Concrete Products

DEC 2018

Concrete Products covers the issues that attract producers of ready mixed and manufactured concrete focusing on equipment and material technology, market development and management topics.

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Page 44 of 83 December 2018 • 43 COVER STORY SUPERIOR CONCRETE DC Dump and tanker trucks enter Superior Concrete DC at the least-trafficked of four surrounding streets, and navigate tire-cleaning grates inbound and outbound. A skid steer with sweeper attachment works in tandem with a water truck to minimize dust from the extensively paved operation. Also contributing to dust control are coarse aggregate stockpile sprinklers and a fabric roof shelter for the sand, set back- to-back with a similar structure for the maintenance shop. The plant is well equipped for high volumes of temperature controlled mixes, running Pearson Systems' P-30 Direct-Fired Water Heater, with 30,000-gal. tank, and companion PH-3000 Air-Cooled Chiller. Neighborhood sensitivity and permit-besting gestures do not stop with water and dust factors. The new plant has a height restriction of 65 feet, almost 20 feet below the prior operation's level. At the expense of some production capability, Superior Concrete dropped equipment and silo height to 53-55 feet and built an enclosure with architectural, insulated wall panels to make the main structure aes- thetically pleasing to neighboring businesses and future residents, while eliminating dust emissions during batching. Concrete Plants Inc. of Severna Park, Md. and Steel Systems Inc. of Quarryville, Pa. configured material handling, ramps and the enclo- sure around a Stephens Mfg. portable, 250 yd./hour Eagle batch plant with 10-yd. Workhorse reversing drum mixer. Compared to conven- tional tilt drum models, the reversing drum better suits low slump mix production, has fewer moving parts, and requires less maintenance. At Superior Concrete DC, the mixer choice contributes to overall plant height reduction, and equates to an output potential of 250 yd./hour versus a tilt drum alternative's 180-200 yd./hour range. Along the rear site elevation, facing the DC United Soccer Stadium entrance, Superior Concrete partially conceals view of four covered conveyors, 30-in. x 140-ft. at 18.5 degrees, charging four 50-ton overhead aggregate bins. Concrete Plants and Steel Systems completed the material handling and storage plan with 450-bbl. fly ash and slag cement silos alongside the front and rear alley enclosure entrances, respectively. A horizontal silo at grade, placed beneath the main conveyors, is the primary cement storage vessel and feeds the Eagle model's 350-bbl. in-truss silo. POTOMAC CROSSING The DC plant relocation occurred with Superior Concrete's assimilation of DuBrook Concrete Inc. assets, acquired in 2015 and netting a north- ern Virginia market presence. To concentrate production along corridors most accessible to target projects, Superior Concrete has maintained DuBrook's flagship Chantilly plant near Dulles International Airport, and—after a nearly four-year permitting and site preparation phase— opened a third ready mixed site in Lorton, Va., along Interstate 95. The Dulles, DC and Lorton points form a triangle framing or in proximity to a sizable portion of building and infrastructure work ahead for Metro Washington, including Arlington, Va., areas of Crystal City and National Landing pegged for Amazon HQ2 and attendant commercial and residential development. The Chantilly and Lorton plants are also strategic to the Dulles Corridor, which has become the top U.S. location for leading technology players' data centers. "We looked at long-range factors for Washington, D.C. and north- ern Virginia and saw the case for investment. The market has strong dynamics, barriers to entry and commercial building prospects suited to U.S. Concrete," says Superior Concrete General Manager Todd Mar- tineau. "Between infrastructure and commercial building contracts, there are unique opportunities for the types of high performance and specialty concrete applications where we excel." "U.S. Concrete has made a major commitment to this market by purchasing DuBrook Concrete and building two greenfield ready mixed plants over a span of three years," he affirms. "We have positioned ourselves in the capital region and are looking for more opportunities to grow."

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