Bryan Adair Concrete Construction Sets World Record for Continuous Concrete Pour

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1 The Contractor s Source June 21, 1999 Serving the Construction Industry in Arkansas, Louisiana, Mississippi, Oklahoma, and West Tennessee Bryan Adair Concrete Construction Sets World Record for Continuous Concrete Pour Inside: ACP Feature on Concrete Industry News Bid Information

Bryan Adair Concrete Construction Sets World Record for Continuous Concrete Pour Bryan Adair Construction Company (BACC) of Broken Arrow, Oklahoma recently completed the largest continuous place and

2 Bryan Adair Concrete Construction Sets World Record for Continuous Concrete Pour Bryan Adair Construction Company (BACC) of Broken Arrow, Oklahoma recently completed the largest continuous place and finish concrete project on record. The record was set on a 556,500 square foot warehouse floor project for Hannah s Potpourri Company in Fayetteville, Arkansas. The previous advertised record was a 248,000 square foot continuous place and finish floor. To prepare for the record-breaking event, on January 16, BACC completed a 105,000 square foot test run on the east end of the warehouse pad as a prelude to the record-setting event. The project staging and various processes were analyzed including supplier access and performance, crew performance, equipment, machinery, site conditions and the required washout area accessibility and design. The project began on Friday, February 12, at 9:48 p.m. and continued for 26 1/2 hours until the For the record-breaking effort, BACC provided a crew of 105 men to work on segmented and alternating 12-hour shifts in order to complete the project. last of the concrete was placed early in the morning on Sunday, February 14. Workers were on the floor for several additional hours to complete the finishing, cutting and curing aspects of the project. The total amount of concrete used on the project was 10,440 cubic yards and was within 31 yards (3/10 of 1 percent) of the estimated neat-line amount. BACC completed all the subgrade work to the site including foundations, dirt work, vapor barrier, under slab fill, forming, column reinforcement, all blockouts, fine grade and pad maintenance of the site during the event. Four concrete companies Mid- Continent Concrete, Tune Concrete, Arkhola Concrete and Beaver Lake Concrete continuously supplied the concrete to the site for the duration of the project. Concrete suppliers delivered an average of 39 truckloads of con- As the concrete was being poured, four Somero Laser Screeds with computers and laser directed leveling capabilities were used to assist with placing and precisely leveling the floor. In addition, five Spectra-Physics laser systems were used to insure the overall levelness of the floor.

The total amount of concrete used on the project was 10,440 cubic yards and was within 31 yards (3/10 of 1 percent) of the estimated neat-line amount. crete per hour or roughly one every 90 seconds.

3 The total amount of concrete used on the project was 10,440 cubic yards and was within 31 yards (3/10 of 1 percent) of the estimated neat-line amount. crete per hour or roughly one every 90 seconds. The actual delivery amount averaged 391 yards per hour, which is about 6.5 yards of concrete per minute. To complete the pour, 4,888,000 pounds of concrete, 18,512,000 pounds of rock, 15,485,000 pounds of sand, 15,660 pounds of fiber and 343,200 gallons of water were used. With well over 1000 truck loads of concrete delivered to the jobsite, maintenance of the site was a substantial effort as the trucks drove onto, turned around and then traveled in reverse throughout the entire pad area. A John Deere 650 LGP laser-actuated dozer and a John Deere 210 LE backhoe and boxblade worked continuously to maintain the grade of the pad. The loaded concrete trucks traveled in reverse (backed up) over 157 miles and required a washout area of over 3 acres. Two To prepare for the event, on January 16, BACC completed a 105,000 square foot test run on the east end of the warehouse pad as a prelude to the recordsetting event. Schwing concrete pump trucks, a 1-36M and 1-45M, were used to deliver concrete to areas difficult to reach or areas of soft ground. There were a few spots where the ground was soft from all the rain we had last week, said Bryan Adair, owner of Bryan Adair Construction. We didn t want to run the trucks back and forth over the soft spots to avoid rutting. That s why we brought in the pump trucks. As the concrete was being poured, four Somero Laser Screeds with computers and laser directed leveling capabilities were used to assist with placing and precisely leveling the floor. In addition, five Spectra-Physics laser systems were used to insure the overall levelness of the floor. To finish the slab, 26 rider-type trowels we used. The trowels, including Whitman and White Star Machinery, used 12 sets of blades and 20 sets of pans to complete the project. The finished floor required a total amount of saw cutting over 15 miles using five Soff-cut Concrete Saws, to help control cracking. Additionally, floor tolerance measurements achieved were Specified Overall Value FF 59/FL 54 with a minimum local value of FF 37/FL 35. For the record-breaking effort, BACC provided a crew of 105 men to work on segmented and alter-

Concrete suppliers delivered an average of 39 truckloads of concrete per hour or roughly one every 90 seconds. The actual delivery amount averaged 391 yards per hour, which is about 6.

4 Two Schwing concrete pump trucks, a 1-36M and 1-45M, were used to deliver concrete to areas difficult to reach or areas of soft ground. ( Below) Four concrete companies Mid-Continent Concrete, Tune Concrete, Arkhola Concrete and Beaver Lake Concrete continuously supplied the concrete to the site for the duration of the project. Concrete suppliers delivered an average of 39 truckloads of concrete per hour or roughly one every 90 seconds. The actual delivery amount averaged 391 yards per hour, which is about 6.5 yards of concrete per minute. Four concrete companies Mid-Continent Concrete, Tune Concrete, Arkhola Concrete and Beaver Lake Concrete continuously supplied the concrete to the site for the duration of the project. nating 12-hour shifts in order to complete the project. However, there were also numerous other BACC employees on-site to assist with the various support and back-up aspects of the project for a total of over 120 personnel directly involved with the event. Five pre-project coordination meetings were held which included the owner, concrete suppliers, equipment suppliers and BACC supervisory personnel. In these meetings, each aspect of the project was analyzed to determine the most productive format, address

In addition, coordination meetings with the concrete suppliers were held in advance of the record-breaking attempt to review details associated with concrete delivery to the project.

5 potential problem scenarios and to resolve coordination issues. A follow-up meeting was also held with all the suppliers to review the performance on the overall project as well as recommend ways to improve efficiency and productivity. In addition, coordination meetings with the concrete suppliers were held in advance of the record-breaking attempt to review details associated with concrete delivery to the project. Items discussed included scheduling and stockpile of raw materials, adjustments to workshifts for overtime, procurement of the required mix design additives and preparations to support the production plants and their associated maintenance and delivery equipment. Somero Enterpises, the Laser Screed Company for the project, set up a refreshment tent, which served as an operations center for the event. It provided a centrally located and easily accessible location for the required additional safety equipment, a staging area for equipment maintenance and refueling as well as an information area. Addition-ally, the tent became a reference point for the project for all suppliers, visitors and the location where meals were served to all persons involved with the project. (Above) A John Deere 650 LGP laser-actuated dozer and a John Deere 210 LE backhoe and boxblade worked continuously to maintain the grade of the pad. (Below) To finish the slab, 26 rider-type trowels we used. The trowels, including Whitman and White Star Machinery, used 12 sets of blades and 20 sets of pans to complete the project. Reprinted from the June 21, 1999 issue of Construction News.

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