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Your Kingdom Awaits

Three Putzmeister concrete boom pumps continuously place 5,640 cu. yd. of concrete for a new 40-story hotel tower addition at the Trump Taj Mahal - Atlantic City.

Traffic logistics involved coordinating 600 mixer trucks during the non-stop 14 hour process.

To develop the 50,000 sq. ft. foundation, concrete contractor L. Feriozzi Concrete Company of Ventnor, NJ places the 5,000-psi concrete mix to a nine foot depth.

J&R Concrete Pumping of Vineland, NJ supplies both the high volume concrete boom pumps and experienced operators to ensure a reliable and speedy completion.

The long reach of the Putzmeister BSF 58-Meter was needed for efficient concrete placement at the furthest point of the large octagonal hole.

With the goal of keeping each of the high volume pumps continuously fed at rates up to 200 cu. yd. an hour, three ready mix companies were employed for the pour.

Your Kingdom Awaits

40-Story Hotel Tower Addition to Trump Taj Mahal in Atlantic City on the Fast Track

STURTEVANT, WI (February 1, 2007) – “Your Kingdom Awaits You” is the catchphrase being used to entice visitors to the famous Trump Taj Mahal Casino Resort in Atlantic City. This Trump kingdom is expanding with a new 40-story hotel addition, designed to accommodate more visitors to its Boardwalk destination.

Eager to welcome guests to the new $250 million tower expansion, the Trump empire has implemented a fast track construction schedule. The official groundbreaking occurred in July 2006 and Bovis Lend Lease, the construction manager is tasked with project completion by summer 2008. As a result, the concrete contractor, L. Feriozzi Concrete Company of Ventnor, New Jersey must place 58,000 total cu. yd. of concrete in a very efficient manner to maintain the schedule. The company is employing Putzmeister concrete placing equipment to get the job done right.

Designed by the Friedmutter Group, the primary architect, the new Taj Mahal tower is rising next to the existing 40-story Trump casino and hotel, which Feriozzi helped build 15 years ago. Unlike the previous structure, however, the new tower is requiring new and more advanced construction and concrete placement techniques to ensure speedy completion.

Before the foundation pour
Instead of using traditional pilings, the foundation design is a massive underground floating footing that will support the 450 ft. tall tower. To accomplish this, a large 210 ft. by 210 ft. octagonal hole was excavated to a nine-foot depth, which required dewatering at four feet before continuing downward. Prior to the major concrete foundation pour, approximately 700 tons of rebar were installed along with a four-inch mud mat to support the rebar from sinking.

During the pour
For placement of the foundation, the objective was to continuously pump about 5,500 cu. yd. of concrete to a nine-foot depth to fill the large and atypical hole. This feat had to be accomplished without disruption to casino activities at the resort. Therefore, the crew had to tackle traffic logistics, especially with the nearby motor coach terminal, which accommodates up to 22 full-size buses at any one time. This involved intense coordination to prevent any delay to passenger buses entering the casino or inconvenience to the visitors aboard.

The staging of concrete boom pumps, flow of ready mix trucks and clean out of equipment was precisely scheduled in advance of the mid October 2006 pour date. Police officers were also hired to make certain the plan was effectively implemented in an orderly fashion.

The pour started at four o’clock in the morning with three Putzmeister boom pumps responsible for pumping concrete non-stop until an anticipated late afternoon conclusion. The high performance equipment and qualified operators were supplied by J&R Concrete Pumping of Vineland, New Jersey. Because the pumping company has handled countless complex concrete placement jobs, it was thoroughly prepared to handle the rigorous logistical and performance demands of this particular project.

“Typically, large foundations in this area can be divided into separate pours; however, the design of the rebar needed to create an acceptable joint meant that the most cost-effective way was to do a monolithic pour,” says Junior Scarpa, President of J&R and industry veteran of over 50 years. “We had one unusually huge hole in the ground where we needed to place concrete at a fast, reliable and non-stop pace.”

With access from only one side of the foundation and to avoid dragging hose, a large BSF 58-Meter concrete boom pump was needed for its long 174 ft. horizontal boom reach. This model was situated at the furthest point of the octagonal hole. Two additional pumps were positioned on each side of the 58-Meter to assist. All three units feature high outputs over 200 cu. yd. per hour for fast concrete placement; however, the 58-Meter had the capability to attain even greater volume – up to an amazing 260 cu. yd. an hour.

“The 58-Meter definitely proved to be the workhorse,” says co-owner Joseph L. Feriozzi of Feriozzi Concrete. “We couldn’t feed concrete fast enough into its hopper, even with the pump running wide open.”

With the clearly defined goal of keeping each of the high volume pumps continuously fed, three ready mix companies were deemed necessary. These New Jersey based companies included Ralph Clayton & Sons of Lakewood, Penn Jersey of Pleasantville; and Atlantic County Concrete and Material, also of Pleasantville.

About 600 ready mix truck loads and 14 hours later, concrete placement of the 50,000 sq. ft. foundation was successfully completed without any delays. Although many diligent personnel deserved kudos for a job well done, the hardworking boom pumps played a key role in the success of this project. The 5,640 cu. yd. of concrete required was placed in record time.

“We have a second generation relationship with J&R Concrete Pumping,” says Joseph L., “and we’ve come to rely on their experienced services and their choice of equipment. We’ve dealt with other boom pump brands in the past that presented a lot of problems; however, Putzmeister products have always performed to a higher, more reliable level for us.”

The climb upward
As the building rises, Feriozzi is relying on other Putzmeister equipment from J&R’s fleet. The BSF 36-Meter pumped the first level of columns and shear walls, and the BSF 58-Meter is presently pumping concrete for the shear walls and core slab up to the fourth level. Once this is complete, a BSA 14000 high pressure trailer pump will take over pumping to a new MXR 36/40Z separate placing boom mounted to a tower inside the core of the building. This will rise throughout the construction via a self-climbing system. This combination of equipment will be responsible for placing over 50,000 cu. yd. of concrete.

With its long 115 ft. horizontal reach, the placing boom was specifically selected for its ability to place concrete for all shear walls and slabs from one convenient location. This one-location approach is designed to save time and money by avoiding crane picks of the boom. An aggressive five-day working cycle is anticipated to handle one floor per week. The contractor is confident in meeting this cycle, contingent upon weather conditions.

Although the concrete for the foundation mat pour was a typical 5,000-psi mix, a super plasticized mix of 9,000-psi is required for the first twelve floors. This will be followed by a 7,000-psi mix for the next 14 floors and 5,000-psi for the remaining upper floors.

To pump the various concrete mixes without difficulty, Feriozzi has placed its confidence in the BSA 14000 trailer-mounted concrete pump – a model featuring both the highest pressures and highest outputs in the world. Joey L. notes, “Over the past 18 years, we’ve relied upon the 14000 to efficiently handle our high-rise projects and wouldn’t consider using anything less.”

After the pour
For quicker concrete completion, a process of poured-in-place decks without field formwork called Filigree Wideslabs is being used. Common to the Northeast area, this method involves two interconnected concrete placements – one performed in a factory and one done on the
job site.

First, thin 2-1/4” pre-cast concrete panels with appropriate reinforcement are produced at a nearby factory in New Jersey. These panels, which become the lower portion of the deck, are shipped to the job site for erection on shoring. Then, while supported on columns, the panels are poured-in-place with concrete to achieve the upper portion of the deck.

Overall, the process was designed to accelerate construction of the structure, while enhancing its physical and aesthetic properties. In fact, Feriozzi incorporated a similar Filigree method with the existing Trump Taj Mahal tower, using structural steel frames instead of columns.

Casinos boom, Feriozzi business expands
Casino construction is nothing new to the family-owned Feriozzi business. In the 1940s, Louis Feriozzi ventured from Italy to the Jersey shoreline and built houses where he conveyed concrete via wheelbarrow. When Louis’ son Joseph and daughter Concetta became involved in the business, they advanced it into commercial construction. Five years later, Louis’ sons Michael and Tony joined the family business, helping it grow to the next level. In the 1980s when Atlantic City casinos began to boom, the company naturally capitalized on this opportunity and built a reputable name in this specialty market.

Today, as the previous generation of male Feriozzi owners has passed away, the following generation is making their mark in business. Under the ownership of Concetta as CEO along with her four nephews – Joseph W. and Stephen (sons of the late Joseph Feriozzi) and Joseph L. and Michael (sons of the late Michael Feriozzi), the company has diversified into roadwork in addition to high profile casino, high-rise and other specialty concrete projects.

Feriozzi’s involvement in the latest Trump project will result in 786 rooms added to the existing Taj Mahal, which currently has 1,250 rooms. This expanding guest room inventory is believed to be a critical component, as Atlantic City transforms into a destination for visitors seeking its range of entertainment options.