A L A BAMA CO NCR E TE I NDUSTRIES ASSOC IATION M AGAZ IN E | FA L L 2016
ConcreteWorks is a publication of the Alabama Concrete Industries Association and features articles and photographs pertaining to product applications, educational opportunities, as well as innovative construction techniques impacting the industry. Please email rlindsay@ alconcrete.org with any comments regarding featured articles in ConcreteWorks or to suggest a story idea for a future edition. Rebecca Lindsay,
Art Director & Editor
TABLE OF CONTENTS
Koch Foods, one of the top poultry
Upping the Ante
Wind Creek Casinos are widely known
processors in the nation, expands their
throughout the state, and concrete was a
South Alabama facility and enlists one
main component in both the Montgomery
of the Alabama Concrete Associationâ€™s
and Wetumpka facilities. (ON THE COVER)
members to supply the material.
Thompson Tractor Company hosted the
The Top Block
The Associationâ€™s annual award was given
2016 Truck Driver Championship, with
to Nequette Architecture & Design for Fire
cash prizes and many incentives for the
Station No. 10, located in the Ross Bridge
top drivers in the state.
Community of Hoover.
John Sorrell, Editor
Alison Corey knew at an early age she wanted to become an architect, and has quickly made a name for herself with Chapman Sisson Architects in Huntsville.
T WE R II N NG TO OW ER G F ATS S FE E AT Koch Foods, one of the nation’s top poultry
to send it through a concrete pump so it had
processors, recently looked to Hodgson
to be a pumpable mix,” says Hodgson.
Concrete to supply material for a major
The project kicked off in early 2016 with
expansion at one of their south Alabama
pours to construct a series of delivery
facilities. The company is in the midst of
a major project to advance its processing
Manager Bill Hodgson says the walls
Next, Hodgson worked with crews utilizing
capabilities and expand its capacity. This
and tunnels eventually became the sub-
a special rig to install auger cast pilings
includes major upgrades to the company’s
basement of the new facility, allowing easy
designed to support the massive silo.
feed mill located just below Montgomery,
access for rail car and truck loading.
“The ground down there is prairie mud.
AUGER CAST PILINGS
Alabama. Building the updated facility
It’s very plastic and this is one of the
took months of effort and was a four-stage
“The tunnels were mostly just poured walls.
favored methods they use here around
process. Some phases of construction
They did have a floor that was done first.
Montgomery to stabilize the ground under
required continuous product delivery and
Then, a network of tunnels were poured
the foundation,” says Hodgson.
coordination of up to 30 trucks at a time.
with regular 4000 psi concrete. We did have
Each pile is cast in place using a hollow
keep up with the fast pace of placement.
stem auger with continuous flights. The
“Central dispatch was here for the pour
auger is drilled into the soil and/or rock
because there were so many trucks
and then slowly extracted, removing the
involved. Those trucks enabled us to be
earthen materials as concrete is pumped
finished shortly after daylight and everything
through the hollow stem. Hodgson says
the cementitious material pumped into the
also had great cooperation from our raw
piles is a specialized 12-bag grout that
material suppliers. We went through many
strengthens to 5,000 psi in 28 days.
truckloads of cement, as well as sand and
gravel. It took a lot of effort.” “The facility is built on that foundation of auger cast piles. A network of piles were
installed down under the earth between 20 and 30 feet deep and filled with grout.”
By early summer, it was time for the final stage of the expansion project: placement
of a massive slip-form silo. This stage of construction required scheduling almost a
Contractors then moved to lay a large
full week of continuous deliveries. For six
monolithic foundation to tie all the piles
days, crews worked round-the-clock to
accommodate the 24-hour a day pours.
about 2000 cubic yards of concrete. “This
“Once we started, we couldn’t stop until it
was a significant challenge as the contractor
got to the very top,” says Hodgson, “so we
required a delivery rate of up to 300 cubic
went for six straight days, 24 hours a day,
yards per hour to the site,” says Hodgson.
Crews began those deliveries shortly after
When trucks arrived at the project site,
midnight. Roughly 30 trucks were used to
their concrete was poured into a pump
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linked to two mini-placing booms on the
Throughout the slow moving week-long
work platform. As the platform was raised,
pour, extra effort was made to keep truck
the mini-placers went up as well. Hodgson
drivers consistent. “We tried to keep the
notes this type of placement was an
same people so that the drivers would
extremely efficient way to reach the entire
know what to expect on the job site,” says
perimeter of the silos.
Hodgson. “Also, the contractor was then familiar with them and comfortable with
While the earlier monolithic foundation pour
them and knew those drivers could take
required 300 yards an hour, the slip-form
care of what needed to be done.”
project was much slower. “They wanted to raise the elevation only a few inches per
hour,” says Hodgson, “so the rate of slip was about 24 yards an hour.”
The end result: three impressive 240-foot silos now stand high above the grassy
Day and night crews kept the flow of
pastures surrounding the facility. “It’s a big
concrete coming even throughout crew
silo,” Hodgson notes, “made up of two 70-
changes. Dispatchers were also careful to
foot diameter silos with a 35-foot diameter
keep the pace of concrete steady without
silo in the middle. It is without a doubt the
biggest slip-form concrete structure around
the success of this complex process to
Montgomery right now.”
constant communication between the plant and job site. “It took a lot of coordination
ABOUT KOCH FOODS
and the contractor kept us well informed as to what was needed; that’s key.”
All phases of the 2016 project were part of Koch Foods investment in new, state-of the-
Keeping the deliveries on track was further
art technology to advance its processing
capabilities and expand its capacity. Koch
As overnight lows in the 70’s gave way to
Foods is a company that prides itself in
daytime highs in the 90’s, Quality Control
leading the innovation curve for the poultry
had to keep up with the fluctuations. “In
industry by investing in regular upgrades to
order to keep up with the variations and
its production facilities. Founded in 1985
keep the slip-form on schedule, they had to
as a one-room, 13-employee chicken de-
make changes on the fly,” says Hodgson.
boning and cutting operation, the company
“Our QC folks worked very hard.”
is now one of the top poultry processors in the U.S.
FALL 2016 5
THOMPSON TRACTOR HOSTS 2016 TRUCK RODEO On a beautiful Saturday in April, Thompson
including 42 drivers (a new record), their
Tractor Company hosted ACIA’s annual
family members and many volunteers.
known as the “Truck Rodeo.”
Attendees enjoyed Chic Fil-A biscuits and a delicious barbecue lunch following the
Although the morning was brisk, the sunny
competition. GameTruck and Balloons &
skies made for a beautiful day and the event
More were on hand to provide entertainment
was enjoyed by more than 200 people,
for the children.
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With the support of Thompson and the other sponsors, ACIA was able to award several cash prizes to not only the top 3 competitors but 8 other drivers as well. In addition, Thompson Tractor held a “Front Loader” competition, and the top three winners received tickets to an upcoming race at Talladega Superspeedway. The association would like to thank this year’s sponsors who helped make the event such a success; Beck Industrial, Gulf Coast Trucking, McNeilus Trucks, Nextran Trucks, Sherman Industries, Thompson Tractor and Truckworx.
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16 TRUCK RODEO
CHAMPIONSHIP PARTICIPANTS 1st place – $750 Jeremy Johnson Ready Mix USA 2nd place – $500 Ashley Gassaway Ready Mix USA 3rd Place – $250 Rex Walters Builders Supply 4th place – $175 Edward Martinez Sherman Industries
TOP: Jeremy Johnson with Ready Mix USA accepts 1st Place Trophy from Bill Warr with Thompson Tractor MIDDLE: Ashley Gassaway with Ready
5th place -$125 Gaylon Lovelace Ready Mix USA
Mix USA accepts 2nd Place Trophy from Warr
6th place – $100 Ron Ramsey Sherman Industries
BOTTOM: Jimmy Williams accepts Team
Team winner of the Truckworx Team Trophy- Ready Mix USA
Trophy for Ready Mix USA
Thank you to all who participated, and we look forward to seeing you again next year!
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CONCEPT TO CREATION A L ISON COR E Y - C H A PM A N SI SSON A RC H I T EC T S
At just 10 years old, Alison Corey drew her
“As a kid, my family and I would walk
Alison graduated from Ball State University
first set of house plans on a sheet of graph
through houses under construction around
in 2007 with a Bachelor of Science degree
paper. Now 20 years later, she already has
our neighborhood, and I was fascinated
in Architecture. She then continued at
an impressive career as an architect with
with the arrangement of spaces and started
Ball State and received her Master’s of
Chapman Sisson Architects in Huntsville.
drawings house plans on graph paper in 4th
Architecture in 2009. After graduation, she
Grade, she says. “Ever since then I have
relocated to North Alabama and joined the
Growing up in West Chester, Ohio, Alison
been interested in the profession and took
Chapman Sisson team.
recalls her love of architecture developing
engineering and architectural courses that
early in life.
were offered by my high school.”
The firm has many projects that include the
“THE ABILITY TO SEE SOMETHING YOU MODELED AND DETAILED ON THE COMPUTER TAKE SHAPE DURING CONSTRUCTION...IS THE MOST REWARDING PART.”
FIRST BAPTIST CHURCH FOYER ??????????, AL
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G ET TO K NOW
What are your favorite hobbies? During my personal time I enjoy reading
intriguing to me because of how the little parts come together to make a whole finished product, a small scale version of Architecture. What is the one tool you can’t live without? The Computer. Anyone who knows me well know that I have horrendous penmanship.
been very fond of sketching beyond diagrams. Thankfully for me, we are in the digital era and I was able to embrace various computer programs, digital modeling, and BIM during school. In fact, a coworker and I head the BIM Department and Revit Standards for our office. What’s the last book you read? James Patterson’s The Beach House. Patterson is my favorite author and I am slowly making it through all this books, which is a huge feat considering how many he has written. Recently, I have been reading baby books to my son.
use of concrete under its belt, including a
sea and landscape creating a structural that
project recently featured in ConcreteWorks.
is also a piece of art.
“Whitesburg P8 is my favorite personal
“I also love the innovation used in the
project that used concrete and was
fiber-reinforced concrete lattice on Rudy
Chapman Sisson Architects is a young,
featured in the last issue of the magazine,”
Ricciotti’s MuCEM in Marseille, France,”
dynamic group of talented people who
says Alison. The University of Huntsville
says Alison. “This building shows that
desire to serve our clients through
Nursing building is another of Chapman
concrete can be used to make thin and
outstanding architecture and quality
Sisson’s projects that uses concrete, and
design work. Our goal is to be the best
the concrete panels on the exterior are
ABOUT CHAPMAN SISSON
at what we do and provide exceptional
white to match the existing building. It is
Not only is she a successful architect,
customer service and build lasting
Alison is the president of the North Alabama
American Institute of Architects (AIA) and is
Martin Sisson began their architectural
Alison chooses to use concrete in projects
busy being a new mom to her four-month old
careers in the early 1980’s. During this
due to its durability, life cycle cost, minimal
son, Mason and wife to her husband, Filip.
time, they progressed rapidly in project
maintenance, versatility, and optimal energy performance.
management and leadership roles. A when asked what her favorite thing about
Both architects developed a passion
being an architect is, she replies with a smile.
for exceptional customer service and
Some of her favorite (famous) projects that
adjusting the practice of architecture
use concrete include the Cidade das Artes in
“The ability to see something you modeled
around the needs of the client. In
Rio de Janeiro by Christian de Portzamparc is
and detailed on the computer take shape
1997, Chapman Sisson Architects
one of my favorite famous concrete buildings.
during construction and then ultimately walk
was formed from this passion. CSA is
Concrete is used to create an interplay
through the finished project. To me, this
dedicated to generating creative design
between volume and empty space. The
aspect mixed with a happy client is the most
solutions to meet its clients’ needs.
curves in the concrete echo the surrounding
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F E AT U R E
UPPING THE ANTE Windcreek Casino-Wetumpka
F E AT U R E
Situated on the banks of the Alabama River stands Windcreek Hotel and Casino, a AAA diamond-rated hotel in the heart of
Hospitality is the principal gaming and hospitality entity for the Poarch Band of Creek Indians. The company operates six properties throughout the state and the Florida Panhandle, with three of the properties in Alabama. When Uzan + Case Structural Engineers and Creative Partners was given the opportunity to be a part of the project, they jumped at the chance, albeit challenging at first. Because the drawings were issued in multiple Work Packages to facilitate the construction schedule, this project was somewhat of a challenge,” says Mary Kay Knight, Principal, P.E. “It was effectively a fast-track project, and we began our early schematic design in September 2011 then issued our foundation package ‘for construction’ the following year.” During the next four months, the firm issued six subsequent packages for the remainder of the structural framing for both the Casino and the Hotel buildings. Construction continued for another year after that. For the lateral analysis and the posttensioned floor plates, the hotel was designed using ETABS and Concept, a
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F E AT U R E
â€œThe decision was made to support the structures on a 22-inch thick pre-stressed concrete mat foundation bearing on compacted engineered fill over the in-situ clay soilsâ€?
F E AT U R E
program for linear, nonlinear, static and dynamic analysis, and the design of building systems. The casino itself was primarily designed using RAM software, a program used for structural design. “Concrete was the only solution for the areas around the oval-shaped aquarium, a unique feature of the project that sits at the center bar on the casino floor,” she says. “This required a 32 foot, zero inch square concrete pit below the gaming floor to accommodate all of the water filtration and pumping equipment. And due to the saltwater environment, we utilized corrosion inhibiting admixture in the concrete mix.” The hotel’s structural frame is a shear wall lateral system, and the floor plates are post-tensioned concrete flat slabs which provided a simple solution to a typical residential-loaded floor. “The hotel has a high-bay executive suite on the upper floor that overlooks the river with
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F E AT U R E
two 30 inch diameter concrete columns that span 25 feet from Level 21 up to the curved steel-framed roof,” says Knight. “The outdoor area on Level 21 is designed for a large hot tub, a working fireplace, and floor pavers. The perimeter has a tall glass guardrail screen wall. All of this on a slab that cantilevers about 9 feet.” When asked why concrete was a good product for this structure, Knight explains that by using concrete for the hotel, the floor system remained very thin, which is reflected in the guest-room balconies. “This was a challenging but really fun project to be a part of,” Knight says. “But my favorite part of the building has to be the aquarium at the center bar. Who doesn’t love to gaze at sharks swimming while
contact pressure of 2000 pounds per
enjoying a cocktail?”
square foot (psf) with a maximum average uniformly distributed contact pressure in the
BB KING’S BLUES C L U B AT W I N D C R E E K CASINO MONTGOMERY
range of 850 to 900 psf. “The decision was made to support the structures on a 22-inch thick pre-stressed concrete mat foundation bearing on
CONCRETE WAS ALSO INCLUDED IN: ♣♣♣♣♣♣♣♣♣♣♣♣ Restaurant and Casino Floors & Roof: Concrete Floor Due to Large Spans and Heavy Mechanical Loading.
At Montgomery’s Windcreek Casino, the
compacted engineered fill over the in-
iconic BB Kings Blues Club on Beale Street
situ clay soils,” says Danny Raines, P.E.,
was recreated right here in Alabama. The
SECB, VP Weatherford & Associates. “The
project consisted of a 2-level restaurant,
pre-stressed mat foundation provided the
swimming pool and spa on the roof of BB
only feasible solution to supporting the
Concrete Slab on Long-Span Composite
King’s. Connected to the restaurant’s
heavy structure while not penetrating the
♦♦♦♦♦♦♦♦♦♦♦♦♦♦ Hotel Floors & Roof:
building are a 5-story hotel on one side and a two-story open gaming floor area on the
“Our favorite design aspect of the building
other. The design for the structure began
was the unique utilization of pre-stressing
Cast-In-Place Post-Tensioned Wall/Beams
in July of 2014 with the grand opening in December 2015.
conditions and provide an efficient design,”
The entire structure was supported on pre-
says Danny Raines, P.E., SECB, VP
stressed concrete mat foundation, but due
Weatherford & Associates. “This helped
to archeological considerations the in-situ
reduce the overall amount of materials
soils could not be disturbed. The mat slab
and minimized the weight on the weak
was designed for a maximum localized
The total project contained over 30,000 cubic yards of concrete
F E AT U R E
â€œThe hotel has a high-bay executive suite on the upper floor that overlooks the river with two 30 inch diameter concrete columns that span 25 feet from Level 21 up to the curved steel-framed roofâ€?
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The American Institute of Architects (AIA) Alabama Chapter recognized Hoover Fire Station No. 10, designed by Louis Nequette with Nequette Architecture & Design, as the Alabama Concrete Association’s 2016 “Top Block Award” winner at its annual summer
BLOCK convention in Perdido Key.
The fire station is located in the Ross Bridge community of Hoover, which is traditionally inspired and hearkens back to historic
towns that promote diversity, walkability and great public spaces. “The Ross Bridge Fire Station is designed to fit into the English inspired style of the Village Center,” says Louis Nequette. “We wanted a permanent civic exterior material but wanted to avoid brick. So many of the surrounding homes are brick and we felt the building would get lost in the backdrop of the neighborhood.” For the structure, Nequette decided on a historically appropriate “pebble-dash” stucco finish. For stucco to be a long-term
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ADDITIONAL FEATURES OF
STATION NO. 10 Proportions of the building are heavier than homes beyond, but details provide the public with visual delight and an inviting experience. The Engine Bays are tucked around the corner from the village’s Market Street, allowing more human-scaled spaces to line public street frontage. The living spaces of the station – the Kitchen, Dining and Day Room – buffer the Engine Bays from the street and leave open a view from the street. The office, guest lobby and bunk rooms line the street edge and spatially define the public space. The
wraps around a private courtyard and loggia that provides protected comfortable outdoor space.
low-maintenance exterior finish, it must be
chose to use a concrete block veneer, laid up
“Concrete is a permanent timeless material,
applied to a solid masonry.
like brick with a drainage cavity between the
and only want authentic durable timeless
CMU and Stud wall. On the taller engine bay
materials on our buildings,” says Nequette.
“The recent application of stucco to wood
we apply the stucco directly to a 12” thick
“As you live, you see how fast twenty years
sheathing leads to cracking, requires ugly
load-bearing CMU wall.”
can go by. Our buildings should look as
control joints everywhere, and usually results
good (or better) as the age.”
in the windows projecting from the face of the
In addition, Nequette appreciates how
finish – there’s a reason you don’t see this on
concrete serves multiple needs – structure,
old buildings,” he explains. “To do it right, we
veneer and walking surface to name a few.
ABOUT NEQUETTE ARCHITECTURE & DESIGN Nequette Architecture & Design started in 1999 as Dungan Nequette Architects. Dungan Nequette operated for 16 years, beginning as Jeff Dungan and Louis Nequette struggled to find that “top-down” design firm that would support their desires to create beautiful timeless buildings. The firm quickly grew, but over time different passions of the men allowed two studios to form so each principal could build a team around their interests. Louis Nequette and his team found reward in both the custom work, which allowed for a very personal and often higher budget design solution, as well as the multi family and mixed use work, which required the leveraging and restraint of design solutions to create buildings and places of beauty at lower budgets. Louis’ team learned that the magic occurs when you lend the knowledge, ideas and tricks from one arena to the other. After enduring a long market recession from 2008-12, the firm began to grow again. This growth precipitated the slow transition of Jeff and Louis’ studios into their own firms.
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ACI Field Testing - Birmingham, AL
ACI Field Testing - Birmingham, AL ACIF Sporting Clays Fundraiser Sylacauga, AL ACI Field Testing - Montgomery, AL
ACI Field Testing - Montgomery, AL ACI Field Testing - Mobile, AL
Butch Wyatt Concrete Cup - Birmingham, AL - Oct. 24, 2016
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