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Each of the three pours would normally begin between 5:00am and 6:00am in order to take advantage of a greater supply of concrete in the earlier hours and avoid commuter traffic. With completion by noon, each pour beat the summer heat.

Ralph Clayton & Sons dispatched over 50 mixer trucks, delivering from four batch plants to meet demand. During a six-hour pour, the first three hours required 350 yards an hour and the remaining three hours required an average between 250 and 300 yards an hour.

In total, the overall foundation demanded 7,500 cubic yards of concrete at a three foot depth.

To efficiently place 1,850 cubic yards of concrete for each of three large foundation pours, a combination of Putzmeister equipment was specifically selected to avoid relocating any machine. A BSF 58-Meter and a BSF 36-Meter boom pump along with a TB 110 Telebelt® conveyor were all utilized for their effective reach and high output capabilities.

Junior Scarpa, President of J&R Concrete Pumping, supplied the largest boom pump for the job- a Putzmeister BSF 58-Meter.

The city of Asbury Park was once the 'Jewel of the Jersey Shore.' Today a major 56-acre waterfront redevelopment plan is underway to produce more than $1.25 billion in total economic redevelopment. A centerpiece of the project is North Beach Asbury Park, which features three oceanfront buildings. They share a common foundation, but this is not visually apparent as the architecture of each building is distict.

On the Boardwalk

The "Jewel of the Jersey Shore" under Revitalization

STURTEVANT, Wisconsin (October 10, 2005) - Once upon a time, the city of Asbury Park was the "Jewel of the Jersey Shore." However, bad times fell upon this gem, and its precious past was blighted with the 1970 riots and the subsequent exodus of much of its middle class. In 1987, the first redevelopment attempt was proposed, but a sluggish economy and a redeveloper's bankruptcy prevented fruition.

Today, however, a major 56-acre waterfront redevelopment plan is well underway, which includes residential, retail and entertainment components, municipal services and urban empowerment initiatives. The project is expected to be accomplished in phases over ten years, ultimately producing more than $1.25 billion in total economic redevelopment. Its goal: return the beachfront to its former vibrancy and transform the city's economy.

Asbury Partners, LLC of Asbury Park, New Jersey, is serving as the master redeveloper for the one-mile long and several blocks deep revitalization project, which extends west from the city's fabled boardwalk.

A centerpiece of the city's oceanfront redevelopment is North Beach Asbury Park under the direction of builder/developer Paramount Homes. The initial phase of the project features three oceanfront buildings, which encompass 157 luxury condominiums. They will feature resort-style amenities, and selling prices have ranged from $400,000 to $2 million. Purchasing a North Beach Asbury Park condo is the only chance to live right on the beachfront in the Northeast with reasonable affordability.

The first North Beach Asbury Park condo building was 100% sold in less than a month after its June 1, 2005 release for sale. Therefore, as demand is extremely high and interest rates are still advantageous, faster residential construction is needed.

Quicker construction of the first condo is crucial to meet its scheduled summer 2006 opening. In addition, demand for the oceanfront condos has spurred construction of the second and third buildings, the Seville and the Monterey, to begin up to one year sooner than originally planned. As a result, concrete placing equipment is being used on the site for its speed and efficiency.

On June 29th of this year, concrete boom pumps and a convoy of mixer trucks arrived at the North Beach job site to make the first of five "super pours" of concrete for a large 305 ft. by 250 ft. foundation. Although the three condo structures will share this common foundation, it will not be visually apparent as the architecture of each building is distinct.

Responsible for the concrete work is Weatherby Construction & Renovation Corporation of Ventnor, NJ. To keep the project moving swiftly forward, Weatherby chose to divide the large foundation into four quarters, each requiring about 1,850 yards of concrete for a total of 7,500 yards. The first quarter was also split in half so once the reinforcing steel was installed, the slab could be immediately pumped with concrete and construction commence.

Weatherby utilized various concrete placing companies based on equipment availability, but Putzmeister concrete placing equipment was employed in every pour. For the first smaller 900-yard pour, Rushland Concrete Pumping of Rushland, PA supplied a BSF 36-Meter and a Telebelt® conveyor. For the second 900-yard pour, a BSF 55-Meter from the Alexander Wagner Company in Paterson, NJ along with Rushland's Telebelt® jointly handled the concrete placement.

For the following three larger foundation pours, a combination of Putzmeister equipment was specifically selected to avoid relocating any machine, which would have slowed down the overall concrete placing process. A BSF 58-Meter and a BSF 36-Meter boom pump from J&R Concrete Pumping of Vineland, NJ along with Rushland's conveyor were utilized. A BSF 38-Meter boom pump was also on stand-by; but due to all the equipment's dependable performance, it was never needed.

Junior Scarpa, president of J&R and veteran of the concrete industry for approximately 50 years, comments, “To accommodate pumping the larger foundation sections that were each sized 150 ft. by 100 ft., the long 188 ft. reach of our 58-Meter concrete boom pump was an absolute 'must'."

He added, "Once you consider the excavation for setup, the furthest point was 180 ft. so the 58-Meter could reach all spots without additional hose. Plus, to save precious time, the boom pump could remain in one spot from start to finish."

Together, a BSF 36-Meter boom pump and a Telebelt® telescopic belt conveyor would assist from the adjacent side.

According to Richard Bischoff, Vice President/General Manager at Weatherby, "We specifically searched for a Telebelt® because we knew it could place concrete faster than a mixer truck can spin its barrel and empty out. The machine's extremely fast placement of concrete helped minimize labor costs and overtime."
Bischoff added, "When you have such a large pour at a three-foot depth, you need to place concrete quickly so crews aren't standing around, especially at the start of a pour. Therefore, for the bulk placement of concrete on this job, the Telebelt® in combination with the other boom pumps was definitely the way to go."

In 2000, Rushland invested in a Telebelt® to complement its concrete pumping business, which was established in 1996. Currently, the company's fleet consists of three booms and two conveyors housed at the company's facility about 90 minutes from the North Beach job.

Rushland co-owner John Santos Jr. says, "We were one of the first to have a Telebelt® conveyor in our area, and the unit has proven its worth time and time again. We had just taken delivery of our second Telebelt® - the new TB 110 model, and it was operated for the first time on this significant pour. Its reliable performance and fast output were exactly what Weatherby needed to place concrete at top speed."

The pour was handled by working left to right with all units placing concrete simultaneously. Once the Telebelt® reached its fully extended radius and placed concrete to the desired height, the unit was washed out and removed from the site so as to not outwork the finishing crew. The BSF 36-Meter finished up next. It was followed by the BSF 58-Meter, which did the bulk of the concrete placement and finished the pour by allowing a "lava flow" effect to take place near the end.

Each of the three pours would normally begin between 5:00 am and 6:00 am in order to take advantage of a greater supply of concrete in the earlier hours and avoid commuter traffic. With completion by noon, each pour beat the summer heat.

From a fleet of over 250 mixer trucks, Ralph Clayton & Sons dispatched over 50 mixer trucks, delivering from four batch plants to meet demand. The closest batch plant was 25 minutes away in Tinton Falls, NJ, which supplied about 70% of the concrete. It was supplemented by three other batch plants up to 40 minutes away.

According to Bill Grace, General Manager of the Ralph Clayton & Sons facility in Tinton Falls,"Large pours done in a short time frame are always strenuous on ready-mix companies, as we must devote a lot of equipment and personnel to keep all the pumps and conveyors constantly filled with concrete."

During each six-hour pour, the first three hours demanded 350 yards an hour and the remaining three hours required an average between 250 to 300 yards an hour. The concrete was a high strength 5,000-psi mix with a mid-range admixture, which helped bring the slump up without the loss of strength. It allowed pumping at a higher slump for faster discharge and made for a less strenuous task on the finishing crew.

On-site quality control personnel from AEL Testing Labs hired by Tishman Construction Corp, the project's construction management company, diligently inspected the concrete. In addition, the ready-mix supplier's QC team checked the mix at its batch plants and on-site. No concrete was rejected during any of the pours.

The completed foundation serves as the basement level parking, and Weatherby Construction must now complete two elevated concrete slabs - the first will be an additional level of parking and the second will support the first residential level.

Because of each building's large footprint, the BSF 58-Meter is needed for its long reach placing capabilities on each of these levels. Most notably, it is required beyond a 120 ft. range from the building's edge where the 150-ton crane and three cubic yard concrete buckets are unable to reach. Once concrete work is finished, the balance of these eight-story structures will be structural steel.

As of early fall 2005, the entire North Beach Asbury Park foundation along with half of the first elevated level is complete on all three buildings. The condos will be a welcome addition to this changing environment, which featured festivals and events every weekend this summer, a newly-rebuilt boardwalk with several new businesses, many brand new roads, as well as flourishing restaurants and stores.

SPECS
Builder/developer: Paramount Homes
Construction manager: Tishman Construction Corp.
Concrete contractor: Weatherby Construction & Renovation Corp. - Ventnor, NJ
Ready-mix supplier: Ralph Clayton & Sons, Inc. - Tinton Falls, NJ
Pumping contractors: Alexander Wagner Co., Inc - Paterson, NJ;
J&R Concrete Pumping - Vineland, NJ; Rushland Concrete Pumping - Rushland, PA
Equipment : Putzmeister BSF 58-Meter, BSF 38-Meter and BSF 36-Meter concrete boom pumps; Putzmeister Telebelt TB 105 and TB 110 telescopic belt conveyors