(Silver Award)   Bayport Container Yard, Seabrook, Texas

Contractor:  A.G. Peltz Group, LLC           

Owner:  Port of Houston Authority (POHA)           

Engineers:   LAN Engineering | HVJ Associates Inc.           

 A.G. Peltz Group, LLC was contracted by the POHA to place 98,000 SY of 18” Roller Compacted Concrete (RCC) pavement. This marked the fourth large project for the port authority to use RCC, and several additional projects also are planned.  

By 2020, the Port is expected to have 380 acres of mostly 18-in.-thick RCC, making it the largest RCC site in the United States.   Just how much RCC is this?  This amount of RCC would form a 6-in. thick, single lane road stretching more than 800 miles from the state’s easternmost city of Orange to El Paso in the far west corner of Texas

Since 2007, RCC has filled a key role in the port authority’s Bayport Container Terminal expansion, and integral part of a capital improvement program that totaled about $314 million in 2016. High-performing, low-maintenance RCC pavements are strong and dense, so they can handle the weight of heavy container-handling equipment such as gantry cranes that load containers on and off ships.

“The goal was to reduce cost and ensure long-term durability, and port leadership at that time believed RCC offered a sound solution,” said POHA Chief Construction Engineer, Brock Lewis, who commented that the environment, working with surrounding jurisdictions, meeting numerous business requirements, and excessive rainfall in the Houston area were challenges during construction. “By placing RCC, we were able to return to business sooner than expected while also minimizing down time.”  POHA was also able to reduce the construction schedule by four months, while keeping maintenance to a minimum. 

This facility and POHA’s overall increased container-handling capacity is keeping pace with increasing demand, including more and larger ships that pass through its waters, thanks in in part to the Panama Canal expansion.

 

(Gold Award) Walmart Distribution Center, Mebane, N.C.

Contractor: Morgan Corp.                          

Owner:  Wal-Mart Stores, Inc.   

Engineers:   Kimley-Horn              

The successful completion of the RCC pavement at Wal-Mart’s Distribution Center #6858 marked a significant milestone in advancing RCC pavements.  It was the first RCC paving project ever built by the world’s largest retail company, and building on the project success, Wal-Mart Stores, Inc. is now specifying RCC for many other distribution centers in the United States.

Since Morgan Corp. completed this project, the giant retailer has since specified RCC for its distribution centers in Mobile, Ala.; Bentonville, Ark. near the firm’s headquarters; and Cocoa Beach, Fla.

The Mebane distribution center project used 83,300 SY of 10.5-in. thick RCC; 7,100 SY of 6-in. thick RCC; 5,400 SY of 11-inch reinforced concrete dolly pads; and 2,450 linear ft of curb and gutter.

Construction was completed in just over six months, in spite of many difficulties including delays by other parties with site preparation; severe winter conditions; the complex details of reinforced concrete dolly pads, which used a combination of PNA Construction Technologies* patented dowel baskets and square dowels.

Morgan Corp. has been awarded the contract to build the second Wal-Mart RCC project at its Super Distribution Center in Mobile, Ala. This upcoming project encompasses 380,000 SY of 10-in. RCC, and is scheduled for completion in mid-2018.

 

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* ACPA Member.