The floor tolerances for this Merck Pharmaceutical manufacturing facility were specified at Ff60 Fl40. The Donley’s Concrete Group finishing team exceeded the specified slab tolerance and ended up with Ff 78 Fl 47.
The structure houses the main switchgear for the entire Merck facility. The high tolerance floors were installed to allow massive transformers to be replaced with an air pallet system that utilizes a cushion of air to lift and float the transformers across the floor to the desired location.
Donley’s provided concrete construction services for this new four-level Amazon Fulfillment Center facility on the former Rolling Acres Mall site. Donley’s placed 72,000 cubic yards of concrete in just eight months.
Our scope of work included:
- Building foundations (approx. 18,000 cubic yards of concrete)
- Slab on grade (650,000 sq. ft. footprint) with stringent quality requirements for floor flatness (FF 50) and floor levelness (FL 34.5)
- Three levels of slab on metal deck (approx. 36,000 cubic yards of concrete) with tolerance requirements FF 30 and FL 15
- 60 loading docks with dock leveler pits
The concrete construction for the Ajinomoto expansion, the pharmaceutical manufacturer, consisted of deep foundations, spread footings with piers, cast-in-place walls, stem walls, and curbs. The main structure was a heavy structural steel building, supporting a 10″ slab on metal deck. The structure was solid enough to allow the construction of two floor to ceiling 18′ high x 2′ thick blast walls on the second and third levels.
DCG also completed extensive concrete paving around the site for the new dryer structure. We carried the masonry block and complete reinforcing steel package for the building in our concrete scope of work. Ajinomoto manufactures amino acid for several different food manufacturers and applications.
The Fresenius Kabi drug manufacturing facility consists of over 400,000 square feet of foundations, walls, slab-on-grade, and elevated slabs. It also includes a high bay storage unit that houses extensive racking / storage and an automated selection system. The floor slabs in this area required a very high tolerance to accommodate the automated selection system. The high bay area was completed in three separate placements, with a total of 2,300 cubic yards of concrete to create the 30” thick mat slab. All other floor slabs in the facility had a tolerance of Ff50 / Fl30. Donley’s team has exceeded all specified floor tolerances on this project.
Donley’s construction and safety team created a site specific safety plan that allowed this work to be completed on schedule and in a safe manner. Our team placed 17,880 cubic yards of concrete and over 511 tons of reinforcing steel to complete Fresenius Kabi.
The cast-in-place concrete for this pharmaceutical company’s (NOVO Nordisk) wastewater treatment facility includes 17′ high cast-in-place radius walls for the bio-reactor digesters and clarifiers.
The bio-reactor cast-in-place 30′ slabs required over 30 placements with an extensive water stop detail at each construction joint. The walls for the bio-reactor were also limited to a maximum 30′ pour break along with water stops at each joint.
Over 30% of the cast-in-place walls were topped with a cast-in-place walkway and work platform. These platforms were completed with a wall-mount flying table system. As a part of Gannet Fleming’s team, Donley’s placed 8,000 cubic yards of concrete and 750 tons of reinforcing steel to create this state-of-the-art NOVO Nordisk wastewater treatment facility.
The Cross Generating Foundations project included the addition of a wastewater treatment facility to an existing 2,390 mega watt coal fired generating facility which is owned and operated by Santee Cooper. The new facility enables the plant to treat coal ash water to meet more stringent EPA regulations.
Donley’s Concrete Group scope included the following which totaled nearly 33,000 cubic yards of concrete placed on the project.
–36″ thick matt slabs and foundations
—–Cast in place pits placed within sheeting / shoring and slide rail boxes up to 16 feet deep
–Slab on grade, sloping clarifier slabs
–26 foot high push walls
–Piers, columns, and beams
–Stem walls and curbs, with trench drains and embedded angle
–Massive tank and pump pads which included anchor bolts up to 3.5” in diameter and set to a tolerance of 1/32 of an inch
–Topping slabs and trench infill for over two dozen separate structures
In January 2017, working with Choate Construction / Raleigh as construction manager, DCG finished the Sanderson Farms processing plant and wastewater treatment facility in St.Pauls, N.C. The $8M contract included a turnkey concrete package, consisting of large spread footings, grade beams, pits and trenches for the processing facility, 285,000 sq. ft. of slab on grade and elevated slabs, including 400,000 sq. ft. of exterior concrete paving. The project had 21,000 cubic yards of concrete placed out of an onsite concrete batch plant. Donley’s Concrete Group’s portion of the project was completed in 11 months and is DCG’s second processing facility for Sanderson Farms.
Donley’s worked on the Sanderson Farms’ Poultry Processing Plant located in St. Pauls, North Carolina.
Donley’s Scope of Work includes:
- turnkey concrete construction
- spread footings
- grade beams with steam walls for precast
- cast trench boxes
- stone base with high tolerance sloped to floor drains
- elevated concrete
- freezer and ice room slabs
- curbs and exterior paving
Donley’s has been awarded the Spirit AeroSystems Tool Expansion in North Carolina. The facility manufactures miscellaneous parts for the aeronautical community.
The scope of work for the project includes:
- turnkey concrete construction
- pile caps
- grade beams
- tie beams
- loading docks
- stone base
- high floor tolerance slab on grade, including misc. site concrete
“BMCD and Spirit are also very thankful the goal was met and was done safely even in the inclement weather. Donley’s continued working through the rain which was acknowledged by Spirit in addition to our team. The efforts are very much appreciated and BMCD and Spirit look forward to working with Donley’s team in the future.”
Donley’s Concrete Group served as concrete contractor to DPR Construction on a facility expansion project for Cree, Inc. (Cree NCE Expansion), located in Durham, North Carolina.
Cree, Inc. is a market-leading innovator of lighting-class LED’s, LED Lighting, and semiconductor solutions for wireless and power applications.
Donley’s scope of work included:
- light demolition of existing mud slabs
- installation of typical pier foundations, wall footings, and retaining walls
- slab-on-grade consisting of 90,000 sq. ft. of 14″ thick mat slab
- 80,000 sq. ft. of cast-in-place elevated flat plate decks
- 80,000 sq. ft. of elevated composite decks on structural steel