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2009 PROJECT OF THE YEAR

Concrete Facts magazine sat down with CFA Technical Director, Jim Baty to find out more about this program for you. See what Jim had to say about this very important membership benefit.

Why should your members consider this award program? Awards programs are created to do two primary things. The first is to raise awareness of the professionalism and quality of the market that they surround and the second is to provide an easy way to make a statement about companies and their achievements. Depending on the focus of the sponsoring organization, the identity created in the program might be very specific to an application or a material or it might be more generalized to the abilities of a profession. The CFA now represents a great many contractors doing such amazing and incredible variety in their businesses. This is in part due to the economy but we have seen this transformation for many years. The CFA Projects of the Year program removed the singular focus on wild and “wooly” or unbelievable basements and broadened the effort to identify the full breadth of the talent, craftsmanship and professionalism of today’s CFA Foundation Contractor.

What influenced the increase in submittals this year? Some have suggested that with the sagging in the economy, contractors have more time on their hands to consider the projects they’ve done. We know that isn’t the case at all, in fact, it is a challenge to find the time to identify the achievements and provide the evidence of successful projects for an awards program that can and does take focus away from attracting or winning that next all-important job. However, as competition has strengthened and the volume of projects waned, it is evident that contractors saw this year as a chance to really describe what they can do. Submitting a project for a program like this validates companies on a national level, something they can point to on a local level with pride. Even the basic act of submitting and having that project evaluated or publicized is being seen as a chance to extend marketability. Consequently, we had our largest number of submittals–so many that it appears this awards program may have the opportunity to rival more nationally-recognized programs in the media.

What do you see for next year’s program? Based on what we have seen the past couple of years, we would anticipate another impressive crop of projects. Therefore, we will move the deadline for submittals forward to October 1st. This will give CFA staff the time necessary to prepare, publish and host the awards on our website. Voting this past year was so successful through the internet, compared to previous years at the World of Concrete alone, that it is obvious more people want to be involved. We will streamline a bit of the information on the request form but really continue to push members to identify the uniqueness and quality of the projects they do, even if they are a single job of a given caliber each year.

What do you think is the single biggest misunderstood fact? That is pretty clear. This program was known as the “Basement from Hell” for so many years (notice the emphasis on single award). The past few years, more categories have been broadened to continue representing the volume and variety of work these companies are performing. The program now boasts categories for different basement sizes, above-grave residential, commercial work, multi-family work and we anticipate this list growing. We suggest that if you don’t find a category for a type of project you finished, ask us or make one up. You might find others doing similar work that can challenge you to take it up a notch.

What would you like to say to this year’s participants? The CFA is very excited that you found value in the Projects of the Year program. We thank Action Concrete, Ekedal Concrete & Masonry, Bartley Corp., Basement Contractors, Modern Poured Walls and Louisburg Foundation for their hard work and dedication in producing these submittals. Many great comments were received and we hope you identify this participation to your local market. We now challenge you and encourage your peers to begin finding and submitting projects for next year. You may not feel something completed was outstanding but chances are the rest of the market and your peers might.

What is your hope for the future of the program–beyond next year? We believe the level of quality that is being evidenced and the sophistication of these projects is such that this program should see 50-100 entries or more per year. Our experience as judges and sponsors for similar programs suggest that being able to continue expanding categories, awards recognition and strengthening the ways projects are evaluated only pushes a program like this to higher levels of appreciation and representation. As this program grows, the popularity and attractiveness we seek to create will allow us to come up with new ways to promote it and use it to influence the market in which we operate.

Make your plans for 2010: Submittals will open August 1, 2009 and will close October 1, 2009 Contact the CFA headquarters by emailing Jim at jbaty@cfawalls.org, calling 866-232-9255 or checking the CFA website, www.cfawalls.org, for more information on this program and the past projects being recognized.

2009 CFA PROJECT OF THE YEAR

COMMERCIAL/MULTI-FAMILY

PROJECT 2 ENTRY INFORMATION

RHODES HALL ANNEX FOR CLEMSON UNIVERSITY – Clemson, SC

Submitted by

ACTION CONCRETE CONTRACTORS

SIZE:                  345 linear ft.
32,000 total sq. ft.
FOOTINGS:   360 yds. concrete
30 tons steel
WALLS:           Total concrete 292 yds.
Total steel 47 tons
Heights: 14’ to 16’
Thickness: to 10”

THE STORY

The complications presented by this project meant the use of our Robotic Total Station became very important. Tolerances were tight so there was little room for error. The job site had no lay-down or staging space, so a mobile tower

crane was used to stage items and move them as needed in the most efficient way possible. The structure included shear wall footings that were three feet thick with double mats of steel and inner stirrups spaced at nine inches o.c. Workers had to climb inside the mats just to tie the bars. Two cantilevered, beveled, and tapered beams were part of a monumental stair case that required a lot of time for shoring and forming.

THE REST OF THE STORY

Jason Sherman from Action Concrete says “The general contractor selected us for two reasons…a good estimate and our continued working relationship where we offer superior knowledge and workmanship.”

Action Concrete had to showcase this superior knowledge at this difficult site. Sherman says “This jobsite had no laydown space. Therefore we utilized our mobile tower crane in order to stage items in the most efficient way possible.”

In addition, this was a LEED certified building, so Action Concrete worked close with their concrete supplier to ‘create’ a special mix in order to utilize 25% fly ash and still achieve strength within 7 days in order to strip shoring.

ABOUT ACTION CONCRETE CONTRACTORS

Action Concrete Contractors in Greenville SC and Asheville NC is specialized in residential and commercial reinforced concrete construction including rebar placement, concrete placement through pumping or pouring, concrete footings, foundations and concrete slaps, poured walls including retaining walls and the all important waterproofing, and stamped concrete designs.

Action Concrete employs a fl eet of concrete construction equipment for concrete pumping with pump boom capacities exceeding 150 feet or 50 meters of pumping distance and for gravel spreading.

Contact Information
info@actionconcretecontractors.com
875 Tunnel Rd;
Asheville NC 28805
828-210-2025
www.actionconcretecontractors.com

ABOVE GRADE CONCRETE HOME

PROJECT 3 ENTRY INFORMATION

MB VISNIC – MANGUM RESIDENCE

CONCRETE HOUSE  – Stevensville, MD

submitted by

BARTLEY CORPORATION

SIZE:                 2,260 linear ft.
24,000 total sq. ft.
FOOTINGS     240 yds. concrete
7.75 tons steel
WALLS:           Total concrete 776 yds.
Total steel 34.75 tons
Heights 4’ to 14’
Thickness 8” to 10”

THE STORY

A 24,000 sq. ft. concrete house is enough to catch anyone’s attention. Even with such a large house, we committed to quality and placed a strong emphasis on the details to achieve a beautiful structure of lasting value. For example the half-suspended elliptical spiral staircase showcases the innovation and fine architecture emphasis placed on the construction. Craftsmanship on the arched openings in the radius walls showed ability to deal with challenges. Changing the plans from ICFs to poured-in-place concrete insulated walls demonstrated our leadership as a concrete contractor to use our CFA, trade, and supplier resources. The elliptical staircase and radius arches were the most difficult challenges. We met the challenges by creating mock-up drawings during on-side meetings with Doka form systems and Lite-Deck. Additionally, the project included above grade formed walls and slabs on the first and second floors. Together the structural features of arched openings in radius walls, and the elliptical, spiral and partially suspended staircase at the rear elevation made this one of our most challenging projects.

THE REST OF THE STORY

Jim Bartley says they were selected for this project by one of their customers, builder MB Visnic. The owner/architect designed the house for ICFs. Jim says they lobbied to change the foam block to ThermaEZE insulated walls and were successful.

Technically Bartley Corp. worked with the builder to plan the attachent of finishes to the concrete/foam walls. They placed a superintendent on site to manage everchanging details.

To estimate this project, Bartley Corp. talked to several CFA members about their estimates and experiences with similar work. They then priced the first and second floors as if they were basements and added on the cost of scaffolding and cranes.

Jim Bartley says ‘This waterfront concrete house sits on the shores of Chesapeake Bay. For years to come, boating spectators will see this work of art and the landmark will give concrete construction a strong association with beautiful architecture.

ABOUT BARTLEY CORPORATION

Founded in 1970, the Bartley Corporation pioneered residential concrete foundation construction to the Mid-Atlantic region. Today they represent the benchmark of quality. Their commitment to service and innovation has made them an industry leader. They provide both commercial and residential services.

Contact Information

jim@bartleycorp.com
16613 New Hampshire Ave, 
Silver Spring, MD 20905
301-384-2700
www.bartleycorp.com

SINGLE FAMILY 2,000-5,000 SQ . FT.

PROJECT 13 ENTRY INFORMATION

ASSAEL RESIDENCE – Newport Beach, CA

submitted by

EKEDAL MASONRY & CONCRETE, INC.

SIZE:          3,000 total sq. ft.
 Total concrete 103 yds.
 Total steel 30,000 lbs.
 Heights: 8” to 10’
 Thickness: 12”

THE STORY

The project had many phases: #1 – a seawall repair consisting of two 25 inch deep, 24 inch diameter caissons; #2 – 12 caissons drilled on the bay side of the project to support the grade beams and a five-inch thick slab on grade; #3 – a 24 inch mat slab, installation of wall-steel, and shotcrete walls; #4 – set-up of shoring and a structural deck above the base and rebar; #5 – a five-inch thick slab on grade poured; #6 – a cantilevered slab pour which started at the front of the house and hung five inches out over the seawall directly above the bay. Footings at the basement level consist of a 24 inch deep mat slab with #6 rebar, 12 inches o.c. top and bottom. Wall verticals are #6 and #7 at eight inches o.c. with #5 horizontal at 16 inches o.c. Footings at first floor level are 24”x24” grade beams with #6 and #4 ties 12 inches o.c. Basement walls range in height from 8’6” to 10 feet tall and are shotcrete with a hard trowel finish. One of the challenges of this project was layers of bedrock difficult to drill through. Also, conditions required bracing from one PL to the opposite PL which was left in place until the structural slab was poured. This project was challenging in that the footprint of the foundation covered nearly the entire square footage of the lot

 

THE REST OF THE STORY

Ryan Ekedal says they were selected by the homeowner because of their reputation for careful planning and attention to detail. They have an extensive check list of preparations overseen by Ekedal’s owner, detailer, estimator, and Superintendent.

They feel their work with the architect, engineer, and general contractor to generate ideas and methods will help save time and money for the project.

He says “We do a great deal of pre planning to eliminate problems and increase production. This in turn allows our projects to be finished quicker and reaffirming the clients trust in choosing the general contractor.”

“We have fewer problems with the building department because they appreciate our professionalism, reputation, and our strong relationship we have built with them.”

With the loyalty and commitment that we build with our clients, they can always count on us to help with other problems which may arise.

ABOUT EKEDAL MASONRY & CONCRETE COMPANY

Ekedal Masonry & Concrete, Inc. has over 30 years of experience in all phases of a project, from surveying to completion. Their diverse client base has provided us with them knowledge and ability to perform on a wide variety of projects, be it the simple or the most complex designs. Ekedal Masonry & Concrete, Inc. specializes in building high-end custom homes. They are an integral part of all aspects of their projects, saving money through quick and efficient completion.

Contact Information

rekedal@ekedalconcrete.com
220 Newport Center Dr., #11-288,
ph: 949.729.8082
www.ekedalconcrete.com

SINGLE FAMILY OVER 5,000 SQ FT

PROJECT 12 ENTRY INFORMATION

 

VILLA DEL LAGO RESIDENCE – Newport Coast, CA

submitted by

EKEDAL MASONRY & CONCRETE, INC.

 

SIZE:                  931 linear ft.
 
23,557 total sq. ft.
 
FOOTINGS:   383 yds. concrete
 
24,450 lbs. steel
 
WALLS:           Total concrete 417 yds.
 
Total steel 73,282 lbs.
 
HEIGHTS:       10’6” to 15’6”
 
THICKNESS: 1’4” to 8”

 

THE STORY

 

This project consisted of footing sizes varying from 24 inches wide x 1’6” deep to 10 inches wide x two feet deep with rebar ranging from #4 to #7 at 12 inches o.c. Footings stepped one to three feet with multiple elevation changes and the walls had over 50 corners and several angles. Complicating the structure were corbels along the tops of the wall to pick up the structural steel and several of the walls were battered 10 to 16 inches. Also, there were vast concrete columns to support the massive structural concrete deck. Forming the walls and the structural deck used new HDO plywood to achieve a better finish and to decrease the chance for deflection. Concrete additives were used for walls and deck to increase flow-ability around the tight bar spacing (four inches in some spots) and to achieve a higher quality finish. In order to accomplish the high level of detail, we used in house expertise to draw up wall profiles of every wall and column (60 total) with elevations, beam pockets, hardware, embeds, etc. The detailer also detailed all rebar for the structural deck and walls which ended up being over 500 pages of complex rebar details.

THE REST OF THE STORY

Ryan Ekedal says that like the Assael home, the home owner of this project selected Ekedal Masonry because of their reputation.

Ryan says that like all their jobs, their detailer drew up wall profiles of every wall & column (60 total) with elevations, beam pockets, hardware, embeds, etc. The detailer also detailed all rebar for the structural deck and walls which ended up being over 500 pages of complex rebar details.

It is this type of attention to detail that led to the success of this project.

ABOUT EKEDAL MASONRY & CONCRETE COMPANY

Ekedal Masonry & Concrete, Inc. has over 30 years of experience in all phases of a project, from surveying to completion. Their diverse client base has provided us with the knowledge and ability to perform on a wide variety of projects, be it the simple or the most complex designs. Ekedal Masonry & Concrete, Inc. specializes in building high-end custom homes. They are an integral part of all aspects of their projects, saving money through quick and efficient completion.

Contact Information

rekedal@ekedalconcrete.com
220 Newport Center Dr., #11-288,
ph: 949.729.8082
www.ekedalconcrete.com

PROJECT 1 ENTRY INFORMATION

JOCASSE CLUB, UNIT 1 – Salem, South Carolina

submitted by

ACTION CONCRETE CONTRACTORS

SIZE:                  751 linear ft.
3100 total sq. ft.
FOOTINGS: 281 yds. concrete
14 tons steel
WALLS:           Total concrete 340 yds.
Total steel 23 tons
HEIGHTS:      31’
THICKNESS: 8” to 24”

PROJECT 4 ENTRY INFORMATION

DEE’S RESIDENCE – Norman, Oklahoma

submitted by

BASEMENT CONTRACORS

SIZE:                  525 linear ft.
4,618 total sq. ft.
FOOTING:      112 yds. concrete
5,200 lbs. steel
WALLS:           Total concrete 326 yds.
Total steel 26,500 lbs.
HEIGHTS:       2’, 10’, 12’ and 24’
THICKNESS: 6” to 14”

PROJECT 5 ENTRY INFORMATION

NORTON RESIDENCE – Bay Village, Ohio

submitted by

MODERN POURED WALLS

SIZE:                 810 linear ft.
3,967 total sq. ft.
FOOTINGS:   116 yds. concrete
8,085 lbs. steel
WALLS:           Total concrete 156 yds.
Total steel 20,370 lbs.
HEIGHTS:       3’ to 14’6”
THICKNESS: 8”, 12”

PROJECT 6 ENTRY INFORMATION

MORSCH RESIDENCE – Bucyrus, Kansas

submitted by

LOUISBURG FOUNDATION

SIZE:                 760 linear ft.
9,650 total sq. ft.
FOOTINGS:   94 yds. concrete
6,000 tons
(9,000 ft) steel
WALLS:            Total concrete 207 yds.
Total steel 12,000 lbs.
(18,000 feet)
HEIGHTS:       1’ to 16’
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Concrete FACTS, a publication of the Concrete Foundations Association, is THE voice for residential concrete industry news, market intelligence, business strategies, technical solutions, product information, and other resources for professionals in the cast-in-place concrete industry. Subscriptions to Concrete FACTS is available to anyone involved or interested in the residential concrete industry as a service to your industry. Please contact CFA Headquarters to find out more about your free subscription or Email Us