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Large Manufacturing Facility

Manufacturing

The large manufacturing plant expansion houses all new coffee bean processing, roasting, and packaging. The expansion has added nearly 100 new jobs to the area. Our scope of work included a foundation perimeter wall,  1,000 cubic yard 4’ thick mat foundation to support a silo structure, and slab on grade including vapor barrier, dowel baskets, armor edge, and extensive reinforcing steel.  This facility also houses a new mezzanine level for process equipment with a triple layered floor including a waterproofing membrane.

The slab on grade was placed after the walls and roof were installed.  This created a logistics issue getting a pump as well as concrete trucks inside the building.  Significant planning was required to ensure the project flow was efficient and maintained project schedule.

The complicated flooring system and high-quality tolerances required strenuous planning to maintain. Due to the complicated construction of the slab, a truss screed was utilized to maintain floor flatness tolerances. 

The 4’ thick 1,000 cubi yard mat foundation was a significantly complicated structure.  The heat generated by a mass concrete pour was a large concern. Consultants were utilized to discuss means and methods for placing mass concrete for the mat foundation.

Standing water is always a significant issue but amplified on this project in that the window of opportunity to install the triple layer slab on metal deck was crucial to hit so the schedule could be maintained. The overall sequencing of this project was atypical requiring field supervision to identify all potential means and methods to maximize our team’s efficiency.