Association News

Industrial Paving – Gold Award

Gold Award – CSX Intermodal Terminals – Winterhaven, FL

Contractor: McCarthy Improvement Company*

Owner: CSX Intermodal Facilities

Engineer: CSX Intermodal Facilities

Only three years after initial construction, the Central Florida Intermodal Logistics Facility near Winterhaven, Fla., had outgrown its originally design capacity of 300,000 containers per year.  An expansion project included construction of additional gantry cranes, high mast lighting and more than 13 acres of additional tractor trailer parking, loading and unloading areas.

McCarthy Improvement Company was contracted to perform the concrete paving, which totaled 67,000 SY of concrete.  The project specifications required a mix capable of attaining a compressive strength of 4,000 psi at 28 days. McCarthy developed a mixture that met the required strength in less than seven days, which helped expedite cure of adjacent paving lanes. The mix design included Type II portland cement, natural sand and granite coarse aggregates. Even though the granite was not locally available, McCarthy chose to “rail-in” granite aggregates from eastern Georgia and use them to improve early strength. 

MCI completed the paving in 23 days of the 74 calendar days allowed from mobilization to the plant site.  The owner previously had issues with roller compacted concrete and asphalt, so the finished project now stands as an excellent example of the versatility and durability of concrete pavements.

* ACPA member.


RCC (Industrial) – Gold Award

Gold Award – Walmart Southeast Import Distribution Center

Contractor: Morgan Corporation*

Owner:  Walmart Inc.     

Engineer: Carlson Consulting Engineers Inc.

This project is a involved the use of roller-compacted concrete for one of the largest distribution centers in America, Walmart’s Southeast Distribution Center in Mobile, Ala.

The story began in 2013, when Morgan Corp. began reaching out to Walmart headquarters promoting RCC for distribution centers, including discussion about a project planned for constructed in North Carolina. After site visits and an RCC seminar, Walmart’s senior managers decided to try RCC to build the pavements at the distribution center in Mebane, N.C., the first RCC paving project built by the world’s largest brick & mortar retailer.  Building on the success of this project, the company is now specifying RCC for all of its distribution centers in the U.S.

Walmart Inc. chose RCC again for the second distribution center located in Mobile. This facility is almost four times as large as the one built in North Carolina.

The project encompassed 382,000 SY of 10-in. thick RCC for truck parking, loading docks and access routes, plus 9,000 SY of 5-in. thick RCC for their  employee access route. In addition, the pavements included reinforced concrete dolly pads. Based on Morgan Corp.’s recommendations, Walmart agreed to change the pavement details to improve design, speed construction and save cost.

A total of approximately 106,000 CY of RCC were placed in 85 paving days, including two partial days where production paving was very limited due to rain.

* ACPA member.

RCC (Industrial) – Silver Award

Silver Award – Container Yard 1 and East End of Barbours Cut Terminal, Houston, Texas

Contractor: A.G. Peltz Group LLC*

Owner: Port of Houston Authority          

Engineer: RPS Group

A.G. Peltz Group placed 69,000 CY of 18 in. roller compacted concrete and mixed 40,000 yards of conventional concrete for the reconstruction of Container Yard 1 and the East End at Barbours Cut Terminal at Port Houston.

Although Port Houston has over 300 acres of mostly 18 in. RCC in service at their adjacent Bayport Container Terminal, this project was the first time RCC was placed at Barbours Cut.  RCC was also used at a live terminal inside the security gates at Port Houston.

The Barbours Cut terminal is in the midst of a modernization program to increase cargo handling capacity from 1.2 Million transportation equivalent units (TEUs) to 2 Million TEUs annually.  Part of this program includes rebuilding and reconfiguring several of the existing marshalling yards without shutting down terminal operations. With its fast construction and ability to handle heavy repeated loading, RCC offered the appropriate pavement solution for the majority of areas within the facility. However, due primarily to existing obstacles, there were also several areas within Barbours Cut Terminal where conventional concrete was the appropriate fit. With a single plant capable of mixing both RCC and conventional concrete, A.G. Peltz was able to mix over 109,000 CY of concrete for this high profile project.

Handling traffic on this project was a significant challenge. All material had to be delivered by drivers, who had a Transportation Worker Identification Credential card or be escorted on-site by the prime contractor. Because the terminal was live and active, paving operations had to remain flexible to accommodate container movement. The contractor’s team worked with port personnel to develop a revised traffic flow to allow the third phase to begin prior to the end of phase 2. This resulted in several paving plan adjustments as containers were moved from ship to stacking areas and as containers were loaded onto trucks from the stacking areas. The revised plan not only reduced the total project length, but also allowed several newly paved areas to be open to traffic as soon as design strengths were realized.

* ACPA member.

RCC (Special Application) – Silver Award

Silver Award –DOT 4 ft. Shoulder and Ramp Replacement, Guilford/Randolph County, N.C.

Contractor: Andale Construction*

Owner:  North Carolina Department of Transportation     

Engineer: NCDOT District 7 RCE

When the North Carolina District 7 Department of Transportation wanted to rehabilitate a 7-mile section of Interstate 85—north and south bound—located between Archdale and High Point, officials selected roller compacted concrete for the 10 ft. outside shoulder. 

Because RCC adds a significantly higher structural value to the shoulders, NC DOT also decided to see if the contractor could pave a 4 ft.-wide inside shoulder as well so that the entire roadway would be concrete.  A typical RCC section of 4 ft. RCC had never been successfully constructed before the North Carolina project.

Andale Construction modified its high density screed paver and with detailed upfront planning handled the project. The construction time for both of the north and south bound lanes was 16 days from start to finish. The typical section of the 35,887 SY inside shoulder was 6 in. in depth with wider areas placed to meet bridge approaches and slope protections.

In addition to the inside shoulders, Andale also replaced the two concrete exit and entrance ramps at the Archdale #111 exit with broom-finished RCC. The ramps were removed, reconstructed with RCC and reopened in 1O total working days, including demolition of the existing 8 to 11 in. concrete section.

The speed with which the RCC was placed saved NC DOT three months of construction time on the inside shoulder and four months on the ramp replacement. The inside shoulders took 16 total days to remove and replace and the ramps took 10 total days – including curing time.


RCC (Special Application) – Gold Award

Gold Award – Roller Compacted Concrete Streets, Roseville, CA

Contractor: FBD Vanguard Construction Inc.*

Owner:  City of Roseville, Calif.   

Engineer: Bennett Engineering

The City of Roseville’s RCC Pilot Project involved reconstruction of several lane miles of existing asphalt pavement road with RCC in multiple locations.

Three diverse roads were chosen for the pilot project. Washington Boulevard is a five-lane arterial; Atkinson Street is a two -lane collector road; and Hickory Street is a residential street.

In addition to reduced lifetime maintenance costs, the first costs for the pavement on this project came in about 10% lower than expected for a comparable asphalt pavement.  The use of RCC is a relatively uncommon in Northern California, but officials decided to consider it for a pilot project.   In all, 60,000 SY of RCC was used.

Multiple factors posed scheduling challenges to this project. The largest challenge centered around completing the RCC pavement construction in a short working period.  With the aim of not disrupting a local school’s operations, summer break (June to mid-August) was determined to be the best time to complete the work.

Other traffic concerns centered around the need for weekend access to the region’s historic Denio’s Farmer Market. This combination market/swap meet is popular in the community, and the operators are known for their continued service, rain or shine.

The schedule gave the contractor less than seven days to pave and achieve maturity opening strength in both directions.  Paving started the day after the market closed and re-opened the day before the next market. The construction was such a success that Denio’s Market hosted an RCC tour at their facility for other agencies, engineers, and developers to come see first-hand the RCC paving process and finished product.

* ACPA member.

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