. These runs will feature over 2,000 linear feet of conduit runs around the building site after completion.

Site & Building Progress Continues

 

View of Duhart Creek as Erosion Control Work Is Performed

Repair work performed on access road due to heavy rains

Overview of site with arch feature shown

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.

 

Foundation finished & Walls Started

Progression of work on the southern wall

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

 

Northern Wall Shown Here

Unloading of the Roof Steel Started

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.

 

Scaffolding and bricks for the mason work for one of the walls

Scaffolding for the Loading Dock Area Walls

Sample of the Bricks used in the Walls

Masonry work was started throughout the building as the walls were finished out.

 

Foundation for wall before concrete pour

Steel Installed for the Retaining Wall

Concrete Pour Retaining Walls

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.

 

 

Building Started at Gastonia

Laser-guided Screed

Power Ride-on Trowel

Slab after pour & plastic sheets installed

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.

 

 

Utility work shown here

Preparation of the base for the filter tanks

Removal of Over Burden - Over 65k cubic yards have been removed so far

Site work continued with underground utilities, removal of overburden/trash and installation of the underground detention system.

 

 

Filter Tanks for Storm Water Discharge

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.

 

 

Arch feature of the site installed

Grouting between the arches

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.

 

 

Arches shown near new Duhart’s Creek location

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.

It’s Been A While…

It’s been a while since the weather has cooperated. Last week, things changed and we found ourselves able to take full advantage of some good weather and continued the work in both building and civil areas.

The arch bridge crew has used the good weather to their advantage as well as the bridge arch construction was started and we expect to complete the arches next week.

Cut and Fill operations continue in the parking field. Storm drain installation in the parking area of the site is now 90% complete.

 

Bridge Center Foundation Completed…

We worked around the weather fronts this week and were able to complete the center foundation component for the bridge as well as the headwall for the Triple 72” on the downstream side.

We also made progress with the vertical construction and completed approximately 50% of footings.  The masonry crews were quick to chase the foundation crews as soon as we poured footings .

In an ideal project, each trade will tend to nudge or “pace” the next trade which is our goal here.

Footing Crews Laying Foundations…vertical construction starts soon.

This week our footing crews started the foundations for the vertical construction once the pad was completed and accepted.

Our civil work continue to progress in and around the weather cycles. While our foundation crews poured out the east footing early this week for the bridge, the remainder of the crew was finishing up H-piles on the center footing. Our plans are to pour the center footing the first of the week. The arch structure is scheduled for delivery next week with erection to follow.

The concrete crews also poured the headwall for the outlet end of the triple 72” pipes.

Building Pad Turnover Milestone Reached

We reached a milestone last week when we turned over the building pad to our building superintendent which means that we are now going vertical with our buildings.

Last week our site crews completed one head wall of the triple 72”’s  storm pipe, that you see below, and have now moved to the next one.

Our foundation crews for the bridge were able to pour one of the bridge footings the first of the week, worked through the week driving H piles and formed the east footing for a Friday evening concrete pour.

The site has changed significantly over the past few weeks, despite the challenging weather. Thanks to all that have helped to make our promises kept thus far.

The Building Pad Turns Over & Pile Driving Begins

With the turnover of the building pad this week, our crews have narrowed down the requirements for turn-over. Stone access road was installed around the building pad and in staging area. Our building superintendent is now on the job to start vertical construction.

We have now shifted the focus from the pad completion to the remainder of the site. Sixteen trucks cycled at a rate of 1.5 rounds an hour as we concentrate efforts to removing about 30,000 CY of overburden that overlays the fill needed to complete the balance of the grading operation.

Our work continues on the spine road through the site and this week we started driving steel H piles and as soon as they are complete we will form and pour reinforced concrete caps to support the double arch culvert bridge crossing Duharts Creek.

Fine Grading Operations have begun, no thanks to the weather!

We have been working a seven day work week the last couple of weeks to get the fill material finished for the pad and staging area, followed by the fine grading operation.  The only exception when delayed by the ice and snow of last week.

We have now completed the sheet piling that surrounds the bridge footings and will start driving “H” piles the first of this week. De-water of the area is the main operation for now.

Our Utility crews have been doing double duty to get the water and storm in around the building.

Taking Advantage of Sunny Days

The New Year brought more un-needed weather to the site.  The week started off with wet conditions.   Taking advantage of sunny day windows the crews are using blending and dying techniques to keep the schedule moving forward.

Durharts Creek bypass was put into place to allow for the bridge foundation crews and pipe crews to work without water running through their work areas.  The creek bypass will stay in place until the arch span bridge is erected.

Storm crew finished out the triple run of 72” pipe. Headwalls will be poured next week.  The bridge foundation crew is hoping to have all the sheet pile piles in by the beginning of next week and start driving “H” piles  that the foots will set on.

The waterline crews have started on the loop feed around the building that will provide both domestic and fire line.

Overburden removal and revealing good fill material underneath is still a huge factor in progress. Crews have hauled nearly 40,000cy offsite at this point.   The site contractor has been running to operations  to remove as much overburden as possible at the same time excavating good fill material to bring the pad and parking lot up to grade.