The Contractor’s SourceJune 21, 1999

Inside: ACP Feature on Concrete • Industry News • Bid Information

Serving the Construction Industry inArkansas, Louisiana, Mississippi,

Oklahoma, and West Tennessee Bryan Adair ConcreteConstruction Sets WorldRecord for ContinuousConcrete Pour

Bryan Adair ConstructionCompany (BACC) o fBroken Arrow, Oklahoma

recently completed the largestcontinuous place and finish con-crete project on record. The recordwas set on a 556,500 square footwarehouse f loor pro jec t fo rHannah’s Potpourri Companyin Fayetteville, Arkansas. The pre-vious advertised record was a248,000 square foot continuousplace and finish floor.

To prepare for the record-break-ing event, on January 16, BACCcompleted a 105,000 square foot“test run” on the east end of thewarehouse pad as a prelude to therecord-setting event. The projectstaging and various processeswere analyzed including supplieraccess and performance, crew per-

formance, equipment, machinery,site conditions and the requiredwashout area accessibility anddesign.

The project began on Friday,February 12, at 9:48 p.m. and con-tinued for 26 1/2 hours until the

last of the concrete was placedearly in the morning on Sunday,February 14. Workers were on thefloor for several additional hours

to complete the finishing, cuttingand curing aspects of the project.

The total amount of concreteused on the project was 10,440cubic yards and was within 31yards (3/10 of 1 percent) of theestimated neat-line amount. BACCcompleted all the subgrade workto the site including foundations,dirt work, vapor barrier, underslab fill, forming, column rein-forcement, all blockouts, fine gradeand pad maintenance of the siteduring the event.

Four concrete companies Mid-Continent Concrete, Tune Con-crete , Arkhola Concrete andBeaver Lake Concrete continu-ously supplied the concrete to thesite for the duration of the project.Concrete suppliers delivered anaverage of 39 truckloads of con-

As the concrete was being poured, four Somero Laser Screeds with computersand laser directed leveling capabilities were used to assist with placing and pre-

cisely leveling the floor. In addition, five Spectra-Physics laser systems were usedto insure the overall levelness of the floor.

Bryan Adair Concrete Construction Sets World Recordfor Continuous Concrete Pour

For the record-breaking effort,BACC provided a crew of 105men to work on segmented and

alternating 12-hour shifts in orderto complete the project.

The total amount of concrete used on the project was 10,440 cubic yards andwas within 31 yards (3/10 of 1 percent) of the estimated neat-line amount.

crete per hour or roughly oneevery 90 seconds. The actualdelivery amount averaged 391yards per hour, which is about6.5 yards of concrete per minute.

To complete the pour, 4,888,000pounds of concrete, 18,512,000pounds of rock, 15,485,000 poundsof sand, 15,660 pounds of fiberand 343,200 gallons of water wereused.

With well over 1000 truck loadsof concrete delivered to the job-site, maintenance of the site was asubstantial effort as the trucksdrove onto, turned around andthen traveled in reverse through-out the entire pad area. A JohnDeere 650 LGP laser-actuateddozer and a John Deere 210 LEbackhoe and boxblade workedcontinuously to maintain the gradeof the pad. The loaded concretetrucks traveled in reverse (backedup) over 157 miles and required awashout area of over 3 acres. Two

Schwing concrete pump trucks, a1-36M and 1-45M, were used todeliver concrete to areas difficult toreach or areas of soft ground.“There were a few spots where theground was soft from all the rainwe had last week,” said BryanAdair, owner of Bryan Adair Con-

struction. “We didn’t want to runthe trucks back and forth over thesoft spots to avoid rutting. That’swhy we brought in the pumptrucks.”

As the concrete was being

poured, four Somero Laser Screedswith computers and laser directedleveling capabilities were used toassist with placing and preciselyleveling the floor. In addition, fiveSpectra-Physics laser systems wereused to insure the overall level-ness of the floor.

To finish the slab, 26 rider-typetrowels we used. The trowels,including Whitman and White StarMachinery, used 12 sets of bladesand 20 sets of pans to completethe project.

The finished floor required atotal amount of saw cutting over15 miles using five Soff-cut Con-crete Saws, to help control crack-ing. Additionally, floor tolerancemeasurements achieved wereSpecified Overall Value FF 59/FL54 with a minimum local value ofFF 37/FL 35.

For the record-breaking effort,BACC provided a crew of 105 mento work on segmented and alter-

To prepare for the event, onJanuary 16, BACC completed a105,000 square foot “test run”on the east end of the warehousepad as a prelude to the record-

setting event.

nating 12-hour shifts in order tocomplete the project. However,there were also numerous otherBACC employees on-site to assistwith the various support andback-up aspects of the project fora total of over 120 personneldirectly involved with the event.

Five pre-project coordinationmeetings were held which includ-ed the owner, concrete suppliers,equipment suppliers and BACCsupervisory personnel. In thesemeetings, each aspect of the proj-ect was analyzed to determine themost productive format, address

Two Schwing concrete pump trucks, a 1-36M and 1-45M, wereused to deliver concrete to areas difficult to reach or

areas of soft ground.

Four concrete companies Mid-Continent Concrete, Tune

Concrete, Arkhola Concrete andBeaver Lake Concrete continuously

supplied the concrete to the sitefor the duration of the project.

( Below) Four concrete companies Mid-Continent Concrete, Tune Concrete,Arkhola Concrete and Beaver Lake Concrete continuously supplied the concreteto the site for the duration of the project. Concrete suppliers delivered an aver-age of 39 truckloads of concrete per hour or roughly one every 90 seconds. Theactual delivery amount averaged 391 yards per hour, which is about 6.5 yards ofconcrete per minute.

potential problemscenarios and toresolve coordinationissues. A follow-upmeeting was alsoheld with all the sup-pliers to review theperformance on theoverall project as wellas recommend waysto improve efficiencyand productivity.

In addition, coordi-nation meetings withthe concrete supplierswere held in advanceof the record-breakingattempt to reviewdetails associated withconcrete delivery tothe project. Items dis-cussed includedscheduling and stockpile of rawmaterials, adjustments to work-shifts for overtime, procurementof the required mix design addi-tives and preparations to supportthe production plants and theirassociated maintenance and deliv-ery equipment.

Somero Enterpises, the LaserScreed Company for the project,set up a refreshmenttent, which served asan operations centerfor the event. It pro-vided a centrallylocated and easilyaccessible location forthe required addi-tional safety equip-ment, a staging areafor equipment main-tenance and refuelingas well as an infor-mation area. Addi-tion-ally, the tentbecame a referencepoint for the projectfor all suppliers, visi-tors and the locationwhere meals wereserved to all personsinvolved with theproject. ■■■■

(Above) A John Deere 650 LGP laser-actuated dozer and a John Deere 210 LEbackhoe and boxblade worked continuously to

maintain the grade of the pad.

(Below) To finish the slab, 26 rider-type trowels we used. The trowels, includ-ing 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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