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Contractors World 2010 Volume 1 Issue 7
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FEATURE ARTICLE

 

The expansion of Solyndra, Inc.’s manufacturing capabilities will add 56,500 m² of production and office area and the new expansion is named Fab 2. USA
Concrete pumped slabs for fast track solar panel plant

In the seismic areas of northern California, earthquake engineering is a fact of life. In the case of a solar panel manufacturing plant being constructed in Fremont, the engineers chose a keyway system to tie large concrete mats together instead of drilling and filling hundreds of piers for the foundation.

The expansion of Solyndra, Inc.’s manufacturing capabilities will add 56,500 m² of production and office area and the new expansion is named Fab 2.

The 100% pumped project is being handled by Joseph J. Albanese, Inc, working with general contractors Rudolph and Sletten, a wholly owned subsidiary of Tutor Perini Corporation.

Albanese has been on the site since September 2009 and has placed a total of 99,400 m³ as of February 2010.
“The engineers came up with a keyway system to join the 52,800 m² mat pours”, explains Mike Aldrich, pump division manager for Albanese. The self-reliant construction firm with 16 boom pumps whose motto is "We Just Get It Done!" has been doing just that as the ‘place and finish contractor’ for the two story structure that will incorporate a concrete roof as well.
“We have had two to three pumps on the project everyday,“ Aldrich said. The company began by pumping ‘rat slabs’ – 100 mm thick ground cover to set the thousands of tonnes of rebar that is incorporated into the 12 mat slab pours. The slabs are poured with custom forms to provide up to 3 m deep keyways that stabilize the foundation.

Pouring 12 individual mats

The 47, 58 and 61 m boom pumps used on the project from the company’s all-Schwing fleet incorporate four-section Overhead Roll and Fold Booms which provide a 180º articulating main section. The 12 mats were poured one at a time with 4 to 6 pumps participating in placing up to 5,350 m³ in over a period of 12 hours. “Because the site is in an urban, industrial area, we begin pouring at four in the afternoon and end up at four in the morning,” according to Aldrich, “We have tight access, so there is only room for one set-up for each pump.” Three ready-mix plants from Central Concrete supply the 4,000 psi (27.6 MPa), 152 mm slump mat slab concrete that was a 70% cement replacement mix.

The 47, 58 and 61 m boom pumps used on the project from the company’s all-Schwing fleet incorporate four-section Overhead Roll and Fold Booms which provide a 180º articulating main section.

This allows the first boom section to be angled away from the pour and gives the operator added convenience to guide the other three sections into the building.

This is particularly useful on the Solyndra project because steel is already erected as the crews pump the 305 mm slabs on grade through up to 100 m of 4-inch hose attached to the end of the booms. The construction of the plant is being aided by Department of Energy financing which has resulted in additional inspections and an increased emphasis on safety. Consequently, trench plates are pre-set before each pour for outrigger support.

[cont . . . ]

Schwing America 561SX Concrete Pump
Schwing America 561SX Concrete Pump

 

Schwing America 558 Concrete Pump
Schwing America 558 Concrete Pump

 

Schwing America 545SX Concrete Pump
Schwing America 545SX Concrete Pump

 

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