Project Highlights « Builders Concrete

Project Highlights

The Drury Inn

The superstructure of this hotel located along 82^nd Street and I-69 was constructed entirely from reinforced concrete and post-tensioned concrete. An insulated concrete forming system (ICF) was designed and constructed to give the perimeter better insulation and sound proofing. Builder’s Concrete supplied over 6,000 cubic yards of concrete for the structure which consists of 5,000 PSI reinforced columns and 5,000 psi cast-in-place, post-tensioned decks. Tendons were pulled in 2-3 days after obtaining 3,000 PSI.

Drury Inn has made a decision to use ICF’s for the perimeter walls in almost all of their future construction. They were able to downsize their entire roof top heating and cooling units thus allowing them to save on their energy costs. Druco has used the post-tensioned ICF perimeter wall system for about 4 years. This was one of the largest ICF jobs in the state.

Extreme Makeover Home Edition May 7th, 2009

In late February, 2009, the owner of Builder's Concrete, Butch Nuckols, got an interesting phone call. It was from Paul Estridge Jr. asking if Builder’s would like to participate in an upcoming project for the popular television show Extreme Makeover Home Edition. The response was of course “YES” and the work began immediately. The show, which has won two Emmy Awards, airs weekly on the ABC Network.

Builder’s was charged with many important tasks over the course of this project. Scott Noel, Builder’s sales manager, took a lead role in the organization and planning of the demolition, excavation, concrete footings, walls, slabs, and exterior concrete. A team of contractors was assembled in less than a day.

The project consisted of the demolition of the existing home which sat on a basement foundation, and rebuilding of a completely new house with a full basement and separate “library” structure all within six days. The schedule was intense, each hour contained specific milestones that had to be reached. One of the challenges that Builder’s Concrete faced was the development of a concrete mix design that would gain enough strength fast enough to allow the project to remain on schedule. For example, the forms for the nine foot tall basement walls were stripped only 2 ½ hours after the wall was completely topped off! The time used for curing was only half of that which was scheduled! The utilization of maturity meters placed inside the various concrete structures enabled the Builder’s Concrete team to give the builder the in-place strength of the concrete structure. This information was critical, and allowed the project to proceed safely ahead of schedule. The mix designs used for the footings, walls and slabs of the two structures gained strength very quickly. Compressive strengths as high as 7,000 psi were reported as early 24 hours after placement. The concrete reached design strength in 3 to 6 hours depending on the structure. Accelerators were added on site to ensure that placement and workability were not jeopardized.

It is amazing how quickly this project came together. From the initial team building process until those famous words “Move That Bus” were shouted, everyone involved really worked well together. And though some members of the Builder’s Concrete team were awake and on the job for 45 consecutive hours (including Butch) they will all say that it was a great experience and that we were happy to be a part of it.

Builder's Concrete would like to thank Estridge for asking us to participate. Also a big “Thank You” goes out to each and every one of the subcontractors, material suppliers and our employees that volunteered their time, services and products that helped make this project a success.

The Builder’s Concrete / Estridge Team included:

Final Grade Excavating Martin Marietta Materials

Sanders Building and Contracting Co. Lehigh Cement Company

Shiel Sexton Co. BASF

Featherston Concrete Engius, LLC

Performance Concrete Pumping, Inc. JA Taylor Enterprises

Jobsite Supply Brown’s Oil Service

Ray’s Trash Service

Home-A-Rama Willows Lot 217

This home was a featured home in the annual Home-A-Rama Show. There were a total of 112 cubic yards of exterior decorative concrete used. This home features several different patterns and textures of decorative concrete. The driveway and back patio were poured and finished using an exposed pea gravel mix. The uniformity in the finish and mix consistency gives this concrete a stunning look. The front and rear porches were poured using Sandstone integral concrete coloring. A Charcoal Release and Ashlar Slate stamp pattern were nicely used to give the concrete a beautiful look of hand laid stone tiles.

Renaissance Bay Concrete Street Pavement

Renaissance Bay site is located in the 7800 Block of Keystone Avenue. When the building project is complete, the site will house over 43 buildings and have 1.7 million square feet of new construction. The entire project will be accessed and utilized by concrete pavement in the streets.

Renaissance Bay demonstrates significant awareness for the use of concrete pavement in residential development. The concrete paved streets allow for a cleaner curb appeal, brighter ambiance with the light reflectivity, and decreased maintenance costs in the future with concrete paved streets. Stamp mixes were utilized at the crosswalk sections with integral color and stamped concrete.

Over 5,500 cubic yards of concrete was placed in the concrete streets. A majority of the concrete was designed for 4,500 psi. Additional High Early mixes were used for quicker access during the various phases of construction

Southeastern Ave. RCC
10-16-08

The Southeastern Sanitary Sewer Project was the revitalization of sanitary sewers and elimination of septic tanks on the east side of Indianapolis, Indiana. The project entailed running sanitary sewer utility lines down the center of numerous streets off Southeastern Avenue. Phase one of this project required each street involved to be replaced the sanitary work was complete. Due to the large increase in asphalt pricing, an alternative for Roller Compacted Concrete was accepted.

The City of Indianapolis Department of Public Works, along with Calumet Civil Contractors and Eagle Valley Contractors used the Southeastern Sanitary Sewer Project as a benchmark for sustainability. Mayor Ballard has poised the Department of Public Works to explore alternatives to complete the needed public work projects on time and within budget. The application of Roller Compacted Concrete allowed the Southeastern Project to come in within budget and move towards a green movement in residential and commercial street project.

The Southeastern Corridor Sanitary Project provided the Department of Public Works a concrete alternative for their current and future projects. Benchmarking off of the Southeastern Corridor project will allow the City of Indianapolis, cities, towns and municipalities an alternative to conventional asphalt paving for public streets.

Builder’s Concrete and Supply worked with many partners to achieve a concrete mix design that provided ease of placement, workable mix design and desired compaction. The mix design was achieved by providing a zero slump concrete mix that was delivered in dump trucks to the site. Once delivered to the job site, the mix was placed with a high density paver that achieved compactions as high as 95% of maximum dry density directly behind the paver.