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.

 

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.

 

 

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.

Weather Slows Progress

The weather did not help the progress of the project any this week due to rainfall totals of almost three inches. The site contractor spent most of the week working on erosion control.

Site View of Erosion Control Maintenance

They were able to get things going later in the week continuing with the triple 72” CMP and the overburden removal.

Triple 72" CMP heads toward stream intersection

Stockpiling Under Cut for Backfill

Undercut Stock Pile Being Loaded Out

Saturday’s work schedule was cut short due to sleet and rain.

Welcome to Greeting From Gastonia

Welcome to Greetings From Gastonia, an online diary containing posts, images and videos of construction of the redevelopment final phase of the Gaston Mall located in Gastonia, North Carolina. Join us as we create a positive environmental impact story that will serve the local community for years to come. [Read more…]

Work Continues For Gastonia

The site grading contractor has been taking advantage of the great weather in late October to get a jump on the undercut for the future building pad. Multiple layers of grid and stone are being used to insure a stable building foundation.

Granular Material and Fabric Covering

Through the month of October, the site contractor has progressed with the installation of the triple 72”CMP (Corrugated Metal Pipe). This is being installed to relocate an existing storm stream under the future parking lot area.

Forming of 72" Pipe Collar

The relocation of the existing outfall sewer was a 24/7 operation after finding the condition of the existing VCP pipe. Crews worked round the clock for 7 days to install, test and cut over more than 1200lf of new 18” sewer line.

Sewer Crew Setting Up For Relocation Process

Night Work for Sewer Relocation

The site contractor was able to get the transition collar from CMP to RCP in on the triple 72” pipes before the Thanksgiving Holiday.