Gold 2010 - NORTH DAKOTA READY MIX & CONCRETE …ndconcrete.org/Awards/PDFbrochures/2010_Awards.pdf · All concrete components were fabricated in North Dakota. Precast beams were

Hardfacts Special Edition NOrth Dakota Ready Mix & Concrete Products Association, Inc.

2010 Board of Directors

North Dakota Ready Mix & Concrete Products

Association, Inc.

North Dakota Ready Mix & Concrete Products AssociationPO Box 1076 • Bismarck, ND 58502 • 701-255-7250

David C. Sethre, P.E.Marketing [email protected]

Celebrating ExcellenceFor more than ten years, the North Dakota Ready Mix & Concrete Products Association. has honored our industry partners who have demonstrated the excellence and overall dedication needed to win our highest project awards each year. This year, we again have identified projects and their promoters and builders who will earn well deserved distinctions in our industry. The people involved in planning and specifying the use of concrete, and ultimately building these projects, will hopefully be recognized and honored, at least at some small scale, with this Hardfacts Special Awards Edition. For it is these people who not only honor themselves with finding effective uses for concrete, but it is their clients, project owners, and the public in general who will benefit from the environmental benefits, the value and the aesthetics that can come from the use of concrete.

Hardfacts applauds all winners, past and present, as they should be proud of their achievements. We hope they continue to provide the highest level of quality and dedication to the concrete industry.

David C. Sethre, P.E.Marketing Director

Gold 2010

Clint Feland PresidentArt Thompson Vice PresidentBrad Epema Secretary TreasurerDan Doschadis Past PresidentAl Christianson DirectorEd Fellner DirectorJeff Stumpf DirectorMark Dettling DirectorJohn Jund Director

NOrth Dakota Ready Mix & Concrete Products Association, Inc. Hardfacts Special Edition

Innovation AwardND Army National Guard Camp Grafton - 4” Concrete OverlayOwner: ND Army National GuardEngineer: Swenson Hagen Engineers PCContractor: Strata Corporation – Construction DivisionSupplier: Strata Corporation – Devils Lake Plant

This project is recognized in the “Innovation” category due to the effective use of new technologies involving thin concrete overlays. This is the first public project constructed in the state to reduce the concrete thickness to 4” for a concrete overlay. The engineers designed the project to take advantage of the bond between the existing degraded asphalt surface and the new concrete overlay to carry the expected heavy loads. Research and experience has shown that an effective bond at an appropriate joint spacing in the overlay will reduce the stresses in both layers, providing a long term economical solution for projects of this type.

Credit is directed to the engineers who did a thorough job in researching concrete overlay design and construction

technologies to minimize the risks for this project. This is the thinnest pavement that the contractor has ever slip-form paved, so the ordinary level of concerns was rampant. However, on the first paving day, the contractor was able to optimize the paver operations within the first few loads, and production occurred at full speed.

In spite of age and fatigue, the existing 5”-9” asphalt pavement was able to be salvaged with the concrete overlay. Asphalt distress included depressed cracks, raveled surface and nominal alligator cracking. Milling operations removed a minimum of material to eliminate depressions at cracks and to provide a uniform surface for the concrete placement. The milled surface provided an aggressive surface to promote the ultimate bond. The project was bid with square yard and cubic yard bid items to account for both material use and installation. Control on quantities was found to be very uniform after some initial overruns at the start of the project.

Based on concrete removal operations at the header, a very good bond between the asphalt base and the concrete overlay was achieved. When the concrete was removed, the bond was sufficient to cause the failure plane to occur in the asphalt, and not at the material interface.

Because of the shallow depth of the saw cuts, the initial saw-cut joints were cleaned and filled with hot-pour rather than providing a traditional sealed joint system with backer rods. Due to the short 6 foot joint spacing, little joint movement will be experienced, so fill material should be expected to perform for a long time.

Mike Baltzer, P.E. was the primary design engineer for the overlay project, while Cale Wegener provided site engineering and inspection. Congratulations to the North Dakota Army National Guard engineering staff and the innovative design engineering team who put together this successful project. Their innovation and leadership will provide a cost effective and long term solution to paving construction at the Camp Grafton facility. Plus, this first thin concrete overlay project will likely lead to additional exploration of the thin concrete overlay technology throughout the state.


Bridge Category

Whispering Bay Bridge ProjectOwner: Whispering Bay CorporationEngineer: Kadrmas, Lee & JacksonContractor: Swingen Construction CompanyPrecast Panels: Wells Concrete, Inc.Ready Mix Supplier: Knife River – ND

The Whispering Bay Bridge provides a visually appealing entrance to a luxury residential development in Bismarck, North Dakota. Its geometric lines and subtle arch provide an aesthetic quality to complement the environment and the style of the community. This aesthetic quality is accomplished through a variety of concrete products, including stained Redi-Rock blocks, precast concrete arch panels and decorative barriers.

All concrete components were fabricated in North Dakota. Precast beams were made by Cretex of Bismarck, arch panels by member Wells Concrete in Grand Forks and retaining wall blocks by Weisz and Sons in

Bismarck. The remainder of the concrete components, including abutments, bridge deck and traffic barriers were cast in place by Swingen Construction Company of Grand Forks.

The decorative metal pedestrian railing is the only component not formed from concrete. This railing complements the concrete design and is connected by concrete architectural pilasters.The bridge was designed and constructed following North Dakota Department of Transportation specifications, and has an expected lifespan of 75 years. The earth tones of the concrete naturally blend into the environment. All visible components of the bridge were given aesthetic emphasis using form liners, shapes, colors and textures. Decorative LED illuminated light panels and ornamental lighting create an after dark ambiance befitting a high-end residential community.

The construction of the bridge was unique because it was done prior to the completion of the 60-foot-wide water channel that now flows beneath the structure, connecting the Whispering Bay development to the Missouri River. Hydraulic analysis used the FEMA flood plain model to evaluate the effects of the Whispering Bay subdivision, which led to the grade modifications were made on the connecting road. The FEMA flood model was used to determine the project’s impact to the 100 year flood plain.


CommercialCategory

Lafarge Minot Cement Distribution Terminal Owner: Lafarge – North AmericaEngineer: EAPCContractor: ICS, Inc.Supplier: Strata Corporation – Minot Plant

The Lafarge Minot Distribution Ter minal was planned as a 200 ton per hour loading and unloading termi-nal for cement and fly ash from rail and truck cars. It went into service in September 2009 and has met or exceeded the design discharge goal. It features storage silos, pneumatic conveyors, (aka air slides), a high-ca-pacity bucket elevator, rail and truck loading and unloading features, and unique concrete framing assemblies. There are ancillary office and sup-port facilities within the terminal. The project was constructed with 5 silos, with provisions for a 6th silo to be installed at a later date. The signature feature of this project, and the basis for submitting the nomination, is the cast-in-place reinforced concrete moment frame that supports up to six 500 metric ton cement product storage silos.

The cast in place silo support frame consisted of a 2x3 bay system that utilized 12 - 36” square columns, with 30”x36” or 36”x36” concrete beams. A total of 345 CY of concrete was used to construct the frame alone.

Several options for the silo support structure were contemplated – steel moment frames, steel concentrically braced frames, and precast concrete and beam framing. Cast-in-place concrete was selected due to several of its relative benefits. It provided flexibility, quick and easy coordinated delivery schedules, optimization of contractors labor force, and the ability to work, even in cold weather. From an engineering perspective, concrete provided the ability to resist column torsion and bi-axial bending, high stiffness for a relatively compact shape, and ease in creating moment frame connections using traditional reinforcing steel. And, of course, Lafarge was interested in the use of materials supplied by their custom-ers. The total volume of concrete used on the project was 1,400 CY.

The total cost of the project was $5.2 million, of which $1.8 million was for equipment, silos, and related material handling equipment. The General Construction costs of the Project were $2.75 million, and the cost of the CIP concrete and reinforcing steel was $650,000


Dickinson Ready Mix Batch PlantOwner/Concrete Supplier: Dickinson Ready Mix Co. & Concrete ProductsTilt-Up Consultants: Innova Associates LiteForm Technologies Benchmark Foam, Inc.Structural Engineer: Advanced Technology Engineering GroupConstruction Manager: General Steel / Pat BrenTilt-Up Contractor: Winn Construction, Inc.Concrete Sub-Contractors: Winn Construction, Inc. J & L Concrete Construction Grizzly Concrete Services (a Division of Tooz Construction, Inc.)

When it came time to replace the existing 33 year old concrete batch plant at Dickinson Ready Mix Co., several building options were considered. The various options were evaluated on several factors including: 1) DRM wanted to showcase the product they sell so they wanted to use concrete and they wanted the concrete exposed; 2) they wanted an energy efficient building; 3) they wanted a durable, low-maintenance exterior; 4) cost-effectiveness was critical; and 5) they wanted to utilize local contractors and sub-contractors. After evaluating the different construction types based on those factors, DRM selected site-cast tilt-up. The new office/batch plant is a 15,780 square foot building which includes a 3,200 square foot office, an 8,000 square foot shop, a 3,600 square foot batch plant and a 980 square foot lab/admixture room.. The complex utilizes tilt-up concrete walls with a post-tensioned concrete roof. The DRM complex used 82 individual wall and roof panels including 75 wall panels ranging between 16’ and 50’9” tall and 12 roof panels up to 60’ long. The 82 panels totaled 27,153 square feet of site cast tilt-up wall and roof. Dickinson Ready Mix used a Lite-Deck Tilt system for both their wall and roof panels. Lite-Deck Tilt panels are cast on beds of expanded polystyrene (EPS) which remain in place when the panels are tilted-up. These EPS beds are profile cut to achieve a structural “concrete beam” in the panel and to insert attachment rail for interior finishing. The wall panels for the batch plant portion of the facility were 13” thick at the beams and 50’9” tall. The 3” concrete face forms the exterior of the panel and the 10” EPS bed provides an average R-31.2 for the walls. Most of the 50’9” panels were 12’ wide and weighed 24 tons.


Post tensioning was employed in the roof panels to enable DRM to reach the desired clear span. The roof panels for the batch plant portion of the facility were 24.5” thick at the beams and were almost 60’ long. The EPS component on these panels provides an aver-age R-60.8. The largest roof panels weighed 30.5 tons. A 12’4” diameter circular opening was designed into the roof panels to accommodate a cement silo that ex-tends through the roof. The casting location in relationship to the panels location in the building was critical so DRM cast panels in a predeter-mined sequence around the building perimeter

on casting beds constructed with 70% flyash concrete. During the erection process the panels were tilted into place, set and braced, then welded and grouted. The roof panels were set in place next. They had to fly over the 50’9”” tall wall panels, eventually bear-ing on previously cast em-beds on the inside of the wall panels. All told, the project utilized 2,432 CY of ready mix concrete.

The result is a state-of-the-art concrete batch plant shel-tered by a building that will serve Dickinson Ready Mix Co. & Concrete Products for years to come with minimum main-tenance over the life of the structure along with minimal life-cycle heating and cool-ing costs. Strength, economy and operational efficiency; such performance is currently recognized as the primary tool of sustainable design for any building in the 21st century.

Site-Cast Tilt-Up Category


Sanitary Pumping Station #60 and Recycling CenterOwner: City of FargoContractor: John T. Jones Construction CompanyEngineer: Ulteig Engineers, Inc.Landscape Architect: Ulteig Engineers, Inc.Ready Mix Supplier: Aggregate Industries - Central Region

All sanitary sewage flow from the newly rehabilitated Lift Station No. 25 collection area and from the new growth areas in southwest Fargo will be pumped to the north side of town through a 4.5-mile, 36-inch diameter force main via the newly constructed Lift Station 60. The new lift station has a peak pumping capacity of 33 million gallons per day (mgd) to handle flow projections through 2028. This is one of the largest lift stations in the City of Fargo, and was con-structed with 6,000 cubic yards of concrete. During the project, Lift Station 25 was upgraded from a 10 mgd pumping station to a 18 mgd capacity. The project was designed in 2008 and construction began in the spring of 2009. The project was completed in 2010.

Due to the highly corrosive nature of the material that is pumped through the lift station on a daily basis and the large forces induced on the structure, concrete was chosen as the primary building component for its reliability, structural integrity, and longevity. The 28 day compressive strength of the concrete was specified as 5,000 psi with a water-cement ration of 0.4 to provide adequate corrosion protection for the steel reinforcing encased in the concrete. The mix design called for type II Portland cement with fly ash constituting a maximum of 30 percent of the cementi-tious material by weight.

The base slab for the lift station is located over 40 feet below grade, so excavation, buoyancy forces, lateral pressure due to the soil and ground water, and settlement were controlling factors for the structural design of the lift station. Due to the extent of the excavation below grade, the contractor was required to provide a shoring system designed by a registered engineer licensed in North Dakota. The excavation was shored with two concrete compression rings and steel sheet pile.


Governmental Category The base slab was constructed of a 3’-0” thick reinforced concrete mat foundation. The base slab extended 5’-6” be-yond the perimeter of the lift station walls to achieve a larger footprint to resist the buoyancy forces. The lower half of the lift station walls were designed with a total thickness of 2’-6” and reinforced with two layers of reinforcing steel. As the depth of the structure below grade decreased, the lateral pressures induced by the soil and water also decreased.

This allowed a one foot reduction in overall concrete thickness to the top half of the lift station walls. The top slab of the lift station also functioned as the finished floor for the operations building that was placed on the top of lift station. The footprint of the lift station is nearly 42 feet wide and 77 feet long. Due to the width of the structure, intermedi-ate concrete beams were cast in the top slab to reduce the span and minimize the thickness of the slab. The top slab is 1’-0” thick and reinforced with two layers of reinforcing steel.

The main operations building was constructed directly above the lift station. The above grade structure is constructed of modular block with exterior face brick and precast hollow core planks for the roof. The parking lot consists of cast-in-place concrete with a depth of 8 inches. The operations build-ing has two wings that extend past the

exterior of the lift station 25’-6” on the north and south side. Due to the large excavation that the lift station required, an extensive amount of engineered fill was place and compacted around the perimeter of the lift station. The fill created the potential for differential settlement between the base slab of the lift station and the wings of the opera-tions building. To mitigate the potential issues with settlement, three 1’-6” thick concrete grade beams measuring 13 feet deep were cantilevered from the lift station on each side to support the wings of the operations building. This allows the entire structure to settle at the same rate and magnitude. The main floor of the wings was constructed with a 1’-0” thick structural concrete slab. One chemical tank was housed in each wing of the building. Since the structure was constructed with concrete, the chemical room slabs were recessed four feet to double as an overflow tank.

The parking slab is now also being used as a platform for a recycling center bin station.


SustainabilityIn Design

Bismarck Public Schools - Sunrise Elementary School Owner: Bismarck Public School District Architect/Engineer: Ritterbush-Ellig-Hulsing PC Structural Engineer: Ulteig Engineering General Contractor: Northwest Contracting Inc. Precast Supplier: Wells Concrete Ready Mix Supplier: Strata Corporation

Cost efficiencies and sustainability are key factors in a school building project. This elementary school proj-ect was no exception, early involve-ment of a precast supplier in part made those goals possible. While this is not designated a LEED project, the design team followed ASHRAE’s Advanced Energy Design Guide for K-12 School Buildings, (ASHRAE is a national organization dedicated to advancing HVAC&R to serve human-ity and promote a sustainable world) while maximizing energy efficiencies and integrating design practices. With this guideline every measure was taken to ensure sustainability goals were met.

Wells Concrete provided a cost comparison of concrete over ma-sonry early in the design phase with preliminary pricing of several options to effectively evaluate differ-

ent wall systems. After thorough analysis of cost and job condition requirements, the design team concluded that the precast concrete walls panels would not only be competitive, but would also help speed up overall construction on the project.

Precast offered substantial aesthetic value to this project as the design team chose three different finishes for ulti-mate esthetics – exposed aggregate, medium sandblast finish and thin brick finish. On the interior, the architect chose a trowel finish providing a paint-ready surface, further eliminating the waste associated with additional interior wall products while minimizing long-term maintenance.

Precast offered many benefits and sustainable features for this school including durability that minimizes long-term operational maintenance and minimized mechanical costs due to energy efficiency through the thermal mass concrete offers. Additionally, concrete’s natural resistance to mold offers a better environment for learning, coupled with its supe-rior resistance to natural disasters and fire, offer savings on maintenance and insurance costs.

The thermal envelope was the number one concern, and the district was pleasantly surprised with the outstanding aesthetics precast offered in the end


45th Street Reconstruction and Paving Owner: City of FargoPreliminary Design: Houston EngineeringDesign/Construction: City of Fargo Engineering DepartmentContractor: Dakota Underground, Inc.Concrete Supplier: Strata Corporation

The City of Fargo continues to upgrade the city street system through the use of concrete pavements with the completion of this and other projects during 2010. The large size of this project is unusual and is two to three times the scale of a normal project contracted by the City. In fact, this $14.5 million project will likely score the largest urban paving project ever constructed in North Dakota. Through effective planning, the Engineers have kept the arterial and collector route construction in line with development progress as the city continues its rapid growth.

Feedback during the public comment period lead to a decision to construct the ultimate 6-lane section rather than to construct a 4-lane section that would likely require widening within the de-sign life of the pavement. This will avoid bothersome traffic disrup-tions for years to come. The public also preferred completely closing sections of 45th Street South during construction in order to complete the entire project in one construc-tion season. This was as opposed to taking two seasons for construction but allowing access along the cor-ridor during operations.

This project involved two phases, the first providing the widening of 45th Street from 26th Avenue South to 32nd Avenue South. The widening converted this segment from 4 through-lanes with right turn lanes to 6 full concrete through-lanes with no turn lanes.

The second portion of the project extended 45th Street from 32nd Avenue to 52nd Avenue. This phase replaced an existing 2 lane rural section asphalt roadway to an urban section using concrete pavement. The new construction involved 6 through-lanes with no right turn lanes. Conbined with the first phase construction work, this project provided 2 miles of new 10” concrete pavement to serve arterial truck route needs. And the new parallel concrete bike

paths connect multiple existing bike and pedestrian pathways between 32nd Avenue and 52 Avenue South in the process.

Auxiliary project components included storm sewer systems and laterals, street lighting, con-crete bike trails, sidewalks and traffic signals. Additionally, the contractor was required to in-stall a 42 inch diameter intercep-tor sanitary sewer between 32nd Avenue and 52 Avenue South before paving.


Mike & Connie Armstrong Residence – DickinsonContractor/Designer: Grizzly Construction Services (a division of Tooz Construction, Inc.)Ready Mix Supplier: Dickinson Ready Mix Co.

The Mike and Connie Armstrong residence is located on Palm Beach Road, in a sub-division located within an oxbow of the Heart River, featuring abundant natural beauty in the bluffs that surround that part of the city. When it came time to update their landscaping, the Armstrong’s wanted something that blended with, and actually enhanced the

natural beauty of their surround-ings. They chose textured concrete for their landscaping project to pro-vide walkways, pool decks, patios and driveways that were functional, durable, low maintenance and blended with their natural sur-roundings.

There was more than 7,100 square feet of decorative concrete and/or concrete pavers placed on this project, of which 6,500 square feet was textured, embossed con-crete achieved using embossing skins. For this project a rough stone pattern embossing skin was cou-pled with Arizona Buff color hard-ener and Mocha antiquing color release to achieve a look of natural stone. The texture/embossing skins allowed them to replicate the look of natural stone with a pattern

of authentic looking veins and ridges, accented by the color release. Because texture/embossing skins have no joints or bond lines, only face texture, they were able to randomly place the skins in any direction, providing the overall appearance of large sections of natural stone.

250 square feet of concrete border was placed adjacent to brick walls to provide a contrasting accent. A Kona Brown chemical stain was used to color the borders. In addition, there was approximately 400 square feet of cobblestone pattern concrete pavers interspersed with the other decorative elements on this project.

All of these decorative concrete ele-ments combine to transform a plain, gray concrete surface into a beautiful, unique, realistic looking natural stone surface that harmonizes with the natu-ral beauty that surrounds this residence.


Decorative Category

Vining Oil Parking & Service Pavement – Devils LakeOwner: Vining Oil CompanyDesign / Build Contractor: Gleason ConstructionConcrete Supplier: Strata Corporation – Devils Lake Plant

The stable economy of the Devils Lake, ND area offers opportunities for expansion for local businesses. After care-ful consideration, Vining Oil Company decided to invest in a new fuel service facility, bait shop, and convenience store located on Hwy #2 East near Devils Lake. Concrete was chosen for this parking lot because of its competitive initial cost, durability, low maintenance costs, and safety characteristics. Concrete’s clean look and upscale appearance enhances any property, plus its increased reflectivity can lower cooling and lighting costs.

Since the anticipated traffic for this facility includes loaded trucks, pavement durability and low life cycle mainte-nance cost was a primary concern. Tractor – trailer traffic around the fuel islands and service bays would invariably execute many sharp turns that can push and tear flexible asphalt pavements. Parking loaded trucks and/or trailers can also push and rut flexible asphalt pavements requiring continual maintenance and repair. The reflective properties of concrete were also carefully considered as this facility is beyond the influence of munici-pal street lights. The lighter surface of concrete reflects more light, thus enhancing the effectiveness of onsite lighting. Offering a brighter, safer, night time environment, while at the same time providing efficiencies in lighting costs, was a very important consideration. Concrete was chosen for its competitive costs, rigid pavement properties, durability, clean look, low maintenance, and ease of installation. A 6 inch depth concrete pavement was placed in phases during a demanding 16 day project schedule.

This 91,000 SF parking area is built with approximately 1700 cubic yards of concrete. Gleason Construction pro-vided a concrete design-build pavement option for Vining Oil Co. that achieved the project engineering performance criteria within the project’s budget. This concrete placement provides a durable, attractive, easy to maintain pave-ment which enhances the productivity and value of this Vining Oil Company service facility.

ParkingCategory

Crookston Sports Center

Owner: Crookston Civic Arena LLC City of Crookston Parks & Recreation Architect/Engineer: Widseth Smith Nolting Contractor: Donlar Construction

Precast Supplier: Wells Concrete

All factors considered Crookston Sports Center was ideal for precast from the beginning, though the hurdles were many in en-suring the project worked financially. To be certain this project came together effectively the Widseth Smith Nolting design team sought the help of Wells Concrete for design and budgeting input on precast. With Wells Concrete’s help early in design the team was able to assemble a cost effective master plan, pull together construction and site logistics, gather product sizes and details, gain insight on energy efficiencies, maintain compliance with B3-State of Minnesota Sustainable Building Guidelines for structural and architectural considerations, and establish a solid budget.

Precast offered a functional, durable, and cost effective building system with double tee precast wall panels. Site work and production of double tees (off-site) took place concurrently to streamline the schedule; that given precast walls and stadia were erected in a mere 58 days.

As with any spectator space, view is critical; long-span horizontal panels allowed for large openings to maximize viewing. At the same time, long-span precast concrete hollow-core plank in the mezzanine areas provided a solid platform for spectators and further minimized vibration and noise transfer. The use of precast allowed for custom figures to be cast in the flat wall panels providing a prominent entrance to this space at minimal cost.

The focus for the Crookston Sports Center owner team was function, durability, and schedule; more succinctly they needed to leverage their budget in every way possible. Final reviews with the owner have proven this project to have accomplished their mission.

PrecastCategory

Documents

Gold 2010 - NORTH DAKOTA READY MIX & CONCRETE …ndconcrete.org/Awards/PDFbrochures/2010_Awards.pdf · All concrete components were fabricated in North Dakota. Precast beams were