Rooms-to-Go distribution center, Lakeland, Florida: a giant undertaking

Concrete Construction, Dec, 2002

The Rooms-to-Go concrete tilt-up project faced a number of unique challenges due to its size, the Florida heat, and a scarcity of water. In addition, the project required a crew of 60, working in all phases of the concrete construction process--placing foundations, forming and pouring slabs and panels, erecting panels, and patching--all at one time. The more than 40 main slab placements consumed an average of 600 yards of concrete per day, 6 days a week--a final total of more than 38,000 cubic yards of concrete.

In the intense Florida heat, a steel measuring tape tends to expand as the day heats up, so intermediate control points were set to maintain accuracy in measurement of the slabs on grade and panels.

During slab and paving placements, the aggregate bins were being drained daily. The volume of concrete being placed each day left little time for the ready-mix supplier to restock and properly wet down the aggregate. Having a strong relationship with the ready-mix supplier helped to minimize these problems. The building subbase was sand, which created a challenge in maintaining proper moisture content. The crew hauled water long distances from the building to wet cure the slab.

A high-speed transport lane, which was placed 6 months after the original slabs, began cracking at the load-transfer dowels. This was a result of concrete shrinkage in the new lane after shrinkage in the main slab had long since ceased. The contractor switched to a PNA diamond-plate dowel system, which allowed for side-to-side movement of the newly placed lane, thereby minimizing cracking.

The final building, 1,650,000 square feet with 479 tilt-up panels, is more than 1.5 miles around.

PROJECT PARTICIPANTS

* Contractor: Seretta Construction, Orlando, Fla.

* Project Superintendent: Alfredo Garcia, Orlando, Fla.

* Project Manager: Andrew S. McPherson, Vice President, Orlando, Fla.

* Owner/Developer: Seaman Development Corp., Duluth, Ga.

* Ready-Mix Producer: RMC Ewell Industries, Lakeland, Fla.