Stadler Rail

This industrial manufacturing facility construction project featured complex embedded rail systems designed to move train cars through welding, sandblasting, and painting operations. The work required multiple isolated concrete pours, precise block-outs, and high-tolerance layout to accommodate future equipment installations. 

Executed in three phases, the project included a 12-inch double-matted slab-on-grade with embedded components, a 21.5-inch-thick mat foundation for a sandblasting booth, and a specialized service pit structure for below-grade access. Additional scope included cast-in-place electrical vaults and heavily reinforced structural concrete elements. 

Concrete was placed in temperatures as low as 14°F using cold weather concrete practices, including heated blankets and continuous monitoring. Anchor bolt placement with 1/8-inch tolerances was achieved using robotic total stations, ensuring accuracy for equipment installation. In heavily reinforced areas with limited access, dual concrete pumps were used to maintain placement efficiency. 

Lithko delivered key value engineering solutions, including eliminating an unnecessary waste slab and optimizing control joint layouts to reduce cracking. The use of shrinkage-reducing additives improved long-term slab durability and surface performance. 

The project leveraged BIM coordination using Revit and AutoCAD, enabling precise modeling of complex rail systems, foundations, and wall geometries. These models were integrated with robotic layout tools for real-time verification, improving accuracy and reducing rework. Rigorous QA/QC processes ensured all embedded items, elevations, and reinforcing systems met strict industrial tolerances.