Expansion of PACON Facilities
Appleton, WI
Unique use of RCC floor system and cast in place exposed aggregate tilt-up wall
At this 1960’s construction business expansion required the existing distribution space to be converted to manufacturing by adding new distribution space along with the associated office, locker room, and auto parking.
Presence of high organics in the soil and high groundwater resulted in the geotechnical recommendations to remove and replace native soils with well-compacted structural fill to a depth of 30′.
Due to the high cost of over $1 million and problems associated high ground water with this approach, I elected to bridge these soils and construct the building without this soil remediation.
Total construction savings of over $2 million and cut at over 9 months off the construction schedule!
Poor soil conditions resulted in the need for all crane movements, to lift and erect these heavy concrete tilt-up walls. to be performed by working from the new building RCC floor system; this was accomplished with no damage to the floor system!
Longevity
Current photos were taken in 2017 and highlight the building use, the exterior architectural appearance of the exposed aggregate concrete walls, and the floor system which has performed excellently since constructed. One photo at the opening between this newer 1990’s construction and the existing 1960’s construction, highlights the lack of any settlement between buildings.
Building use 50’ high racked storage of heavy finished paper products within this distribution facility
Alternate to Soil Replacement - RCC
Exterior storage areas and roadway materials in this construction area were salvaged. The 4’ high building grade for truck and railroad grade access was accomplished using 18” of 3-5” aggregates, topped with 18” of salvaged ¾” aggregates and asphalt, and finished with 12” of RCC for the building slab.
Concrete Tilt-up Wall
Use of site-cast concrete tilt-up walls system, which acted as the
RCC Floor System
Photos taken in 2017 demonstrate that this floor system subjected to these 50′ heavy paper rack storage system and 24/7 fork truck traffic are performing
Membrane Roof System
Twenty-five (25) warranty on a totally adhered Fleeceback EPDM membrane roof system provide long-term best lifecycle value.