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.

 

 

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.

 

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.

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.