With a student population of more than 40,000, and within walking distance to the state capitol and downtown retail district, the University of Wisconsin—Madison campus is a hub of activity year round. The demand for new housing, retail stores and parking space on the prime downtown real estate near campus is continually on the rise. Upon completion in 2015, two mixed-use projects just a few blocks from each other, Hub at Madison and Ovation 309, will help meet that demand with assistance from five Putzmeister America, Inc. (Putzmeister) truck-mounted concrete boom pumps, four Putzmeister separate placing booms and pin towers, and one Putzmeister Telebelt® TB 130 Truck-Mounted Telescopic Belt Conveyor.
J.H. Findorff & Son Inc., general contractor for the two projects, turned to the expertise of Gordy’s Concrete Pumping Service (Gordy’s) to place the combined 46,000 yards of concrete required for the developments. An industry leader for nearly 50 years, Gordy’s owns a fleet of 18 boom pumps and Telebelts. They have also added three placing booms in the past two years, bringing their total placing booms up to eight. When the placing booms aren’t busy with Gordy’s contractors, the company rents them out to fellow concrete pumping companies across North America.
Hub at Madison
Located on the 500 block of Madison’s well-known State Street, Hub at Madison (The Hub) is scheduled to open in August 2015, offering nearly 1,000 new bedrooms with luxury amenities for students, retail and office space, and several hundred parking spaces. Different sections of the approximately 490,000-square-foot building on 1.6 acres of land will range from four to 12 stories.
To place the 22,800 yards of concrete for the project, Gordy’s is utilizing several truck-mounted boom pumps, two placing booms, and telescopic belt conveyor from its extensive fleet of Putzmeister equipment.
“We utilized many different pieces of equipment for this job,” said Mike Salmon, manager for Gordy’s. “While it took a lot of coordination, we were able to match just the right pieces for the various placing requirements.”
At the beginning of the project, Gordy’s used a Putzmeister Telebelt® TB 130 Truck-Mounted Telescopic Belt Conveyor to place the mat foundation. It was also used to backfill with aggregate around the outer walls of the slab.
Also placing concrete for the foundation work were Putzmeister 42-, 46-, 55-, and 63Z-Meter Truck-Mounted Concrete Boom Pumps. First the slabs were poured, and then the team went on to do the vertical work—core wall, columns, walls—sometimes the same day and sometimes the next day.
As they built up, concrete was pumped through a 36-Meter with .16H pump cell switched over to the high pressure piston side, which was located at ground level, and up through a tower placing system to two Putzmeister MX 36/40Z Placing Booms. The system was able to easily reach the maximum project height of 160 feet (49m).
“The two placing booms were able to reach to all four corners of the project,” said Salmon. “They have played a key role in helping us to keep this project on schedule.”
Just a few blocks away, another massive mixed-use project is well underway. When completed, the $60 million, 14-story Ovation 309 building will comprise two levels of underground parking, 9,500 square feet of retail space, nearly 14,000 square feet of office space, including 30,000 square feet for the Madison Fire Department, 255 apartment units, and a rooftop garden and clubroom.
Gordy’s has been utilizing several pieces of Putzmeister equipment to place the 24,000 yards of concrete required for this project, as well. The process and set up of concrete placing equipment— including Telebelt, truck-mounted boom pumps, and placing booms—at Ovation 309 is almost identical to what the team has been using at The Hub. The maximum height at this second project is slightly higher at nearly 162 feet (49m).
Limited Ground Space
With real estate at a premium at both downtown job sites, bringing in truck-mounted boom pumps became more difficult as the project progressed. The construction team decided to utilize one truck-mounted boom pump at ground level on each site to pump the concrete through pipeline, to the self-climbing placing booms set up on the floor they were currently working on.
“By using placing booms, we were able to limit the footprint of pumps on the street,” explained Salmon. “With the Putzmeister self climbing system we did not need the crane to raise the placing tower, which keeps the crane free for all the other aspects of the projects. This was essential in order to stay on schedule.”
Due to the efficient use of the placing booms, the team was able to finish the concrete structure an unexpected 42 days ahead of schedule.
Restricted Pour Schedule
Since both projects are located in the center of busy downtown Madison, the city is, naturally, concerned about traffic flow and noise. Thus, it placed restrictions on the times Gordy’s was able to place the concrete.
“We are only allowed on the street from 9:00 a.m. to 3:00 p.m.,” said Salmon. “That means we have to pour at least 100 yards an hour to get pours in and appease the city. It is a balancing act to minimize noise for the residents, while also making sure not shut down any lanes of traffic. It wouldn’t be possible without Putzmeister’s placing equipment—it’s been instrumental in helping us to meet all those expectations.”
With the expertise of Gordy’s team of experienced operators and the precision and reliability of its fleet of Putzmeister equipment, both projects are scheduled to be completed in 2015, providing this crowded area of Madison, Wis. with a variety of new options for living, working, and playing.