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2016WinterShotcreteEMag

square columns. The shotcrete process was used in varied thicknesses from 12 to 72 in. (300 to 1800 mm) depending on type of wall, and 24 in. (600 mm) diameter circular columns. The base contract volume was approximately 19,232 yd3 (14, 704 m3) plus an additional 13,885 yd3 (10,616 m3) in change orders. The base contract work consisted of 12,520 yd3 (9572 m3) of structural perimeter walls (one-sided finish); 3904 yd3 (2985 m3) of interior I-beam walls (two-sided finish); 2436 yd3 (1863 m3) of interior steel-reinforced walls (two-sided finish); and 372 yd3 (284 m3) of columns: 101 circular columns with a 24 in. (600 mm) diameter; 16 circular columns with a 12 in. (300 mm) diameter, and 16 square columns measuring 3 x 3 ft (900 x 900 mm). The change order work was an additional 13,000 yd3 (9939 m3) in one-sided wall smoothening and 885 yd3 (677 m3) of one-sided walls with a rubber float finish. The shotcrete process was used for all vertical elements on this project. The project ran from December 2012 to August 2015. Superior Gunite used a 5000 psi (35 MPa) concrete mixture supplied by Ferrara Bros. Building Material Corp. and Tec Crete Transit-Mix Corp. to aid the general contractor in meeting Federal DBE goals. The coordination between the providers and teamwork was instrumental in making this job a success. The major challenge was shooting through the difficult East Coast winters that required tenting and heating the placements through the 0°F (–18°C) temperatures. All structural walls and columns required a steel trowel finish. This was especially difficult when it came to circular columns. To aid in the precise finish of the columns, workers used fabricated trowels and a cutting rod that were shaped to the curve of the column. Fig. 3: One of the four levels of interior walls Fig. 4: Each of the three bays shown is a future train corridor for Long Island Railroad. To the right you can see square columns The Outstanding Infrastructure Project Project Name CQ32 Project Location Queens, NY Shotcrete Contractor Superior Gunite* General Contractor Tutor Perini Civil Architect/Engineer New York Metropolitan Transportation Authority Capital Construction (MTACC) Material Supplier/Manufacturer Ferrara Brothers Building Material and Teccrete Lab Tectonic *Corporate Member of the American Shotcrete Association Frank E. Townsend III is the East Coast Region Manager for Superior Gunite. He is a civil engineering graduate of Worcester Polytechnic Institute, Worcester, MA, and received his master’s degree from the University of Missouri, Columbia, MO. Townsend comes from the U.S. Army Corps of Engineers and has been running Superior’s East Coast operations (predominantly New York, New Jersey, Connecticut, and Boston, MA) for 4  years. Townsend is an active member of ACI Committee 506, Shotcreting; a member of ASA; and currently serves on the ASA Board of Directors. 2015 ENR top 20 under 40. Shotcrete • Winter 2016 23


2016WinterShotcreteEMag
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