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constructionfirm · 6 years

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FedEx Hub Selects Oldcastle for Retaining Wall System

Completed this past summer, the sprawling new FedEx® Ground Distribution Hub in Middletown, Connecticut, by many measures, qualifies as one the state’s all-time largest construction projects, with the largest retaining wall on the continent to date. To begin transforming the previous Aetna site into FedEx’s airport- style nexus of distribution, massive volumes of earthworks needed to be reconfigured and contained by an intricate and durable segmented retaining wall (SRW) system. Oldcastle APG’s Anchor Vertica® Retaining Wall System along with Mirafi geogrid reinforcement were chosen to carry out the plans for these enormous wall structures.

Opened for operation in 2018, Terry Chappell, owner of the wall installation company, Earth Retention Systems, says this vast undertaking stands out as one of the largest and most complex Segmented Retaining Walls in North America. “When you think of how FedEx has been fueled by the rise of Amazon and other online retailers, it makes sense that their hub would need an incredible amount of space,” he said.

As part of a nationwide expansion, FedEx’s new campus project broke ground in Middleton in May of 2016 with an ambitious two-year time table. According to company officials, the growth is a response to greater consumer preferences for online shopping resulting in exponential increases in daily package shipments over the past decade.

Anchor, an Oldcastle® Company, was selected as the exclusive supplier of the retaining wall block and geogrid materials. Anchor’s Cranston, RI plant manufactured all the Vertica Block for segmental retaining wall project. “This selection was based on competitive price, proximity to the project, technical support, manufacturing capabilities, and the overall resources to supply such a large project on a tight time frame,” explains Scott Vollmer, SRW market manager for Oldcastle APG’s East region. Anchor Vertica® has been selected over and over again as the ideal choice for large-scale retaining walls that require strength, durability, and a clean look in a near-vertical appearance.

The shipping giant’s hub campus project involved moving an astounding 2.5 million cubic yards of earthwork that required six retaining wall structures, encompassing more than 11,000 linear feet of SRWs to re-grade, stabilize and optimize the site. The project also called for more than 650,000 square yards of geosynthetic reinforcement. Oldcastle’s Belgard business unit worked with the project’s retaining wall design engineers to calibrate specifications for installing Anchor’s® SRW units onto a Mirafi® geosynthetic reinforcement base. The two products were used in tandem to create this magnificent engineering feat. The Mirafi® base provided the stabilizing foundation for the vertically rising Anchor® SRW units. The completed retention wall configuration is comprised of more than 300,000 square feet of SRW block built to soaring heights of 60 feet, spanning two miles.

“Due to the size, complex installation and overall scope of the wall project, we knew right from the start it would have to be a collaborative effort by all to be a success story,” remarked Chip George, general manager for Earth Retention Systems, LLC, installation contractor for the wall project. Along with his company, George notes that “the general contractor, Manafort Brothers, and the Belgard Commercial team all worked together to make that happen.”

“The design of the massive walls needed a proven system such as Vertica Wall with Mirafi geogrid reinforcement,” explained APG’s Vollmer. “Vertica’s four-degree batter was another advantage of the system and allowed for optimal site layout.” In practice, this ratio translates into a wall that steps in one inch for every four inches of height.

Terry Chappell agrees that the Vertica Block batter was a huge benefit for the project’s design. “The batter is 4.1 degrees so it provides more room at the top of the wall due to the vertical degree of setback. The batter design allows you to gain as much space as possible at the top of the wall which is especially important with a 60 ft. wall.” He further explains, “Owners and design engineers want to utilize as much area on every site for additional parking or a larger building envelope to get the biggest return on investment. On a 60 ft wall with a conventional 7-degree batter, the setback consumes 7’ 6” of space at the top, whereas the Vertica’s 4-degree batter takes up only 4’ 2”. That alone provides 3’ 4” ft. of extra useable space throughout the more than 11,000 linear ft. of walls constructed on this project.”

The biggest challenge on this project was the tight schedule that had to be met. Manafort and Earth Retention Systems had to work very close to hit all the milestones on the project. The companies changed their plan of attack numerous times to accommodate weather and to allow other contractors to perform their scope of work. “The schedule was very aggressive to begin with, said Chappell, with several days of rain and many other variables the team encountered. “It made the schedule even more challenging as we installed about 3,500 sq. ft. of wall per day during good weather and our average daily production rate was between 2,200 and 2,500 sq. ft. per day.” Despite the obstacles, Earth Retention Systems finished ahead of schedule. “I was especially very proud of my employees on site and in the office as well as our partner companies for stepping up and meeting the challenges of this project.”

Upon completion, the 260-acre FedEx distribution site now houses a 525,000-square foot main building with several concourses branching off of it. The complex will serve as a key distribution hub for FedEx packages. The grounds also include a self-contained maintenance garage and salt storage shed to assure a steady logistical flow–swift package delivery is at the heart of every decision.

Belgard’s® Anchor Segmented Retaining Wall system provided structural stability for ground retention as well as an aesthetically pleasing landscape design for the campus. The entire segmental retaining wall project, one of the most complex in North America, was opened for business in September 2018. “This major feat of engineering is one of the most successful SRW projects within the Oldcastle family,” said Greg Piper, VP of sales for Anchor, North Region.

About Belgard® Commercial Belgard Commercial is part of the Oldcastle Architectural Group, the largest concrete products manufacturer in North America. With over 180 locations and a company culture characterized by a commitment to customer satisfaction, Oldcastle adheres to a level of service and consistency that no other supplier can match. Our combination of local market presence and national capabilities allows us to meet and exceed the demanding needs of an ever-changing industry.

[Applications include terraced walls, site development, bridges, multi-family developments, DOT roadways, water channels, pools, extreme loading, and more. Textured units are available in straight or beveled face.]

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coolbirdpuppy-blog · 7 years

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Landscaping Pavers

Have a look pavers that are Boral were used by the House Rules groups . This Enviro 300 capping's surface arouses the end of guillotined natural rock. This Roswell, Ga., outdoor area is designed by J&J Landscaping and Neptune Pools and uses Belgard pavers with a cobblestone impact manufactured by Georgia Masonry Supply of Atlanta. User friendly more info here, Cinco stone matches the range of landscaping solutions and Permacon masonry. It may be installed in modular or linear designs, and matches with Melville 80 pavers. This fresh honeycomb paver combines perfectly with Cassara pavers, plus it has the exact same look and all of the benefits of this Melville Collection. It allows you to delineate the regions of your outdoor living area. The rectangle may be utilized to make texture accents and original color on your landscape design. The Valestone Hardscapes Brandford slabs is a terrace stone with smooth feel and joints that are straight. Here is where you can browse through images of projects completed with solutions. The Melville Tandem capping is ideal for minimalistic and modern landscaped spaces. Urbanika stone with a texture is also available in the exact same family. A paver with a yesteryears look, typical of the rock pathways found in areas old. Permapro was made to accommodate to curved or straight installations.

No-Dig 20 ft. Landscape Edging and Paver Edging Kit, Edging And Accessories Are Black In Colour.

Perfect for patios, it is possible to install 16" x 16" or 16" x 24" sizes separately or combine them for a personalized look. pavers Use stone pavers such as studio or a backyard shed, in a garden, indicates Danna Cain, owner of Garden & Home Design at Atlanta. This paver is readily utilized to create a herringbone pattern to get a look or a running bond pattern for a look that was linear. Nature's colors and textures are always in vogue and adds sophistication that elevates your outdoor decor to the next level. The addition of a step in to your outdoor living space marks the transition between branches and different levels . Having a conclusion that exposes the material's grain together with modern lines, Lexa Tandem walls lend a trendy yet refined air to any environment. The colours you select for the pavers can make a brand new patio or walkway seem as though it has been on the house, suggests Southview Design.

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blackpjensen · 7 years

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2017 Product Roundup: Hardscapes

1. Aqua-Bella Designs

The Triple Basalt fountain kit is a set of three solid columns with varying heights made of volcanic rock. Sizes are 18, 24 and 30 inches. The rocks have an 8- to 10-inch diameter. Basalt is a dense crystalline material, about 10 percent heavier than granite.

2. Anchor Wall

ChiselEdge Edgers are a landscaping component to the ChiselWall system. Three unique face patterns give the edgers a distinctive look similar to hand-chiseled stone. Entrances and tree rings are some possible project applications, according to the company.

3. Belgard

The Tandem Column Kit from Belgard’s natural collection can be installed by setting the grid on the U-Start base or a solid base, attach veneers to the column with connectors and cap the column. It can be used for new columns or around existing deck posts and installation for patios, outdoor kitchens, pillars and outdoor living rooms. The column grid height is 42 inches and comes in two colors: Avondale and River Street.

4. Cambridge Pavers

The Cambridge Ledgestone Wall has a natural-looking rock face with bold ridges and deep clefts. The wallstones are 4 x 8 x 12 inches, and can be used in many single-sided applications from a freestanding and retaining wall to steps and edging. A Ledgestone Wall Corner for left and right corners is also available.

5. Fireboulder

The Large-Linear fireboulders are hand carved and designed to accommodate a 36-inch linear burner. Dimensions and weights of these boulders vary, but typically weigh between 900 and 2,000 pounds. The dimensions are roughly 71 x 28 x 15 inches.

6. Keystone Retaining Wall Systems

The Keystone Country Manor Wall has stones with three finished sides and an interlocking pin system. The stones come in 2-, 3- or 5-piece systems to reach a 3-foot height, or higher with proper engineering. The stones have an Old World charm and look hand-laid, according to the company.

7. Pavestone

The Bishop’s Hat pavers from Pavestone consist of two geometric concrete pavers with many design options. The two shapes modulate together to form patterns with different color choices. Each stone weighs 10.05 pounds. These pavers are suggested for courtyards, driveways, parks, patios, pool decks and more.

8. Pine Hall Brick

Rumbled StormPave Permeable Pavers are full-range, 4-x-8-inch clay pavers with beveled edges. The large spacer bars provide spacing for washed aggregate filled joints that allow water to drain freely between the paving units. The pavers initial rate of infiltration is more than 500 inches per hour. The dimensions are 4 x 8 x 2.25 (or 2.75) inches. The pavers are available in 10 color options.

9. Porous Pave

Porous Pave is a pour-in-place permeable paving material that is porous and flexible. The highly porous material allows for large amounts of water to drain through it, draining up to 6,300 gallons per hour per square foot. The product’s flexibility allows the material to withstand freeze-thaw cycles without cracking or heaving. It is made in the U.S. from recycled tires and the high rubber content ensures good traction even when wet.

10. Techo-Bloc

From the Techo-Bloc Stonedge Collection, the new Travertina Raw slabs have the texture of natural travertine in a concrete material. This product line has been improved to make it more durable than the natural alternative, especially for winter climates. The collection has been expanded with a double-sided, structural retaining wall system, two wall caps and pool coping with three color tones.

11. Unilock

The Eco-Optiloc permeable pavers form Unilock are environmentally friendly and can solve drainage issues, according to the company. They have a patented L-shaped design for a lock-up that can withstand heavy loads residentially and commercially. The design creates small voids between the pavers providing drainage into the sub-base. Surface textures can be customized for commercial projects.

12. Rosetta Hardscapes

The round fire pit kit from Rosetta has six different sized stone pieces as part of the layout pattern, plus the stone caps. From the base to the cap level, the fire pit height measures 14.5 inches. Gas conversion kits are available, as well as different color choices based on location.

Have a new product? Submit entries using our Product Form for Turf, Turf Design Build and PLOW, a supplement to Turf.

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