Pouring This Much Concrete Must Be Done with Care and Attention
Part II
Rebar, Rebar, and More Rebar
Duffey Southeast was on site preparing for concrete placement of the satellite antenna foundations. Two 34m concrete pump trucks were used during this concrete pour. The reason for utilizing two pump trucks this size is due to the mass quantity of concrete that must be placed within the antenna foundations. The foundations have a diameter of 145.5’ with a depth of 10’. Additionally, these foundations are reinforced with (2) rebar mats top and bottom with #10 rebar at 4” centers which gives a tremendous amount of strength for ensuring the foundations can withstand the load and pressure applied during antenna operations.
The complexities associated with the size and depth of the foundations bring in many variables we must consider before and during concrete placement. To minimize risk during placement we have a third-party testing company on site performing QC testing of concrete quality prior to being placed. Their job was to ensure the concrete meets all approved mix designs and specifications as noted in the drawings. The third-party inspections crew played a pivotal role in maintaining quality during concrete placement.
Why We Pour Overnight
The reason we have concrete pours so early in the morning is to eliminate any variables that would put the cement trucks out of limits for their batch time. The batch time is how long you have to get the concrete off the truck and placed. We faced a batch time of 90 minutes from leaving the concrete plant to get the concrete off the truck and poured out. Also, early morning pours (Midnight – 2am) minimize the potential risk of having trucks wait in traffic and any other road hazards that could prevent the concrete truck from arriving on site within the time constraints. It’s vital to make sure that the concrete truck has minimal stops from the plant to the site.
The Finished Foundation Shouldn’t Appear Complex.
To the common eye this foundation will look like a typical concrete slab. However, what we build doesn’t come from nothing. There are high-level in-depth procedures that must be completed accurately to maintain the strength and integrity that is needed for these Satellite Antennas while they are in operation. The complexities associated with constructing a foundation of this magnitude must undergo rigorous inspections processes and pre planning to optimize success.
Good Communication, teamwork, and accountability are what Duffey Southeast practices everyday to ensure success of the project.
