CONSTRUCTION DIGEST

INSIDE Volume 84 Number 9 • JULY 2009

Construction Digest

Publisher´s Message pg 1

Industry News pg 7

Serving Illinois, Indiana, Kentucky, Eastern Mo. and Ohio

StAtE-OF-tHE-ARt HEALtHCARE FACILIty uNDER CONStRuCtION Association News pg 19

“Approximately 75 percent of the replacement hospital building footprint sits on an area that is very silty and wet and the finished elevation of the basement is 2 feet below the surrounding water table.”

Tony Nugent Project Manager Gilbane Building Company

Case Study pg 24

Special Report Shelby Materials pg 26

by Aram Kalousdian A new state-of-the-art 47-acre integrated healthcare campus in Elmhurst, IL, just west of downtown Chicago, IL, is being constructed for Elmhurst Memorial Healthcare. The project began in March 2008 and it is expected to be completed in May 2011.

The project includes an 815,000-squarefoot replacement hospital, a 25,000-squarefoot addition to the Center for Health in order to accommodate its increasing outpatient volume, a 20,000-square-foot energy center and parking for 2,000 cars. The project also includes two medical office buildings that will each be 90,000 square feet. The medical office buildings are currently in the planning stages. One of the medical office buildings will focus on cardiac care and the other will focus on women’s services and cancer care.

The replacement hospital will include approximately 259 private patient rooms and 15 operating rooms and will serve cardiology, oncology and women’s services centers.

Gilbane Building Company is the construction management company for the project. Gilbane’s headquarters is in Providence, RI. The company has a regional office in Chicago, IL. Hammes Company is the program manager for the project.

There has been an extensive amount of site work on the project. “We have a deep foundation system in place. The replacement hospital is sitting on piles. We have less than ideal soil conditions on this project,” Tony Nugent, project executive for Gilbane Building Company said.

“Approximately 75 percent of the replacement hospital building footprint sits on an area that is very silty and wet and the finished elevation of the basement is 2 feet below the surrounding water table.

“Before excavating for the basement, we installed sheeting that provides water retention and is a cut-off wall. That was driven around approximately 75 percent of the building footprint. The basement is approximately 170,000 square feet.

“Once the cut-off wall was in place, we drilled approximately 1,400 auger cast piles into the ground.

Those are clustered three to five per column and capped with a large concrete cap.

Continued pg 5 »

A Clear Vision For The

Future

Construction Digest is back and with it, is our renewed commitment to the industry. The magazine you are reading dramatically emphasizes the fact that we have modernized the size and graphics to make your reading experience more beneficial. The essence of Construction Digest is, as always, the people, projects and events that make our industry interesting and successful.

Continued pg 3 »

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July 2009

Page 3 Construction Digest

Associated Construction Publications, LLC www.acppubs.com Administrative Office 1200 Madison Avenue, Suite LL20 Indianapolis, IN 46225 (317) 423-7080 • Fax (317) 423-7094

A Clear Vision

Publisher John White

For The Future

Your new associate publisher is Peter Leviton and Jim Reid. Jim and Peter are responsible for making sure that we are delivering a quality product with information that will help you operate more profitably, especially in these challenging times.

More importantly, as a representative Construction Digest, Jim and Peter will be a resource to cover your events, large and small – to take the pictures – to tell your stories – to help celebrate your successes.

Construction Digest is one of 13 magazines that make up the Associated Construction Publications (ACP).

As a former owner of several of the ACP magazines, I seized the opportunity to become publisher of the entire group because I believe the industry needs a positive voice with the right focus. I was fortunate to learn this business from a couple of the best.

Two people in particular helped me understand ACP’s winning formula. Fred Johnston, publisher of Construction Digest, taught me that if you take care of your customer and your customer’s customer you will be successful. Fred served the industry with passion and energy for more than 50 years. We will operate with that simple but effective focus. We are trying to get Fred to come out of retirement. I will keep you posted.

John Weatherhead, who ran the ACP association when separate, independent-minded publishers owned the magazines, taught me that it takes a delicate balance to present the strength and uniqueness of each individual magazine as a unified group. We learned how valuable John was when he left ACP for a few years in the mid 90’s.

ACP struggled in his absence. When he came back, he was able to work his magic and put us back on track. Even though John has retired from ACP, he is still active in the industry and the industry is better for it. Applying what I have learned from John, we will maintain that delicate balance that delivers the local strength and uniqueness in a unified group.

For more than 100 years, the ACP magazines have served our local construction markets, celebrating the successes that have produced a more productive, healthier and safer built environment for our country. Our focus will be on the rebuilding of our highways and bridges, the development of new infrastructure that will serve our communities with clean energy, clean water, and the expansion of alternative transportation initiatives such as light and high-speed rail. As we strive to improve our environment, the contractors who make it happen will be the subjects of the many interesting stories that we will tell.

We are very optimistic about the future of our industry and the opportunity to serve you. Be sure to send us your news and stories so we can showcase your accomplishments. This industry is about you, what and how you do the things that result in better highways, safer bridges and a greener environment.

We want to especially thank our advertisers who make this all possible. Please support them. It is in your best interest. They can make you more competitive and more profitable, and in this challenging economy that is very important.

Associate Publisher Jim Reid

Associate Publisher Peter Leviton

Site-K Construction Zone In the future this page is reserved for the Site-K Construction Zone Greg Sitek, an award-winning editor with more than 40 years of service to our industry. He will provide insight and commentary on national events and issues that impact our businesses. You won’t want to miss a single word.

Publisher:

John White jwhite@acppubs.com

Operations:

Jill Paskoff jpaskoff@acppubs.com

Production:

Peggy Cunningham pcunningham@acppubs.com

Editorial:

Greg Sitek – VP Editorial gsitek@acppubs.com

Sales:

Mary Anne Nichol – VP Sales manichol@acppubs.com Cyndi & Kenny Veach – National Account Managers cveach@acppubs.com

Construction Digest Associate Publishers: Peter Leviton – IL & MO pleviton@acppubs.com (847) 693-8285 Jim Reid – IN, KY & OH jreid@acppubs.com (317) 403-0798 Editorial:

Aram Kalousdian

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Greg Sitek

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Elmhurst Memorial Hospital Architects: Albert Kahn Assoc. of Detroit, Pratt Design Studio, Chicago Program Manager: Hammes Co., Brookfield, WI Civil Engineer: V3, Chicago MEP Engineer: Korda/Nemeth, Columbus, OH GC: Gilbane, Chicago, IL

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July 2009

That was the base for the steel columns. So, the foundation wall surrounding the basement and the footings for the interior columns are all sitting on piles.

The piles go down anywhere from 30 feet to 55 feet below grade. The majority of the existing site was raised from 3 feet to 6 feet in order to accommodate the first floor elevation of the hospital as well as the parking lots. Once we got past the pile caps, it’s pretty much a traditional building structure from there up.”

The site work includes two retaining ponds on the south side of the site. The storm water from the hospital campus as well as some of the surrounding neighborhood streets drains through the site through a new network of storm sewers, which drain into the ponds. The storm water system was constructed in 2008.

The buildings are being constructed with steel and the exteriors include a combination of cold form framing with a brick veneer.

“Constructing a new campus provides us with the opportunity to build a state-of-the-art hospital that meets the needs of our patients, visitors, staff and physicians,” Leo Fronza, president of Elmhurst Memorial Hospital said. “Our vision for a new facility is about improved performance and teamwork – how we positively impact patient safety, patient satisfaction and clinical outcomes.”

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The hospital’s design will focus on the patient’s experience. To promote healing of the mind, body and spirit, the hospital will include extensive landscaping and be surrounded by green spaces, ponds and healing gardens to create a building in a garden concept.

The interior design will use natural light and other features to create a “non-institutional” feel. All patient rooms will include hotel-like amenities, such as room service on request and comfortable places for families to visit and stay with loved ones. In order to promote safety, the patient rooms will be laid out exactly the same instead of having mirrored rooms with left-hand and right-hand orientations.

Beds, supplies and equipment will be located in the same place from one room to another.

“The new Elmhurst Memorial Hospital is evidence that it is possible to create a truly positive experience for everyone who will walk through our doors,” Robert Soukup, chairman of the Elmhurst Memorial Healthcare Board of Trustees said at the project’s groundbreaking ceremony in May 2008.

It will be a hospital where modern technology joins with compassion to treat the whole person, not just an illness. It will be a hospital flexible enough to adapt and grow to meet the ever-changing needs of our communities.”

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Subcontractors on the project include Archon Construction Company, of Addison, IL (site utilities); Dupage Topsoil, Inc., of West Chicago, IL (excavation); Hayward Baker, Inc., of Roselle, IL (earth retention); Case Foundation Company, of Roselle, IL ( Auger cast piles); Abbey Paving Company, of Aurora, IL (asphalt paving); R. Olson Construction Company, of Bloomingdale, IL (concrete); J&E Duff, of West Chicago, IL (masonry); LeJeune Steel Company, of Minneapolis, MN (steel fabrication); Chicago Steel Construction, of Merrillville, IN (steel erection) and Bennett & Brosseau Roofing, of Romeoville, IL (roofing).

Other subcontractors on the project include Thorne Associates, Inc., of Chicago, IL (drywall and acoustical ceilings); Alliance Glass & Metal, of Romeoville, IL (curtain wall and windows); RG Construction Services, Inc., of Elmhurst, IL (exterior studs and sheathing); Otis Elevator Company, of Lombard, IL; VMI Mechanical Systems, of Arlington Heights, IL (heating, ventilating and air conditioning sheet metal); Advance Mechanical Systems, Inc., of Mount Prospect, IL (mechanical piping); United States Fire protection, of Lake Forest, IL; ITG Solutions, Inc., of Homewood, IL (temperature controls) and Meade Electric Company, of McCook, IL. The mechanical, electrical and plumbing engineering firm is Korda/Nemeth, of Columbus, OH and

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ConstructionDigest Digest Construction

the civil engineering firm is V3, of Chicago, IL. The architects are Albert Kahn Associates, of Detroit, MI and Pratt Design Studios, of Chicago, IL. Material quantities include 12,000 linear feet of mostly concrete storm sewer pipe; 3,500 linear feet of polyvinyl chloride (PVC) sanitary sewer pipe; 3,500 linear feet of ductile water main; 330,000 cubic yards of mass excavation; 55,000 cubic yards of granular fill; 33,700 square feet of sheeting; 1,200 piles totaling 60,000 linear feet with 143 tons of rebar and 3,000 cubic yards of concrete; 19,690 cubic yards of stone; an additional 28,000 cubic yards of concrete with 800 tons of rebar; 1,200,000 bricks; 7,500 tons of steel and an additional 7,500 tons of steel with 870,000 square feet of decking.

Additional material quantities include 160,000 square feet of single ply roofing; 32,000 square feet of garden roof assembly; 69,000 square feet of shingle roofing; 3,200,000 square feet of drywall; 630,000 square feet of acoustical ceiling; 41,000 square feet of curtain wall; 18,000 square feet of windows; 250,000 square feet of exterior wall; 15 elevators; 1,500,000 pounds of ductwork; 85,000 linear feet of heating, cooling and medical gas piping; 8,600 sprinkler heads; 1,300 variable air volume box controllers; 1,400 automatic valves; 1,500,000 linear feet of conduit; 2,200,000 linear feet of wire; 16,000 light fixtures and 84,000 electrical devices.

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INDUSTRY NEWS

Construction Digest Page 7

WHAyNE SuPPLy HOStS OPEN HOuSES tHREE NEW FACILItIES IN HOPKINSVILLE, INDUSTRY ELIZABEtHtOWNNEWS AND BOWLING GREEN

Elizabethtown - Lunch was served in the shop area. The bucket of a CAT 299C held the drinks.

Whayne employees and local dignitaries cut the ribbon in front of the Hopkinsville office. Whayne President Monty Boyd, with scissors prepared to cut the ribbon. Dan Kemp, Mayor of Hopkinsville is to the right of Boyd.

Elizabethtown - There were machine simulators at the open house for customers to try their skills.

The No.31 CAT car was a big hit at all the open houses. Here it is seen in the Bowling Green truck shop.

Bowling Green - Russell Upchurch, Whayne Undercarriage Specialist, talked with a guest at the ground engaging tool display.

Hopkinsville - The front entrance was set-up to make it easy for guests to find the open house.

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Customers, Whayne representatives and factory representatives talk in front of the Challenger tractor display in Hopkinsville.

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INDUSTRY NEWS

E&B PAVING ELECtS CHAMBER CHAIRMAN ANDERSON, Ind. – Mike Latchaw, an area manager for E&B Paving, Inc., was elected as the 2009 Chairman of the Board of Directors for the Chamber of Commerce for Anderson and Madison County.

Working from E&B’s Anderson office, Latchaw has been employed by E&B Paving for 21 years and has supported Anderson-area business development initiatives throughout his tenure.

“Mike’s involvement with the Chamber of Commerce reflects his commitment to promoting growth in Anderson and the Greater Madison County community,” says Gary Stebbins, E&B Paving’s president. “E&B Paving is a long-time Chamber member and we appreciate Mike’s efforts in supporting its programs and members.”

FINKBINER tuRNS 40 BURR RIDGE, Ill - Finkbiner is taking time this year to thank its customers for their business as they celebrate their 40th anniversary of business. Finkbiner has been representing Gomaco, Gradall, Liebherr, Mauldin, Universal Engineering for most of those 40 years if not all and has recently added Terex (milling machines, road stabalizers and concrete plants), Cedarapids Pavers and Sakai Rollers.

Construction Digest

MAJOR ENGINEERING AND LAND SuRVEyING WELCOMES FELtZ AND EARLEyWINE INDIANAPOLIS - Michael J. Feltz, P.E joined Major Engineering as Director of Engineering. He brings nearly 23 years of experience as a planner, designer, construction engineer, and project manager. His career includes six years with the Missouri Department of Transportation and eleven years serving Indiana clients on projects that have included roadway and highway improvements, traffic control analyses, traffic signal designs, bridge designs, and multi-use path studies and designs. Feltz also has considerable non-transportation experience including: stormwater management & collection systems and sanitary sewer systems. He is currently licensed as a Professional Engineer in Indiana, Illinois, and Missouri.

Michael J. Feltz

Jayson R. Earleywine, P.E also joined Maps Engineering as a Project Engineer. He has nearly sixteen years of engineering experience, of which the last eight have been in Indiana. Earleywine has served as the lead designer on many roadway improvement, intersection improvement, and multi-use path projects that were administered by the Indiana Department of Transportation, and he has experience with site development projects. Earleywine is licensed as a Professional Engineer in Indiana.

With these hires, Major Engineering and Land Surveying will now offer design and construction engineering services for roadway, highway, multi-use path, and other transportation-related projects. In addition, these engineers will be capable of assisting our clients with drainage, utility relocation, Jayson R. Earleywine and site development needs.

CHuRuBuSCO, IND. BREAKS GROuND FOR $3 MILLION WAtER IMPROVEMENtS PROJECt E&B PAVING RECEIVES 15 INDuStRy AWARDS FOR RECENt PROJECtS ANDERSON, Ind. – E&B Paving, Inc., received 15 awards during the first quarter of 2009 for its work on transportation construction projects throughout Indiana.

At its annual World of Asphalt Conference, the National Asphalt Paving Association honored E&B with 11 awards for its work on: > State Road 13, State Road 37 and 146th Street (all projects managed from E&B’s Noblesville, Ind. office) > U.S. 36, State Road 67 and U.S. 32 (Muncie, Ind. office) > U.S. 35 at State Road 32 and U.S. 31(Kokomo, Ind. office) > U.S. 231, U.S. 35 and U.S. 31 (Rochester, Ind. office) A team led by E&B received the Indiana Department of Transportation’s 2009 Indiana Partnership for Transportation Quality Achievement Award in the Major New Reconstruction-Urban category for its work on State Road 66 (Diamond Avenue) in Evansville. The Indiana Chapter of the American Concrete Pavement Association (ACPA) also recognized this project with an “Excellence in Concrete Paving Award” in the State Roads category.

E&B’s Concrete Division, based in the firm’s Rochester office, was further honored with two additional ACPA “Excellence in Concrete Pavement Awards” for its work on: > I-65 interchange at I-80/94 in Gary (Divided Highways-Urban category) > Delphi Municipal Airport Runway rehabilitation (Overlays category) “We are proud to accept these awards on behalf of our entire workforce which is dedicated to delivering world-class transportation construction solutions to public and private sector customers throughout Indiana,” says E&B President Gary Stebbins. “These awards add to the impressive collection of honors our firm has received during the past 42 years and we are grateful for this recognition from our industry’s association leadership.”

CHURUBUSCO, Ind. – The Town of Churubusco recently broke ground for their water treatment plant. A groundbreaking ceremony celebrating the beginning of this project was held outside the Churubusco Town Hall.

The Town of Churubusco is currently utilizing well water with disinfection. “This is a project that has been in the works since 2001,” stated Frank Kessler, town council president. “This treatment plant will greatly improve the water quality for Churubusco residents.”

The water improvements project will be funded through a $500,000 Indiana Office of Community and Rural Affairs Community Focus Fund grant, $1,290,000 State Revolving Fund (SRF) loan and $1,290,000 SRF bond anticipation note (stimulus funds). The new water treatment plant will include a new building with multi-cell rapid gravity filters, vertical turbine high service pumps, below grade clearwell and a mixed oxidant disinfection system.

The elevated water tank rehabilitation project will involve structural and coating rehabilitation of the 400,000 gallon potable water elevated storage tank located off Weston Avenue located on the north side of Churubusco.

“Due to the timing, the Town has been able to utilize stimulus funds toward this project making it very advantageous for Churubusco to complete this much needed project,” said Mark Jesse, vice president and project manager from Bonar Group. “It is a great day for the Town of Churubusco and a proud day for Bonar Group.” Jesse commemorated the beginning of the project by providing town officials with a plaque at the groundbreaking celebration.

(l-r) Vivian Sade, council member; Dave Gerig, Gerig-Ottenweller Contracting LLC – general contractor for water plant; Frank Kessler, council president; Geri Johnson, clerk -treasurer; Mark Jesse, vice president/project manager, Bonar Group.

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ROLAND At KAtC Technicians take first place in more than half of categories at INDUSTRY NEWS annual competition SPRINGFIELD, Ill - Roland Machinery technicians took top honors in five categories at this year’s Komatsu Advanced Technician Competition (KATC), including the title in the team competition, where a group of technicians had to troubleshoot and fix a BR580JG crusher. Teams were not told ahead of time what machine would be in the team competition.

“Teams go into that competition blind,” explained Roland Training Manager Mike Bond. “It’s also not as common a machine as a wheel loader, dozer or excavator, so there really was no way to prepare for it.

Our guys did an outstanding job of diagnosing the problems and finding a solution to fix them. We’re very proud of their efforts.”

Along with Bond, the Roland team included Training Manager Mark Members of the Roland team who attended the KATC were Sperber and Technicians Perry Zach (L-R) Adam DePeau, Perry Zach, Chad Williams, Dan and Adam DePeau, who were among a Dillie, Andy Wilkerson, Trainer Mike Bond and Trainer group of seven that represented Roland Mark Sperber. at KATC. The competition is designed by Komatsu to test technicians’ ability to listen to customers, diagnose preset problems using their knowledge and source materials and find a solution to fix them. Roland technicians who competed had to first win an in-house competition.

Zach repeated his success from last year, taking two individual first-place titles. This year, he won the D155AX-6 crawler dozer and WA500-6 wheel loader competitions. Last year, he placed first in the excavator and wheel loader categories. DePeau took the top spot in the HM400-2 articulated truck and D39PX-22 crawler dozer categories. Each first-place finish netted the winners a trophy and a cash prize.

Dan Dillie placed second in the CK35 skid steer category, rounding out Roland’s top-two finishes.

Second-place award winners also won a cash prize.

“The purpose of the KATC is to improve technicians’ troubleshooting skills, which in turn benefits the customer in decreased downtime,” said Bond. “We place a great emphasis on our technicians’ training, and it shows in competitions such as the KATC. But more importantly, it equates to less time to troubleshoot, diagnose and fix customers’ machines so they can get back to using them for production. KATC just confirms that we’re doing the right thing.”

The team competition, which Roland technicians won, focused on a “mystery machine,” which turned out to be a BR580JG crusher. Teams of distributor technicians competed to find the problems associated with it.

Roland Technician Perry Zach (above center) receives one of his two first-place awards from Komatsu’s John McFarland (left) and Mike Tajima. Zach took first in the D155AX-6 crawler dozer and the WA500-6 wheel loader categories.

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Komatsu’s John McFarland (left) and Mike Tajima (right) present the top award to (L-R)Adam DePeau, Perry Zach and Mark Sperber for winning the team competition.

Adam DePeau (below center and above in cab) won the D39PX-22 crawler dozer and HM400-2 articulated truck competitions.

Contestants were judged on their ability to use resources such as manuals and computers as they diagnosed and fixed a problem with a particular machine. Komatsu personnel acted as “customers” whose machines weren’t running properly. They also served as judges.

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MILEStONE CONtRACtORS L.P. HOSt COLuMBuS OPEN HOuSE COLUMBUS, Ind. – Milestone Contractors L.P. hosted an open house at their Columbus area asphalt plant for Columbus Chamber of Commerce and clients. Guests toured the asphalt plant, its control room and Milestone’s Quality Control Laboratories. Ted Lucas, Milestone president, Buck Ritz, Milestone marketing manager and other Milestone personnel welcomed guest and visitors.

Also on display was a newly constructed slab of porous asphalt pavement. This type of pavement offers developers and planners a new tool for managing storm water. Porous pavements, used mostly for parking lots, allow water to drain through the pavement surface into a stone recharge bed and infiltrate into the soils below the pavement. Such asphalt pavements have been proving their worth since the mid-1970s, and recent changes in storm water regulations have prompted renewed interest in them.

Buck Ritz (left), marketing manager, Milestone exchanges business cards with visitor.

Corey Carr (left), executive director, Columbus Economic Development Board and Ted Lucas, president, Milestone Contractors

Kevin Conwell (safety vest), senior estimator, Columbus office, explains asphalt plant operation from the control room.

E&B PAVING PROMOtES JASON RICHMOND tO BuSINESS DEVELOPMENt POSItION ANDERSON, Ind. – E&B Paving, Inc., announced Jason Richmond, 32, has been promoted to Corporate Business Development Manager, a new position at the company. He will be responsible for identifying, securing and managing business development opportunities in E&B markets throughout the Midwest.

Richmond joined E&B’s Anderson office in 1995 as a laborer on a grading crew and transferred to the firm’s Noblesville, Ind. office in 1998 to work as a Teamster/laborer on an asphalt paving crew. In 2004, E&B appointed him to an Estimator/Project Manager position in the Noblesville office. He earned a bachelor’s degree in organizational leadership and master of business administration degree from Anderson University.

“Jason’s proven performance in growing our firm’s customer base, supporting our marketing and branding initiatives, and understanding the transportation construction needs of public and private sector customers will serve E&B well as we expand our world-class solutions to communities and businesses throughout the Midwest,” says Corporate Sales Manager Chuck Bracken.

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July Page 2009

LOGANSPORt WINS AWARD FOR NEWS LPA INDUSTRY PROJECt

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OHIO RIVER BRIDGES PROJECt INDIANAPOLIS – Indiana Gov. Mitch Daniels’ state budget plan approved by the Indiana General Assembly includes legislation authored by State Rep. Steven Stemler, D-Jeffersonville, establishing a commission to negotiate with Kentucky for a plan to put the Ohio River Bridges Project on a fast track.

Stemler said the creation of Ohio River Bridges Commission in Indiana means both states have adopted the same approach for the Bridges Project and can move quickly. “This puts the project on a fast track for progress and we can all look forward now to building the bridges and creating thousands of jobs,” he said.

The Indiana legislation follows a law adopted last week in Kentucky providing for a bistate authority to fund and build the project, one of the nation’s major transportation improvements. The $4 billion project includes two new bridges linking Louisville and Clark County, Ind. and the rebuild of an interchange where I-65, I-64 and I-71 converge on the Kentucky side.

The bi-state authority to be created could issue bonds that do not count against either state’s debt capacity and tap new revenue sources to supplement available state and federal funds. The project was authorized in 2003, but has stalled because of a lack of a long-term funding plan in Kentucky. Kentucky’s share of project costs is $3 billion and Indiana’s is $1.1 billion.

The project will create more than 56,000 jobs with a $2 billion payroll during construction and thousands of additional jobs after completion. Congestion relief, safer bridges and connecting highways, cross-river lanes for biking and walking and 40-45 more acres adjacent to Louisville’s Waterfront Park are other benefits.

LOGANSPORT, Ind. – The $6.7 million federally funded Broadway Improvements (Old U.S. 24) project in Logansport was recently recognized with a 2009 Indiana Partnership for Transportation Quality Award as a result of its quality process, teamwork and innovative measures provided throughout the duration of the project.

“The City was pleased to be recognized for this important project,” stated Michael Fincher, mayor of Logansport. “I am proud of the outstanding efforts and teamwork of our city staff, Logansport street department, Logansport municipal utilities, INDOT, Bonar Group and Deichman Excavating to make this a successful project for the citizens of Logansport.”

The Broadway improvement project consisted of rehabilitating Broadway (Old U.S. 24) from 6th Street to 24th Street. The project was the third phase of improvements as a result of the relinquishment of U.S. 24 through the City of Logansport. The project included the rehabilitation and resurfacing of the existing pavement through milling and resurfacing with some spot reconstruction.

Three stormwater outfalls constructed on a previous project (Market Street Phase I Project from 12th Street to 24th Street) tie into the proposed Broadway storm sewers and provide storm drainage relief for this project. In addition, the project separates an existing combined sanitary-storm sewer system to create dedicated storm and sanitary sewer systems. Other improvements include a street lighting upgrade along Broadway, new concrete driveway approaches to replace existing driveway approaches, new curb and gutter, sidewalks, curb ramps, traffic signs, striping and pavement markings.

From the beginning of the Broadway project it was apparent that the project would require extensive teamwork. The city, Logansport street department, Logansport municipal utilities, mayor’s office, engineer, contractor and INDOT all worked together throughout the project. During construction, the teamwork was evidenced by the early completion, minimal complaints and productivity of businesses along the affected construction area. All meetings were open and published so that the public could attend if they so desired.

The Broadway project utilized the proper planning, coordination, communication and execution to maximize effort and dollars while minimizing the effects and any unnecessary overruns. Many creative ideas were implemented to keep businesses working and accessible while construction was ongoing. Quick action on problems and unforeseen circumstances allowed for work to continue while resolutions and changes were made. Combining phases and finishing this project in one year instead of the allotted two years, cut costs on mobilization, business, time management by Logansport and Bonar Group personnel, and allowed for businesses to be affected for limited time while getting a quality product.

Michael Fincher

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RuDD EQuIPMENt FOuNDER PASSES AWAy

Editorial cartoon courtesy of © The Courier-Journal

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LOUISVILLE, Ky. – Mason C. Rudd, 90, founder of Rudd Equipment Company, died on Sunday, July 5, 2009. A native of St. Paul, Minn., Rudd graduated from the University of Minnesota in 1939 with a degree in geolog y and petroleum engineering and was a World War II Army veteran.

He founded Rudd Equipment Company, a construction and mining equipment distributor, in 1952 in Louisville, Ky. His son, Michael D. Rudd, who survives him, joined the company in 1975 and acquired the business in 1992. The company now includes 10 full service branch locations covering six states, including Kentucky, Indiana, West Virginia, Western Pennsylvania, Southern Illinois and Eastern Missouri.

Rudd gave significant time and money to benefit health care and health care education in Louisville and was chairman of the old Jefferson County Board of Health for 33 years. The 14-story Rudd Heart and Lung Center at Jewish Hospital bears his name. He held leadership positions at both Jewish Hospital and the old General hospital, in addition to being president of the old Louisville Medical Center.

Rudd’s philanthropy also included education and he was instrumental in improving the Louisville library's book endowment and laying solid groundwork for the children's summer reading program.

He was a benefactor to the University of Louisville and his contributions ranged from the creation of a neurolog y professorship with a gift of $1.4 million, to helping build the $3.6 million Bass-Rudd Tennis Center on campus.

The Rudd Program for Young Artists at Kentucky Opera trains young singers with a grant from Rudd, who was also a longtime patron of the Louisville Ballet.

"There is not a common denominator except a desire to see things (get) better," Rudd said of his philanthropy in 1995 when his name was put on the new $40 million Rudd Heart and Lung Center at Jewish Hospital. "I do want to see a better world."

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MARtIN LutHER KING BRIDGE SAFEty INDUSTRY NEWS IMPROVEMENt PLAN ANNOuNCED

INDUSTRY NEWS

Page 13 Construction Digest

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COLLINSVILLE, Ill. - The Illinois Department of Transportation’s District 8 and Bureau of Safety along with the Illinois State Police, Missouri Department of Transportation and city of St. Louis announced plans today to address crossover crashes on the Martin Luther King (MLK) Bridge. The plan is part of an ongoing effort to reduce crossover crashes.

“IDOT strives to construct and maintain the safest roadways for all of Illinois. Everything we do is aimed at getting people to their destination safely,” IDOT secretary Gary Hannig said. “As a result of these efforts, we will be making improvements to the Martin Luther King Bridge to reduce the number of crossover crashes.” As part of an ongoing department effort, IDOT has evaluated the results of the Road Safety Assessment for ways to mitigate lane departure crashes on the MLK and the resulting impacts to motorist safety, prevailing traffic patterns, and the bridge truss. Based upon these reports, a concrete barrier will be installed from the west end of the railroad structure in Illinois, across the MLK and terminate in St. Louis on the raised traffic island near Lumiere Casino. The barrier’s width and weight will require the MLK be reconfigured to a three-lane structure with one westbound and two eastbound lanes. The conclusion to eliminate one westbound lane was reached based on the recommendation of the study, project constructability and resulting traffic capacity and motorist safety throughout the area’s roadways.

To complete the project, ultra-high reflective pavement markings will also be grooved into the travel surfaces in the area. “With these modifications, morning commuters on the MLK Bridge and the PSB could expect to experience an additional one to three minute delay on a typical commute,” said regional engineer Mary Lamie. “Since two lanes remain for east bound travel, no impacts are expected for the evening commute.” Since January 2009, the Illinois State Police has effectively enhanced patrols in this area modifying the driving habits and addressing other criminal activities that use the bridge for moving between Illinois and Missouri. After installation of the concrete barrier, IDOT will continue to monitor this location to determine if these modifications are effective. If additional measures need to be taken, IDOT will address the possible solutions at that time with the other stakeholders, Missouri Department of Transportation and the city of St. Louis.

This work is tentatively scheduled for a July 2009 letting and is expected to be completed this calendar year. To safely make these improvements, the bridge will be completely closed to traffic when the project gets underway. The closure will be scheduled for 12 days and may be split into two separate phases.

The dates of the closure will be coordinated with the contractor after the award of the contract. The estimated total cost of this project is $2.5 million and will utilize state and federal dollars.

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QuINN ADMINIStRAtION ANNOuNCES PLAN ODOt: WORK BEGINS ON OHIO’S FIRSt tO MAKE CHICAGO tO St. LOuIS HIGH-SPEED StIMuLuS-FuNDED PROJECt RAIL tRAVEL A REALIty update on Ohio’s transportation Stimulus Investments ST. LOUIS, Mo. - Officials from Governor Pat Quinn’s administration were joined by Senator Richard Durbin and rail executives today to announce an agreement between the Illinois Department of Transportation (IDOT) and Union Pacific Railroad (UP) to develop the plan for high-speed passenger rail between Chicago and St. Louis. The Memorandum of Understanding (MOU) is the first of its kind in the country.

"This is a major step forward in reducing the travel time on the fastest growing train route in the state.

The Chicago to St. Louis route would go from taking more than five and a half hours to four hours or less," said Governor Quinn. “I am committed to taking full advantage of federal recovery funds to make high speed rail in Illinois a reality.”

U.S. Senator Durbin and other transit agencies are working with IDOT to win the federal dollars needed to make high-speed rail in Illinois a reality, with the Chicago to St. Louis line as the state’s premier route and top priority. Under the MOU, Union Pacific and IDOT will develop a Chicago to St. Louis rail infrastructure and safety plan to outline how passenger trains will operate safely at 110 mph and UP’s freight trains will operate safely and efficiently.

“This plan will assess and provide estimates to increase track capacity and required safety enhancements,” said IDOT secretary Gary Hannig.

“It will also get travelers to their destinations safely and faster than driving.” The American Recovery and Reinvestment Act included the largest investment in high-speed passenger rail in history, totaling $8 billion. This is the largest investment that the federal government has invested into passenger rail over the last decade – an almost 6,000 percent increase in funding for passenger rail. The four state Amtrak routes in Illinois’ system have experienced some of the fastest growing ridership increases of all the state-subsidized routes in the nation. The Chicago-St. Louis route, also known as “The Lincoln,” stands out as the leading passenger rail corridor in Illinois – achieving a record breaking 57percent increase in ridership in 20072008, the year the state doubled its investment and increased the frequency of trains along the line.

The American Association of Railroads estimate that every dollar spent on investments in our nation’s railroads—tracks, equipment, locomotives, bridges—yields $3 in economic output. In addition, each $1 billion of rail investment creates 20,000 jobs.

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CLEVELAND, Ohio - Work is underway on Ohio’s first transportation project funded by the American Recovery and Reinvestment Act. The Ohio Department of Transportation (ODOT) marked the start of the project near downtown Cleveland - a $1.8 million investment of stimulus funds to widen the ramp from Interstate 490 eastbound to Interstate 77 northbound.

“Today we are making history,” said ODOT director Jolene M. Molitoris, who was joined by local leaders and Congressional officials to launch work on the project. “This is an important job for Clevelanders who have come to rely on this link into downtown Cleveland, especially during recent restrictions on the I-90 Innerbelt Bridge. This is also important for the laborers who have a reliable job because of this investment of stimulus funds.” Motorists will also notice new signs at this construction site, announcing “Putting America to Work: Project Funded by the American Recovery and Reinvestment Act.” Similar orange-and-green signs will be erected when work begins at stimulus-funded projects across Ohio.

Over the next several months, crews will widen the I-490 ramp, improving the substandard shoulder widths and allowing for an additional lane of traffic to travel into downtown Cleveland, but only during restrictions or closures of the Innerbelt bridge. The I-77/I- 490 interchange continues to see an increase in daily traffic, as an alternative route during restrictions on the aging Innerbelt Bridge. In 2008, ODOT engineers restricted traffic on the 50-year-old Innerbelt Bridge and rerouted heavy truck traffic after inspections revealed that a number of steel members were aging faster than expected. This past March, ODOT announced it would build a new $400 million, five-lane, westbound I-90 Innerbelt Bridge with an investment of stimulus dollars.

ADVANCING MORE StIMuLuS-FuNDED PROJECtS CLEVELAND, Ohio - ODOT and the Federal Highway Administration (FHWA) continue to advance additional infrastructure projects closer to the construction phase. To date, FHWA has authorized more than $166.9 million in stimulus investments, including strategic projects at Ohio’s water ports and along its railroads. An additional $182.9 million in projects has been submitted for authorization by FHWA in the next three weeks. Under ARRA requirements, ODOT must have authorized approximately $327.5 million of its $774 million stimulus allocation by the end of June. The remaining amount must be authorized by March 1, 2010. States that meet these timeline requirements can compete for additional money lost by other states that fail to meet these deadlines.

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NEW MODOt DIVISION tO HELP MINORItIES GAIN CONStRuCtION JOBS JEFFERSON CITY, Mo - The Missouri Department of Transportation has created a new division to enhance efforts to involve minorityowned, women-owned and disadvantaged businesses in state construction projects. The new division - External Civil Rights - oversees the department's affirmative action, equal opportunity and nondiscrimination programs, which were previously housed within another MoDOT division. The move will expand these important outreach and partnership programs.

"Creating this new division allows us to place an even greater emphasis on increasing the number of minority, female, and economically disadvantaged individuals working on state transportation projects," said Lester Woods, Jr., the division's director. "This will help us deliver better results when it comes to ensuring a diverse work force on our projects."

One of the division's goals is to build on the progress made in developing pre-apprentice and on-the-job training programs for socially and economically disadvantaged individuals on two of MoDOT's largest projects: the I-64 reconstruction in St. Louis and the reconstruction of almost five miles of Interstate 29/35 and construction of a new Missouri River bridge near downtown Kansas City, Mo. These programs are helping individuals acquire trades that will provide long-term career opportunities.

Over the last two years, more than 70 on-the-job trainees have worked on I-64 and five of them have achieved journeyman status, with many more eligible by next year. At 19 percent, the total work force diversity on the I-64 project is exceeding the federal minority goal of 14.7 percent.

In its thirteenth month of construction, Kansas City's kcICON project is on the path to achieving its overall project diversity goal of 12.7 percent. There are 42 on-the-job trainees working now - three in professional services and 39 in construction. More trainees will be added as construction continues to ramp up for the summer.

"We have committed up to $1.25 million to developing a work force that better reflects the diverse makeup of our community," said kcICON Project Director Brian Kidwell. "We want all of our on-the-job trainees to be successful on this project and acquire the training and skills necessary to sustain long-term careers in heavy highway construction."

A sister division, MoDOT's Equal Opportunity and Diversity Division, works to recruit and retain women and minorities as part of the agency's workforce. David Williams was recently named the acting director of that division.

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WESt VIRGINIA FACES $5 BILLION tRANSPORtAtION FuNDING SHORtFALL OVER NEXt tEN yEARS; SIGNIFICANt BOOSt IN FEDERAL AND StAtE FuNDING NEEDED tO MAKE ROAD AND BRIDGE REPAIRS, IMPROVE tRAFFIC SAFEty AND PROVIDE CONGEStION RELIEF CHARLESTON, W. Va. - More than one-third of West Virginia’s roads are in poor or mediocre condition, 37 percent of the state’s bridges are deficient, and its traffic fatality rate is the third highest in the nation.

And according to a new report entitled “Future Mobility in West Virginia: Meeting the State’s Need for Safe and Efficient Mobility,” the state faces a transportation funding shortfall of $5 billion over the next ten years. Unless West Virginia can address this funding gap, many sorely needed transportation projects will remain unfunded.

According to TRIP, a Washington, DC, based nonprofit organization that researches, evaluates and distributes information on highway transportation issues, eight percent of West Virginia’s roads are in poor condition and an additional 29 percent are in mediocre condition. Driving on roads in need of repair costs each West Virginia motorist an average of $280 annually - $371 million state-wide – in the form of accelerated vehicle depreciation, additional repair costs, and increased fuel consumption and tire wear. The report contains a list of needed roadway repair and reconstruction projects throughout the state that currently lack adequate funding to proceed.

Fifteen percent of the state’s bridges (20 feet or longer) are structurally deficient and another 22 percent are functionally obsolete. The TRIP report contains a list of the 25 bridges in the state with the lowest sufficiency rating, for which repairs are not scheduled through 2009.

“This report shows that West Virginia has enormous deficiencies in road and bridge funding,” said Joe Deneault, chairman of West Virginians for Better Transportation. “The federal stimulus package will not make as big of an impact as we had hoped. And with a projected deficit of $5 billion in surface transportation needs over the next 10 years, we believe it is critically important for the Governor, legislature and Department of Transportation to come together and develop a long-term funding solution for our roads, bridges and highways.”

The report found that West Virginia’s traffic fatality rate of 2.10 fatalities per 100 million miles of travel is the third highest in the U.S. and 54 percent higher than the national average.

The West Virginia Department of Transportation projects a transportation funding shortfall of nearly $5 billion from 2009 to 2018. The Department estimates that $9.75 billion will be needed through 2018 to improve road and bridge conditions, enhance economic development, provide needed safety measures and relieve traffic congestion. However, the state estimates that only $5 billion will be available during that time.

In addition to the $4.2 billion that West Virginia received from 1998 to 2008 in federal funding for road,

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highway, bridge and public transit improvements, the state recently received approximately $211 million in federal stimulus funding for highway and bridge improvements and $19 million for public transit improvements. This funding can serve as a down payment on needed road, highway, bridge and transit improvements, but it is not sufficient to allow the state to proceed with numerous projects needed to modernize its surface transportation system.

Needed projects that can not proceed without additional transportation funding include the following: the widening of I-81, I-64 and I-79 to six lanes to ease congestion in the Martinsburg, St. Albans and Fairmont areas; the replacement of the Dick Henderson Bridge in St. Albans; the widening of US 119 in Charleston from Oakwood Road to Jefferson Road; the installation of high-tension guardrails on numerous sections of I-77 to reduce run off the road collisions; and the construction of a fly over ramp from I-64 to US 119 southbound in Kanawha County to reduce collisions. A full list of projects requiring additional funding to proceed is included in the report.

The current federal transportation program, the Safe, Accountable, Flexible, and Efficient Transportation Equity Act – A Legacy for Users (SAFETEA-LU), expires on September 30, 2009, requiring Congress to authorize a new federal surface transportation program or extend the current program to allow federal highway dollars to continue to be provided to West Virginia. Recent declines in federal surface transportation revenues, as well as significant increases in the cost of transportation construction materials, will make it more difficult for Congress to authorize new, adequately-funded federal surface transportation legislation.

“West Virginia has benefited tremendously from the federal transportation program,” said William M. Wilkins, executive director of TRIP. “While the state has put this combination of federal and state funds to good use in the past, in the coming years, many additional needed projects will remain on the drawing board because of insufficient funding. It is critical that the state adequately funds its transportation system and that Congress produces a timely and adequately funded federal surface transportation program this year.”

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ASSOCIATION NEWS

ASSOCIAtED GENERAL CONtRACtORS OF ASSOCIATION NEWS OHIO HOLDS GOLF OUTING tO BENEFIt SCHOLARSHIP FuND COLUMBUS, Ohio - The Associated General Contractors of Ohio held its annual golf outing at the Bent Tree Golf Club in Sunbury, Ohio. All proceeds from the outing and accompanying raffle benefited the AGC of Ohio Scholarship Fund, which awards scholarships to outstanding students interested in pursuing a career in the construction industry. AGC of Ohio raised over $6,500 at this year’s outing.

The Scholarship Fund, managed by the AGC of Ohio Education Foundation, awards four scholarships annually. The Education Foundation also administers 16 additional scholarships sponsored by the following AGC affiliated individuals and organizations: AGC of Akron, AGC of Northwest Ohio, Baker Concrete Construction, Central Ohio AGC, Tim Galvin, Knoch Corp., Liberty Construction, Precision Environmental, The Ruhlin Co., Shook Construction, Tuttle Construction, and West Central Ohio AGC. The Foundation also selects the recipients of the Mosser Construction scholarships in three Northwest Ohio area colleges.

Since the first awards in 2000, over $100,000 in scholarships have been awarded under the auspices of the AGC of Ohio Education Foundation.

ACEC INDIANA ANNOuNCES ItS ENGINEERING EXCELLENCE AWARDS GRAND PROJECt WINNER PLAINFIELD, Ind. - The U.S. 40 Pedestrian Bridge over White Lick Creek is envisioned as a signature structure for the Town of Plainfield’s trail system. It provides a link from downtown to the Greenways Trail and the future sports complex on the west side of White Lick Creek.

The structure consists of two pair of circular pylons, tilted in two directions and connected to a large plate or medallion at their apex, resembling an A-frame when viewed head-on or from the side. The medallion functions as a connection plate for the four pylons, and provide support for the center spans of the pedestrian bridge through 2-1/2 inch diameter hanger rod attachments. The cast steel medallion at the apex of the bridge blends old and new with the Old National Highway emblem and the Plainfield “P” logo. This bridge shows Plainfield’s commitment to its trails and making their community a better place to raise a family and to live.

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WOOLPERt ACHIEVES LEED-CI StAtuS INDIANAPOLIS - Woolpert announces that the firm’s office space in Woodland Corporate Park VI has achieved LEED for Commercial Interiors (CI) Silver certification by the U.S. Green Building Council (USGBC). LEED-CI is achieved through use of green interiors that are more environmentally friendly and contribute to a healthy work environment.

“Woolpert is not only committed to providing sustainable design solutions for our clients, we are also dedicated to creating sustainable and environmentally friendly office environments for our employees,” said Mike Flannery, Woolpert’s president and CEO. As part of the lease agreement with Duke Realty Corporation, Woodland Corporate Park VI owner and developer, Woolpert requested a LEED-certified office space. Urban Design of Indianapolis and Schott Design were contracted by Duke to provide consulting services to support pursuit of LEED certification including the creation of reports and logs to document sustainable credits based on the latest credit interpretation rulings, standards and guidelines. Woolpert contracted with Reed Doran Associates of Dayton, Ohio, to provide interior design services.

“Because of the high level of cooperation between Duke, Urban Design, Schott Design, Reed Doran and Woolpert, we were able to surpass our original goal of certification and achieve Silver certification,” said Flannery.

“The team’s commitment to sustainable solutions and their overall synergy resulted in a very successful LEED project.”

Factors contributing to Woolpert’s LEED-CI Silver certification include a 20 percent reduction in water use, a 29 percent reduction in use of power for lighting and a 35 percent reduction in power used for heating and cooling over standard practice.

“Woolpert is a longstanding client of Duke’s, and we are pleased that we could surpass their sustainability goals in their Woodland Corporate VI office,” said Charlie Podell, senior vice president, Duke’s Indiana operations. “Duke is well positioned to design and develop buildings that meet the criteria for LEED certification.”

“The best way to describe the success of this project is the total commitment and collaboration of the entire team,” said Mindy Hanni, president of Urban Design. “Sustainable design was at the forefront of each team member’s process. Through this passion and commitment, Silver certification was achieved. It has been a pleasure to work with Schott Design and all of the project team.”

The office also features interior finishes and furniture that do not off-gas chemicals in the indoor air, a comprehensive "green" cleaning program that will keep harsh or toxic chemicals out of the office and day lighting that is available to 75 percent of the office.

CONtRACtORS RECOGNIZED At SAFEty LuNCHEON COLUMBUS, Ohio - The Associated General Contractors of Ohio held its seventh annual Safety Luncheon at the OSU Fawcett Center. The event was held to recognize the safety efforts of commercial building contractors.

The following nine Ohio companies received a Construction Safety Excellence Award (CSEA): Building Division 100,001-300,000 work hours: A. A. Boos & Sons, Inc. (Oregon) 300,001-700,000 work hours: Elford, Inc. (Columbus) 700,001-1 million work hours: Marous Brothers Construction (Willoughby) Over 1 million work hours: Messer Construction Co. (Cincinnati) Construction Management 500,000+ work hours: Turner Construction Co. (Cincinnati, Cleveland & Columbus) Heavy Division 300,001-700,000 work hours: The Ruhlin Co. (Sharon Center) Over 1 million work hours: Kokosing Construction Co. (Fredericktown) Specialty Division 300,001-700,000 work hours: TP Mechanical Contractors (Cincinnati & Columbus) Over 1 million work hours: Baker Concrete Construction (Monroe) CSEA recognizes contractors for their overall safety program. Winners are selected based upon their lost workday and recordable incidence rates; elements within their safety program; level of employees’ and management’s commitment and involvement; new safety programs, procedures and resources; and any unique aspects of the safety program.

The following eight Ohio companies were honored with a Certificate of Commendation for Safety Excellence through the National AGC Safety Awards Program (NASA): -The Dotson Company (Whitehouse) Zero incidence rate -Marous Brothers Construction (Willoughby) 25% below division incidence rate -McNerney & Son (Northwood) Zero incidence rate -R. J. Beischel Building Co. (Cincinnati) Zero incidence rate -Richard Goettle, Inc. (Cincinnati) Zero incidence rate -Rudolph/Libbe, Inc. (Walbridge) Zero incidence rate -Terra Con Construction (Wapakoneta) Zero incidence rate -TP Mechanical Contractors (Columbus) Zero incidence rate

Firm: Butler, Fairman & Seufert, Inc. Project: U.S. 40 Pedestrian Bridge Over White Lick Creek Owner: Town of Plainfield

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NASA honors contractors with Certificates of Commendation for incidence rates of 25 percent below a company’s division average and/or a zero incidence rate. Nationally, approximately 3,000 contracting firms participate in NASA each year.

Luncheon sponsors were Compensation Consultants, Inc. and CareWorks. The sponsor of the safety meeting before the luncheon was Tuttle Construction, Inc.

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AGC OF OHIO ELECtS OFFICERS FOR 2009 COLUMBUS, Ohio - The Associated General Contractors of Ohio (AGC), a commercial construction association, has elected its 2009 Officers and Executive Committee. The election took place at the Annual Meeting of the Board of Directors during the AGC convention in Nassau, Bahamas.

Don Dreier, Executive Vice President of Donley’s Inc. in Cleveland, Ohio, was elected President of the association for 2009.

“I’m honored to assume the leadership role for AGC of Ohio,” Dreier said. “As a board, we will continue to work to assist the construction industry in Ohio.”

The remainder of the Executive Committee includes: 1st Vice President: Joe Kovaleski, The Lathrop Co. (Toledo) 2nd Vice President: Mike Deiwert, The Ruhlin Co. (Sharon Center) Treasurer: J.D. Flaherty, Jr., Construction Systems (Columbus) Immediate Past President: Charlie Izzo, Infinity Construction Co. (Cleveland) Secretary: Rich Hobbs, AGC of Ohio (Columbus)

Construction Digest

OHIO StAtE’S CONStRuCtION MANAGEMENt tEAM PLACES FOuRtH At NAtIONAL COMPEtItION Joe Kovaleski

Mike Deiwert

COLUMBUS, Ohio - The student Construction Systems Management Team from The Ohio State University placed fourth in their first-ever national competition.

The Associated Builders & Contractors, Inc. Central Ohio Chapter, sponsored the OSU team to compete in the ABC National Construction Management Competition, held annually for universities from across the country. For the first time, Ohio State’s ACSM Club assembled a Construction Management Team to compete. The competition’s objective is to construct an entire building plan from estimating, scheduling and marketing; to a final presentation to the panel of project managers and estimators.

The Ohio State Construction Management Team was shortlisted in making the final round of five teams, and placed fourth out of 20 teams in the competition!

In addition, the Ohio State team won the Estimating category, dethroning the three- consecutive-year champ – University of Florida. The competition was a great experience for the team as they endured a seven-hour “Bid Day” with all 20 teams competing. The top five were announced and the Ohio State team then presented the project to the judges’ panel of “owners” who also asked questions.

The professional setting at the competition provided real-world experience that will benefit the students in the construction industry after graduation. The Ohio State Construction Management Team plans to work with ABC Central Ohio to complete in future National Construction Management Competitions.

The top five teams included: 1. University of Washington 2. University of Cincinnati 3. Brigham Young University 4. Ohio State University 5. Virginia Tech

Charlie Izzo

Rich Hobbs

J.D. Flaherty, Jr.

CALuMEt CIVIL CONtRACtORS EARNS AWARD INDIANAPOLIS - Employees of area heavy-highway construction contractor, Calumet Civil Contractors, received the Asphalt Pavement Association of Indiana’s highest quality pavement recognition at the association’s recent 2008 Hot Mix Asphalt Winter Conference in Indianapolis.

Calumet Civil Contractors earned the award for Reconstruction/City, one of six categories, for their project in Noblesville on the Town & Country Blvd round- about. The project was one of 29 nominated state wide for quality asphalt pavement construction. Robert Woods, retired Indiana Department of Transportation engineer, performed the judging on behalf of the association. Projects were evaluated using a 12 point scale describing ride quality, construction quality, and current project condition.

The other student Construction Management programs competing included: Alabama Auburn Central Florida Colorado State Florida International Georgia Tech LSU Minnesota State University - Mankato Northern Iowa Pennsylvania College of Technology Purdue Southern Miss University of Florida University of Houston University of Wisconsin – Stout ABC Central Ohio and the Ohio State Construction Management Team was sponsored by: Area Energy & Electric; Barton Mallow; Gutknecht Construction; Jess Howard Electric Co.; HVG; JF Painting Co.; Key Blue Prints; Lithko Contracting, Inc.; Messer Construction Co.; Miles-McClellan Construction Co.; Pepper Construction; Shelley, Metz, Baumann and Hawk; and Vivid Design Group.

PREVAILING WAGE DOES NOt APPLy tO OFFSItE WORK COLUMBUS, Ohio - The Ohio Supreme Court today held that a labor union lacked standing as an “interested party” to represent all employees working for a contractor in a prevailing wage lawsuit when only one employee had signed an authorization card with the union. The Court held that employees who work offsite are not subject to prevailing wages.

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(Left to right) Jim (Todd) Moyer, Jessica Wolfe, Jake Miller, Matt Bensman, Eric Adamski, Alex Belkofer, Eric Reish and Jack McMinn.

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ASSOCIATION NEWS

July Page 2099

ASPE ACCEPtS ASSOCIATION NEWS NEW MEMBERS

FOuNDAtION’S FIVE FINESt

Board Selects Five Winners From Record Number Of Applicants

FORT WAYNE, Ind. - The American Society of Professional Estimators, Fort Wayne Chapter 65, is pleased to announce that Robert Curia, P.E, Associate Professor at IPFW and Natalie Reinhardt have been accepted into full membership of the ASPE Professional Construction Trade Organization.

CALL FOR ABStRACtS 2010 ISAWWA ANNuAL CONFERENCE AND EXPO SPRINGFIELD, IL MARCH 16-18, 2010 SPRINGFIELD, Ill - Abstracts are now being accepted by the Technical Program Committee for presentation at the Illinois Section American Water Works Association 2010 Annual Conference and Expo which will be held in Springfield, Illinois, March 16-18th, 2010.

Papers are being sought in all areas of public and private water supply and treatment such as: Fundamental Topics Customer Service Water Tanks Legislative Energy Efficiency Water Treatment Clarification

Water Management GIS Distribution Watershed Pharmaceuticals Source Filtration Arsenic Treatment

Water Quality Sustainability Engineering Emergency Planning Water Protection Coagulation Radionuclides treatment

If your paper is selected, the Technical Program Committee will determine the day it is best suited. Presentations will be 30 minutes maximum including up to five minutes of question and answer time.

Registration fees for the day you are speaking are complimentary along with any group meal served that day. There will be no honorariums or travel fees paid. You will be given the opportunity to supply your handouts on the Conference CD that will be distributed at the Conference. All presentations will be pre-loaded on the computers to insure a smooth transition between speakers. Upon acceptance of your presentation your Power Point will need to be submitted by February 15th, 2010.

PowerPoint’s will be uploaded to an ftp site. Instructions will be provided to those whose papers are accepted.

All abstracts are to be submitted electronically on the Illinois Section AWWA website at www.isawwa.org.

Information that will be requested on the Abstract Submittal Form are: -Title of Paper -Authors Names, titles and company -Presenters Names (who will be there that day) -Primary Contact Person (one person who will coordinate all of your presenters on this paper) -Long Abstract (for review by the Technical Program Committee - no more than 400 words) -Short Abstract (for the printed program - no more than 8 sentences) -Biography of presenters (what you would like read to introduce the speakers - limit 300 words total) Selection of papers is based on an evaluation of abstracts by the Technical Program Committee, considering quality, originality of subject, technical content, and significance to understanding and improving the water environment. Thank you in advance for your abstract submittal! Please be sure and spell check your short abstract as it is what will be in the program.

INAWWA SPRING DIStRICt MEEtINGS NASHVILLE, Ind. - The Indiana Section American Water Works Association (InAWWA) just completed a round of Spring District Meetings in May at 5 locations across Indiana. Many attended these highly informative programs and obtained essential contact hour credits.

Several members of the Indiana Delegation also attended AWWA’s Annual Conference and Exposition (ACE ’09) in San Diego. This event is favorably attended by water operators and professionals each year from throughout the world.

On July 29, the Indiana Section will host its Annual Golf Outing at Eagle Creek in Indianapolis. All proceeds and donations from this event are contributed directly to Water For People, an international organization dedicated to helping people in developing countries improve their quality of life with sustainable drinking water resources, sanitation facilities and health/hygiene education programs.

After a short summer break, the next round of District Meetings will take place in September.

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Construction Digest Page 21

ROSEMONT, Ill. - The Builders Foundation has announced five scholarship recipients who can now work toward careers in construction with less financial strain.

2009 honorees Konrad Dabrowski, Matthew Egan, Jolisa Gold, John Moran and Jason O’Boyle bring the total number of recipients to 23 since the inception of the scholarship in 2003. In that time, the Builders Foundation has awarded over $70,000 in funds to these future leaders of the construction industry. These students will be awarded renewable, Konrad Dabrowski $3,000 yearly scholarships.

The funding for the program comes primarily from the Builders Foundation Golf Outing, which this year will take place Wednesday, July 29 at Makray Memorial Golf Club in Barrington.

Konrad Dabrowski is a Sophomore at Iowa State University majoring in Construction Engineering. He graduated from Prospect High School in 2007 and plans to graduate from Iowa State in 2011.

“One of the biggest factors in my wanting to be in the construction industry is my family,” Dabrowski said. “My father has been doing construction work for over 23 years. Ever since I was a little kid, my dad would bring home plans for his next project and try to explain what everything was. This fascinated me.”

Matthew Egan is a Junior at Marquette University majoring in Civil Engineering. He graduated from Carl Sandburg High School in 2005 and plans to graduate from Marquette in 2010.

“Growing up, I had a curiousity about the development of infrastructure as well as buildings going up around me,” Egan said. “I knew from the start that I was destined to be part of the hands-on, fast-paced construction environment.”

Jolisa Gold is a Lockport High School graduate and a Junior at Milwaukee School of Engineering majoring in Construction Management. “Working for my uncle’s construction business when I was younger pulled me closer to the management side of construction,” Gold said. “My familiarity with the client/contractor side of the busiJohn Moran ness as well as relating to and understanding the labor/field workers will help me work more efficiently in the future.”

Marquette University Civil Engineering major John Moran is a product of Providence Catholic High School. He plans to graduate from Marquette in 2010. “Nothing would make me happier than to create and supervise a building that would ultimately become part of the magnificent Chicago skyline,” he said. “I already take pride in the two condo buildings I worked on, but having my own building would just make my career.”

Jason O’Boyle is a Sophomore at Milwaukee School of Engineering majoring in Architectural Engineering. He graduated from North Boone High School in 2007.

“Building strong communities and strong relationships can be accomplished through working in the construction industry,” O’Boyle said. “My career goal is to be the best professional engineer that I can be. I would like to be the guy that people know they can Jason O'Boyle come to with their questions.”

Helping students is par for the course for assocation members In 2008, the Builders Foundation Golf Outing raised over $30,000 for scholarships for the fourth year in a row. This year's outing will be held Wednesday, July 29 at Makray Memorial Golf Club in Barrington.

Registration and sponsorship information is available at www.bldrs.org.

BCA AWARDS tHREE CONStRuCtION SCHOLARSHIPS FORT WAYNE, Ind. - The Building Contractors Association of Northeast Indiana has announced recipients of its 2009 scholarships. These awards are offered to students who are pursuing careers in construction or a related field.

The $1500 Presidential Merit Scholarship recognizes significant personal attributes such as volunteer service to social welfare groups or special extracurricular activities, in addition to academic achievements. This year’s winner is Pablo Lopez - Attending Purdue University North Central Fall 2009- Construction Engineering & Management Technology, Plymouth High School Graduate.

The $750 Construction Career Academy Scholarships are awarded to high school seniors who graduated from the BCA’s Construction Career Academy and are pursuing post-secondary construction education after high school graduation. This year’s winners are: Kenny Kill - Attending Trine University Fall 2009 – Electrical Engineering, West Noble High School Graduate.

Zachary Grable - Attending Ball State University Fall 2009 – College of Architecture and Planning, Columbia City High School Graduate .

20/07/2009 16:29:41

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ASSOCIATION NEWS

INDIANA CONStRuCtION ASSOCIAtION ANNOuNCES BOARD EXPANSION Four Additional Directors Assembled to Lead Construction Association.

INDIANAPOLIS - Indiana Construction Association (ICA) recently announced the expansion of its Board of Directors to eighteen members by adding Todd Fredrick, Michael T. McCann, Cheryl P. Melancon and Bruce Wylam.

Fredrick has been president of Primco, Inc. since 1998. He is a graduate of Purdue University-Fort Wayne, wa degree in Civil Engineering Technology and Construction Management. Fredrick has served as a member of both Indiana Constructors, Inc. (ICI) and Build Indiana Council (BIC) Board of Directors. A member of the ICA/INDOT Joint Cooperative Committee since 2005, Fredrick has also served as the vice president of the Indiana Chapter of the American Concrete Pavement Association.

McCann is senior vice president and COO of Pepper Construction Co. of Indiana, LLC and has more than 25 years of progressive experience with the company. McCann serves on the IUPUI Construction Engineering Management Technology (CEMT) Advisory Board and is a part-time instructor for the university. Past board memberships include positions with Metro Indianapolis Coalition for Construction Safety (MICCS) and Associated General Contractors of Indiana. In addition to being a LEED® Accredited Professional, McCann is also a member of the International Council of Shopping Centers (ICSC) and the Lean Construction Institute.

Melancon has been president and owner of The Hoosier Company since 1988. She served on the ICI Board of Directors and was its president in 2000. She is a past member of the BIC Board of Directors and is currently serving as Treasurer of the Build Indiana Political Action Committee. She has served on the Indianapolis Chamber of Commerce Board of Directors and as Chair of the Indianapolis Chamber Political Action Committee. A native of Bloomington, Melancon received a Bachelor of Science degree in Business from Indiana University.

Wylam is vice president of Client Services for Hunt Construction Group. A 1981 graduate of Purdue University with a Bachelor of Science in Building Construction Technology, Wylam has over 27 years of experience in the construction industry. He currently oversees Hunt’s delivery of all development and preconstruction phase services to its clients, including management planning, scheduling, cost estimating and budgeting, value analysis and constructability consulting. Wylam is a member of the Dean’s Industry Advisory Council at the Purdue School of Engineering and Technology and IUPUI, and serves on the board of Finch Constructors, Inc. “We are thrilled to have these individuals join our Board of Directors,” said Charles V. Kahl, ICA President. “We have a strong board made up of experts in the construction industry who understand the current challenges and opportunities we face. For the remainder of 2009, the executive leadership and the Board of Directors of ICA will continue to focus on expanding the association’s presence and influence across the state.

ABC CENtRAL OHIO CHAPtER GRADuAtES 53 APPRENtICES COLUMBUS, Ohio -- The Associated Builders and Contractors, Inc. – Central Ohio Chapter celebrated 53 students’ completion of their apprenticeship training and elevation to craft professional status at the annual apprenticeship graduation banquet.

Three students received the “Outstanding Student Leadership Award” for their exemplary performance in academics, attendance, commitment, and contribution to the apprenticeship program. The recipients were: Nicolas Christen (OSU), Kyle Lyons (Cogburn Electric, Inc.), and Simon Lemaster (OSU).

Many students were recognized for perfect attendance and academic excellence during this school year. Christen earned special recognition for perfect attendance throughout his entire apprenticeship.

ABC Central Ohio also recognized its first-ever double completion. Tim Matthews (OSU) finished his first apprenticeship in electrical back in June 2001. Matthews re- entered the program in 2006 and has now earned his second certificate in locksmith.

ABC Central Ohio trains 250 apprentices in 12 different trade programs registered with the U.S. Department of Labor and the Ohio State Apprenticeship Council. Through articulation agreements with local colleges, all students are enrolled in college courses while in the program, which allows them to receive required college credit toward an associate degree in construction management.

(Left to right) Electrical Graduate, Daniel Neylon (Romanoff Electric); ABC Electrical Instructor and 2006 ABC National Craft Championships Silver Medalist, Shane Jones (Gaylor Group, Inc.).

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Construction Digest

KENtuCKy HIGHWAy INDuStRIES ANNOuNCE SCHOLARSHIP AWARD RECIPIENtS FRANKFORT, Ky. – The Kentucky Highway Industries (KHI) Scholarship Committee, cochaired by Les Geralds, Roger’s Group, Inc., and Jim Wright, Hinkle Contracting Corporation, recently announced the 2009 Scholarship Award Recipients. The total allocation of $59,000.00 will be distributed to the students during the 2009-2010 school year. Since 1998, $259,250.00 has been awarded to deserving students to help them achieve their educational goals.

Vocational Degree- $1,500.00 Kevin Fickey of Belfry, KY. Associate Degree- First Year - $2000.00 Rhonda Burnette of Monticello, KY. Kristin Hale of Frenchburg, KY. Jennifer Hornsby of Central City, KY. Associate Degree- Second Year - $2000.00 Des Moines Thomas of Louisville, KY. Whitney White of Richmond, KY. Bachelor’s Degree – Freshman - $2,500.00 Brittany Besserman of Howesville, KY Shalana Callahan of Mount Sterling, KY. Erica Essex of Lebanon, KY. Seth Fawns of Mount Sterling, KY. Rebekah Harston of Scottsville, KY. Whitley Shae Hill of Grayson, KY. Charli Swift of Compton, KY. Bachelor’s Degree – Sophomore - $2,500.00 Justus Carter of Clarkson, KY. Mallory Carter of Clarkson, KY. Katie Jury of Bloomfield, KY. Bachelor’s Degree – Junior - $2,500.00 Brandon Lee Hayes of Horse Branch, KY. Leah Hayes of Greensburg, KY. Jamie Johnson of Shepherdsville, KY. Stephen M. Mattingly of Owensboro, KY. Tiffany Victoria Owens of Langley, KY. Bachelor’s Degree – Senior - $2,500.00 Lauren Carter of Scottsville, KY. Erin Combs of Mount Sterling, KY. Misti Dawn Meece of Nicholasville, KY. Elizabeth Vonderine Pratt of Clearfield, KY. The Kentucky Highway Industries, based in Frankfort, is comprised of the Kentucky Crushed Stone Association, Plantmix Asphalt Industry of Kentucky, and the Kentucky Association of Highway Contractors.

LOCAL BuSINESSMEN RECEIVE AWARDS FOR COMMuNIty SERVICE FORT WAYNE, Ind.Building Contractors Association of Northeast Indiana announced the 2009 winners of its prestigious Gold Medal Award and Summit Award. These awards recognize individuals who have demonstrated strong professionalism throughout their construction careers and have given significant contributions to local philanthropic organizations.

A $500 donation to winners’ chosen charity was given in honor of their distinguished service in a formal presentation at the annual BCA Spring Membership Dinner & Awards Banquet.

The Gold Medal Award was presented to Charles J. Bodenhafer, CLU, of Wells Fargo Insurance Services of Indiana LLC. He donated his cash award to Early Childhood Alliance and Aging & In-Home Services. The Summit Award was presented to Bob F. Jesse. He donated his cash award to the Indiana-Purdue Foundation.

Charles J. Bodenhafer

Bob F. Jesse

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July Page 2009

ASSOCIATION NEWS

Page 23 Construction Digest

AWARD PRESENtAtIONS AND StRAIGHt tALK ACEC OF INDIANA HOLDS ANNuAL ASSOCIATION NEWS AWARDS MEEtING ABOut SAFEty tOOK CENtER StAGE At tHE INDIANAPOLIS – The American Council of Engineering BuILDERS ASSOCIAtION’S SPRING MEEtING Companies of Indiana (ACEC-IN) held its annual awards meeting.

ROSEMONT, Ill. - Award presentations and straight talk about safety took center stage at the Builders Association’s Spring Meeting, at the Hyatt Rosemont.

Safety Committee Chair Paul Flentge of Pepper Construction Company presented the Builders Association's Safety Awards. Five Best of Class Awards and 20 other Safety Recognition Awards honored companies for their dedication to developing and promoting safety on their job sites.

John Schumacher, of Assurance Safety Consulting, gave the keynote address. In his presentation, - “The True Cost-Benefit of Safety: Is the Effort Worth It?”- Schumacher explained that implementing measures to promote safety could actually benefit a company’s bottom line. Schumacher urged contractors to treat the cost-benefit measurement of safety practices “like you treat your financials.”

“Look at the money you could be saving,” he said, after explaining how better-than-average Experience Modification Rates (EMRs) and low incident rates could save contractors substantial amounts of money in the long run. “It’s the same money. It’s a matter if you want to work for it or if you want to save it through strategic safety programs.”

The EMR, a numerical rating based on a company’s three-year history of incidents, helps determine a company’s workers compensation costs, which Schumacher indicated could have a sizable impact on the bottom line.

“If you have some bad cases, it really does stay with you,” he said.

“I look at this like high school - if you get a reputation it’s going to stick with you for at least three to four years” Although Shumacher’s presentation mentioned that a 1.0 rating is an average EMR, he said he preferred to see companies he works with have an EMR around .8 or .85. His presentation also focused on incident and severity rates, as well as the often-unseen indirect costs of injuries.

“In some cases, you’re looking at hundreds of thousands of dollars if you can click your experience mod [EMR] down a little bit,” he said.

“What I challenge everyone in this room to do is compare yourself to industry averages” with regards to injury rates, he added. He issued a challenge for companies to “try to get better.”

In terms of incidents, his presentation demonstrated that, as he put it, “frequency breeds severity.”

“The difference between a near-miss and a serious case is luck, and you can’t control luck,” he said. “It’s about affecting how people work.”

The indirect cost of losses, which Schumacher said companies don’t often measure because they don’t want to see the cost, none the less clearly makes a difference. He estimated that these costs - including things like investigation time, legal costs, loss of production due to morale, damaged equipment, and more - often measure between two and 10 times the amount of direct costs of incidents.

Schumacher concluded his presentation by encouraging companies to implement effective safety programs. Currently, he said, programs are often “a series of random activities that are set in place without regard to goals or results,” and focus on OSHA compliance rather than actual loss.

“I like to flip that,” he shared, saying that companies should focus instead on the goal of loss prevention. “If you do that, the OSHA compliance will naturally follow.”

Bob Smith of the Levy Company was recognized as his accomplishments during 10 years at Chairman of the Safety Committee. During that time, he helped the association develop a partnership program with OSHA, and instituted collaborative roundtable forum events which allow contractors to share solutions to safety problems.

Although Smith mentioned that discussing safety issues at the meeting was like “preaching to the choir,” he said that “we have too many people who aren’t here, who don’t get it.”

Craig Avery, president of Avery Consulting, LLC and former chair of the ACEC/PAC, was the keynote speaker.

Certificates of completion were presented to the graduates of the 2009 Engineering Leadership Program: Tim Coomes, United Consulting; Angela DeWees, RW Armstrong; Scott Dick, USI Consultants; Rick Durham, Durham Engineering; Sherly George, Stephen J. Christian & Associates; Paul Glotzbach, United Consulting; Kevin Loiselle, Clark Dietz; Chet Parsons, Parsons, Cunningham & Shartle; Chris Ranck, RW Armstrong; Jeromy Richardson, United Consulting; Paul Shaffer, Butler, Fairman & Seufert; Mike Craig Avery, Avery Consulting and Smith, Butler, Fairman & Seufert; Shelby Swango, Parsons BrinckACEC national representative erhoff; Eric Rolle, Shrewsberry & Associates; Darryl Wineinger, United Consulting; Rich Zielinski, American Structurepoint; Michael J. Guzik, Lawson-Fisher Associates; Kevin Jasinski, American Structurepoint; Michael D. Labitzke, Clark Dietz; Cassie Reiter, Crawford, Murphy & Tilly.

The 2009 Sagamore of ACEC was presented to James Reid, publisher of IPW News and Building Excellence. This award was created to honor someone who has helped elevate the engineering profession and has helped advance ACEC Indiana.

ACEC Indiana’s Public Service Award was presented to Bob McCullouch, research scientist, Purdue University. McCullouch has taught classes on a wide range of topics to both undergraduate and graduate students; published articles in technical journals; made presentations at national conferences; and performed over $4 million worth of research for the transportation and construction industries. His research work has produced computer tools and methodologies that have impacted the way these organizations do business. McCullouch is the chairman of the Continuing Education Professional Development Seminar which is held annually in November. He has also served on committees with LTAP, INDOT, ASCE and ACEC Indiana.

The 2009 Consulting Engineer of the Year Award was presented to Scott Sondles. Sondles is a partner in Burgess and Niple, directing its Indianapolis office and sitting on the firm’s board of directors in addition to ACEC Indiana’s board. During his career, he has designed industrial and commercial architectural projects, earthen dams, roads and bridges. The Consulting Engineer of the Year Award was established in 1984 to pay tribute to an ACEC Indiana member who has made a significant contribution to the profession of consulting engineering.

The ACEC-IN president’s gavel was officially transferred to Abe Swidan, Janssen & Spaans Engineering, Inc. from outgoing President Ross Snider, USI Consultants, Inc.

Scott Sondles (l), Burgess & Niple, Inc. (l) 2009 ACECIN 2009 Consultant of the Year and Ross Snider, USI Consultants, Inc. and ACEC-IN president

Bob McCullouch (l) 2009 ACEC-IN Public Service Award

Incoming ACEC-IN president Abe Swidan, Janssen & Spaans Engineering, Inc. (l) received the gavel from Ross Snider, USI Consultants, Inc.

James Reid, publisher, IPW News and Building Excellence (l) receives the 2009 ACEC-IN Sagamore of ACEC from Ross Snider, USI Consultants, Inc.

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ConstructionDigestCS3_2.indd 23

20/07/2009 16:29:45

CASE STUDY

Page 24

Construction Digest

Soil Stabilization Process Keeps Project On Schedule Over 500,000 cubic yards of soil has been treated

By Aram Kalousdian The majority of fill needed on a site near Edwardsport, IN where a coal gasification plant is under construction, is extremely wet and highly plastic clay. There is no time for suspending work due to weather or soil conditions.

In order to counter the problems that soil conditions and weather pose, Mt. Carmel Stabilization Group Inc., of Mt. Carmel, IL is using Lime Kiln Dust (LKD) to dry and modify massive stockpiles of cut that can later be used as fill for the site. To date, Mt. Carmel has treated over 500,000 cubic yards on the project with over 40,000 tons of LKD and has helped to keep its customer, Ryan, Inc. Central on schedule throughout the difficult fall, winter and spring months. Ryan, Inc. Central is the excavating company for the project. Duke Energy Corporation is the project owner.

Coal gasification plants convert coal into a synthetic natural gas that’s processed to remove pollutants such as mercury and sulfur dioxide. The plant under construction will use a methanation process to produce pipeline quality substitute natural gas (SNG), which has an identical molecular structure to that of natural gas.

It is expected to produce 40 billion cubic feet of pipeline quality SNG annually, which is enough to supply 15 to 20 percent of Indiana’s residential and commercial gas demand. Its use is expected to save consumers more than $3.7 billion over the next 30 years versus the price of conventional natural gas, according to a study by Carnegie-Mellon University faculty.

The plant will operate with extremely low emissions of regulated air pollutants and will isolate carbon dioxide so that it can be captured.

The project is being constructed on a 200-acre greenfield site. There is approximately 1.8 million cubic yards of earthwork on the project.

“Ryan, Inc. Central had a lot of dirt to move. There is a lot of cut and fill. The material is somewhat silty and very wet, so lime was put into the bid in order to keep the project moving along,” Doug McPherson, vice president of Mt. Carmel Stabilization Group Inc. said.

ConstructionDigestCS3_2.indd 24

“We saved Ryan, Inc. Central months on its schedule. Ryan, Inc. Central’s dirt work schedule would not allow the company to miss one or two weeks let alone months. The entire winter would’ve been lost, based on the soil conditions out there, the temperatures and the wet spring that we had,” Neil Ryan, marketing manager for Mt. Carmel Stabilization Group Inc. said.

McPherson explained that LKD not only attracts water and needs water in order to react, but it creates heat during the reaction as a thermal exchange, which dries additional moisture. “So, you get the benefit in the winter of not only moisture reduction, but heat in order to keep the material from freezing,” McPherson said.

“They tried to get by without lime for quite sometime, but then when we got out there and did a test strip, they saw what it could do. The rest is history. We’ve been working there for several months.” Mt. Carmel Stabilization Group Inc. began working on the project in the fall of 2008. The company has been working on the project on an as-needed basis.

“A lift of material that is very wet is brought in and we place LKD on it in order to dry it. We blend it and get a good homogeneous mixture of soil and lime in order to take out the moisture. We are actually changing the characteristics of the soil,” McPherson said.

Mt. Carmel Stabilization Group points out that if a site is properly stabilized wet weather will have virtually no effect on the final condition of the site. In fact, many project owners stabilize their sites to help protect against construction and weather damage over a winter season prior to final surfacing.

Six-wheel drive Mack tandem trucks that have spreader boxes on the rear are being used on the project in order to spread the LKD material on the ground. The spreader boxes have dust collection systems on them in order to limit the amount of dust on the project.

20/07/2009 16:29:49

Construction Digest

Page

Mt. Carmel Stabilization Group Inc.’s CAT RM 350 mixes Lime Kiln Dust and soil 16 inches deep. This photo shows the extremely wet soil conditions that were encountered.

Mt. Carmel Stabilization Group Inc.’s Wirtgen WR 2400 is mixing Lime Kiln Dust and soil 16 inches deep in a stockpile area. A Mack truck is spreading Lime Kiln Dust in another area in the background, at the center of the photo.

The material is then mixed in place with a Wirtgen WR 2400 recycler/stabilizer and a Cat RM 350 reclaimer. These soil stabilizers pulverize the soil 16 inches deep so that the lime and soil is blended together.

The Wirtgen WR 2400 is suitable for all kinds of terrain. The machine features a 420 horsepower engine.

Its lifting column design with hydrostatically and individually driven wheels provides ample ground clearance and enables the machine to work with the desired longitudinal and cross slope. A hydraulic differential lock additionally provides the WR 2400 with optimum traction properties.

The Wirtgen WR 2400 is equipped with hydraulic all-wheel steering, enabling it to be maneuvered easily even in extremely confined conditions. An elevated position prevents the working cylinders from getting soiled, which ensures improved operational readiness. The machine’s chassis remains clean, as it does not come into contact with the soil to be stabilized.

The volume of the mixing chamber on the WR 2400 increases automatically in accordance with the current working depth. The rotor can be raised and lowered continuously. In the final analysis, the design provides a consistently homogeneous mixing quality.

The Cat reclaimer’s rotor options provide versatility for stabilization and reclamation applications. The load-sensing propel system helps prevent overloading while allowing continuous work near the rated horsepower.

The Cat reclaimer provides consistent blending due to automatic depth control, a mid-mounted mixing chamber and a multi-speed rotor drive. Excellent maneuverability and operator visibility to the tire edges and mixing chamber allow the machine to perform well in urban environments. Daily service points are accessible from ground level and grouped on one side of the machine.

Case Study

Three of Mt. Carmel Stabilization Group Inc.’s custom built spreader trucks. These Mack trucks are all wheel drive trucks that are designed to get through terrible soil conditions, maintain accurate spread rates and minimize fugitive dust during spreading.

ConstructionDigestCS3_2.indd 25

20/07/2009 16:29:58

SHELBy

By J. Quyle

It has been more than 60 years since John Haehl Sr. and Thomas Wheeler, brothers-in-law, started Shelby Materials. The company has grown from a single crushed stone facility in 1946 to ten locations throughout central and southern Indiana. At those locations, the company operates eight concrete plants and two aggregate mines serving a fifteen county region. Shelby Materials, a leader in the Indiana ready-mix industry, is recognized as an innovator and an environmental steward. Today, John’s sons Philip and Richard Haehl, lead a management team that is committed to providing competitive pricing and exceptional customer service.

The first generation management, from left to right, Wilbur Higgins (book keeper), brothers Thomas J. Wheeler and John D. Haehl (Owners)

Philip, Richard and their three brothers grew up in the business, working at the plants after school and during summers from the time they could hold a broom and sweep floors. “My father was not real keen on vacations,” recalled Richard Haehl, Executive Vice President. “We’ve all done this, every summer, as soon as school was out; we went to work and worked until the day school started back up. Every summer, we were valuable help. We all started in the gravel operation and when we were old enough to get a chauffeur’s license, we started driving the ready-mixed concrete trucks.”

Two of the Haehl brothers chose different career paths after college and the eldest, John Jr. retired in 2002, selling his share to Philip and Richard. “I’m pretty excited about the future of our business from the standpoint that we have another generation coming up through the ranks,” said Philip, President of Shelby Materials. “I have two sons involved, and we have another group of talented people in their 20’s and 30’s that are going to continue to make this a very strong business going forward.”

That confidence in the future of the business comes from knowing that Shelby Materials supplies customers with quality products that provide strong foundations for many of the state’s buildings, residences, recreational and infrastructure projects. Most people in central Indiana are familiar with the blue and yellow ready-mix trucks that deliver the principal product of Shelby Materials, but the majority of those people do not realize the numerous uses for that concrete in our everyday world.

S h el b y M a t e r i a l s In d i a n a p ol i s f l eet a r e c a p a bl e o f p r o v i d i n g m a te r i a l fo r a ny s i z ed j ob

the History of Concrete

Concrete is a material composed of cement, crushed rock or gravel, sand, water, chemical admixtures and other materials. The Neolithic civilizations (7800 BC) were known to have used lime-based concrete in their homes. The Roman Empire, 7800 years later used the same technology widely, enhancing it with additives resembling what we use today. Rome was an enormous city for its time, populated by over a million people.

Infrastructure to support those people included, roads, water, and sewage systems and concrete played a large part in the creation of that network.

In 1824, a British stonemason named Joseph Aspdin, heated a mixture of finely ground limestone and clay in his kitchen stove. He ground the resultant clinker into a powder to create hydraulic cement, one that hardens with the addition of water. Aspdin named the product Portland Cement because it resembled a stone quarried on the Isle of Portland off the British Coast. In 1841, Portland Cement became widely used by local craftsmen when John’s son William improved his father’s recipe and opened the first cement plant in Rotherhithe near London.

Seventy-seven years later in 1918, Duff Abrams developed the modern method of measure for quality concrete. He related the ratio of water to cement (the water cement ratio) to define strength and durability.

His concepts are used every day in the concrete industry.

Shelby Materials State of the Art Clermont Office

The Concrete and Aggregate Experts ConstructionDigestCS3_2.indd 26

By J. Quyle

20/07/2009 16:30:06

July 2009

Page 27

Concrete uses

Today concrete is used in every major building project in one form or another from curbs, sidewalks, swimming pools, streets and bridges to building footings, foundations, columns, walls and floors. More concrete is used than any other man-made material in the world because today’s concrete is extremely diverse, flexible, durable and readily available.

Saving the Environment and the Wallet

Recently, concrete has gained even more popularity due to its environmental and economic benefits.

Consider these facts: •Components of concrete are locally available and can contain recycled materials. Concrete also can be recycled and used as a fill material or road base and not placed in landfills.

•Concrete is generally produced within 25 miles of a job site boosting its sustainability by minimizing the need for transport and supporting the local economy.

•Through concrete's excellent thermal mass, energy consumption in commercial and residential buildings can be reduced by up to 50%, a key component in reducing greenhouse gas emissions.

•Where paved surfaces are required, using materials like concrete with a higher Solar Reflectance Index (SRI) will reduce the heat island effect while saving energy and improving air quality.

•Energy costs for lighting concrete parking lots can be 35% less than those for asphalt. The need for fewer light poles reduces the cost even more.

In the past, asphalt and steel were used as lower-cost alternatives to concrete, but in today’s global economy, the differences in cost have been significantly reduced. Steel, used to structurally support buildings, continues to see prices climb as international supplies tighten and overseas demand remains strong. Asphalt, a petroleum-based product used on roads and parking lots, has experienced substantial cost increases.

These factors have contributed to many architects and engineers reconsidering concrete, not only because it is more durable, but also because it is not subject to drastic price fluctuations. When concrete is used, the estimated cost of a project is less likely to change by the time the project starts. The same cannot be said for asphalt or steel.

Seated (L-R) Aaron Haehl, Matt Haehl, Standing (L-R) Richard Haehl, Philip Haehl

PO Box 280 Shelbyville, Indiana 46176 Phone: (800) 548-9516 Fax: (317) 398-2727 www.ShelbyMaterials.com ConstructionDigestCS3_2.indd 27

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Construction Digest

Knauf Insulation recently completed a $220 million Dollar, 670,000 square foot expansion in Shelbyville, IN. Contracted by Runnebohm Construction, the state-of-the-art technolog y at their Shelbyville headquarters advances product quality, doubles production capacity, and increases energ y efficiency for leading insulation manufacturer.

Modern Concrete

Concrete is extremely versatile and has many uses. (1) Cast-in-place concrete (ready-mix concrete transported in a slurry state and placed in forms) is relatively inexpensive for the structural capacities, durability, and moldable qualities it offers to construction. Today the demands of construction schedules, environmental concerns, and cost constraints are leading the industry and product in directions that were not in the market only a few years ago.

The Pepsi Distribution Facility in Plainfield Indiana contains more than 45,000 cubic yards of concrete and met the scheduling demands for finisher, Scioto-Darby.

on the laser screed operator, and he chased us all the way through to the end of the pour.”

Mobile plant operations allow Shelby Materials to reach any job. In addition to Shelby Materials’ eight permanent ready mix locations, they also own two mobile plants, each capable of producing up to 180 cubic yards of concrete an hour while sitting on the customer’s job site. Placing the plant on the customer’s site provides a unique advantage to customers demanding high volume in remote locations.

Boundaries are unlimited with mobile production, as Shelby High production facilities and up-to-date fleets met the Materials recently completed a demands of Scioto-Darby at the Pepsi Distribution Center in 1.3 million square foot Wal-Mart Plainfield, IN. distribution center in Clearfield, Pennsylvania proves.

Pervious concrete is a relatively new product that could potentially change the landscape of storm water management. Storm water has traditionally been handled with retention ponds, which lead to problems for owners. “Ponds have to be professionally managed, cleaned, treated, and fenced. The infestation of mosquitoes and geese are constant health issues,” said Chris Wolf, technical support manager for Shelby Materials. “If a developer is going to build a 17-acre building on a 33-acre piece of land, they will need a 3-acre pond,” Wolf explained. “In some cities, prime acreage is going for a minimum of $20,000 an acre. Without a storm water mitigation pond, they could re-capture the value of the land through additional retail or warehouse space.

The developer could take full advantage of his property.” Wolf also described instances where developers had to forego small or oddly shaped parcels of land because a retention pond would not fit into the site plan.

Fast Track Construction requires very tight scheduling. The concrete must be placed quickly in high volume to achieve design strength early so the next construction phase can continue.

Shelby Materials has the capability to provide approximately 400 cubic yards of concrete per hour from several of their eight ready mix plant locations. This allows them to tackle demanding pours like the recent Pepsi warehouse job in Plainfield that included 45,000 cubic yards of concrete. With ready-mix trucks hauling about 9 cubic yards per load, it was important that Shelby Materials kept to a tight schedule and had trucks arriving and unloading constantly.

“Many of today’s concrete finishers have laser screeds allowing them to level and finish the floor very quickly,” explained Dustin Hartman, one of Shelby’s sales representatives in the Indianapolis area. “If you have a good screed operator, they can keep up with any ready mix company when it comes to production. Our goal is to try to get ahead of them as fast as we can and keep the trucks coming so that we stay ahead of them.”

“Once you get the trucks on site, you have to make sure that the product is right where it needs to be,” Hartman continued. “I’m like an air traffic controller. I’m telling the drivers where to go and what to do. I say, ‘Come in and square up with the others so I can get another one beside you and another one beside him and so on.’ On that job, we poured about one hundred and fifty yards in five to ten minutes. We got a big jump

Shelby Materials has the means to deliver large volume of concrete on time, and in spec.

ConstructionDigestCS3_2.indd 28

Shelbyville High School sits at the intersection of McKay road, a concrete street poured in mid 70s and Miller Street, poured in 1987 and has required virtually no maintenance.

20/07/2009 16:30:19

July 2009

Pervious concrete is made from carefully controlled amounts of water and cementitious materials used to create a paste that forms a thick coating around aggregate particles. Unlike conventional concrete, the mixture contains little or no sand, creating a substantial void content (15% to 25%). Pervious concrete allows 3 to 8 gallons of water per minute to pass through each square foot of the material. By allowing rainwater to seep into the ground, pervious concrete can be instrumental in recharging groundwater and reducing storm water runoff. This capability can reduce the need for retention ponds, swales, and other storm water management devices.

Storm water runoff is the leading cause of pollutants entering our waterways. Pervious concrete reduces the amount of runoff discharged into storm sewers, directly recharges groundwater to maintain aquifer levels, and mitigates pollutants that can contaminate watersheds and harm sensitive ecosystems. By channeling more water to tree roots and landscaping, there is also less need for irrigation with pervious concrete. Pervious concrete satisfies federally mandated Phase II water treatment requirements.

Concrete pavement for streets and highways is superior because of its structural capacity. Asphalt is not a structural pavement and is dependent on a thick sub-base of stone to support the loads and provide drainage.

When water saturates the base soil, it results in less load-carrying capacity and failures can occur with asphalt paving. Concrete is able to bridge the soft spots and provide support which makes it better-suited for heavy loads like truck traffic. Concrete generally has a useful life twice that of asphalt – commonly serving 20 to 30 years without needing major repair, while asphalt typically lasts 8 to 12 years before resurfacing or significant repair is required. Yearly sealing of asphalt is also a significant expense.

“There is a concrete street on the south edge of Shelbyville that was installed during the mid 70’s and is still providing good service,” Philip offered as an example. “Miller Street was put in during the 80’s; it just turned 20-years-old and has required virtually no maintenance.”

In fact, about 60% of the interstate system is concrete, especially in urban areas where the Federal Highway Administration anticipates heavy traffic loads. Concrete is selected, in large part, because of its durability and sustainability.

Decorative concrete is an affordable alternative to stone or tile and resilient in any climate. Concrete’s workability allows it to take on the colors, textures and shapes of materials such as brick or flagstone, which cost substantially more to put in place, yet concrete provides similar aesthet- Shelby Materials poured this colored concrete at the Inics and good long-term performance. dianapolis Zoo for a water park keeping the kids cool on a Exposed aggregate is another popular hot summer day. finish.

“We can make concrete look like anything,” said Jeremy Ross, a certified decorative concrete installer and sales person with Shelby. “We can make it look like tile or wood planks if someone wanted it. It is pretty amazing what they’ve come up with in the last ten years in the decorative market.”

Color is added to the concrete in one of two ways: either as a hardener or as integral color. Color hardeners are floated on the surface of the concrete before it sets. Integral colors are mixed into the concrete at the plant, which provides color all the way through the mix but is slightly more expensive. “If you drop a hammer on a floor where we used a hardener and a chip came out, you’d see gray underneath it,” Ross described.

“With integral color, if you use a brown color and you drop a hammer on that, when it chips out, it’s still brown underneath.”

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The Don Schumacher R acing complex in Brownsburg , IN.

Shelby has seen the use of decorative concrete expand from just patios and driveways to commercial applications such as roundabouts, memorials, walkways, columns and flooring. “Wal-Mart is using decorative concrete in their new stores as a way to accelerate construction schedules and alleviate tiling the entire 200,000 square foot floor. Tile floors require more maintenance,” Ross recounted. “They also like the fact that with a colored floor a lot of the stains that naturally occur in that environment are hidden.”

Concrete parking lots and driveways are preferred over other materials primarily for their durability, low maintenance, and appearance. They can be an extension of the landscaping or building design. Retail owners face constant repair and maintenance costs with asphalt lots. Previously, the initial cost of asphalt was less expensive than concrete, but the increase in oil prices has changed that. Even when the initial cost of asphalt is less, overloaded trucks often compromise asphalt lots causing the asphalt to fail and require repair.

Often these repairs are not as attractive as the original paving. “We are in an era where the appearance of retail facilities is important to customers,” said Wolf.

Energy and sustainability are served well by concrete construction. Concrete is a light reflective paving which reduces the heat-island effect created by black roofing and asphalt. Concrete reduces the energy demand upon commercial and residential air conditioning systems and increases energy efficiency. Homes and offices are by far the greatest consumers of energy. LEED (Leadership in Energy and Environmental Design) has become a popular building management program. LEED certification for owners certifies that the building completed is energy efficient and sustainable to a specific level.

Green Concrete

Shelby Materials offers recycled fly ash and slag as alternatives to cement in concrete to help designers achieve LEED points from the United States Green Building Council (USGBC). Fly ash, a by-product of coal plants can be used at a replacement rate of up to 25%, and slag, a by- product of iron blast furnaces, can replace up to 60% of the cement content in concrete.

Many people are finding that concrete with fly ash or slag is not just for LEED certified buildings. Both products help increase the density of the concrete, which increases its durability. Concrete made with fly ash and slag also sets more slowly than concrete made from Portland cement. It continues to gain strength over time and has increased resistance to harmful chemicals. The appearance of concrete made with slag is lighter and usually smoother.

“What surprises some people is that concrete using fly ash and slag is actually better than concrete with cement alone,” commented Wolf. “You just have to know the limitations and understand the differences. We spend a lot of time discussing constructability with the specifiers and contractors. They have a lot of things to deal with and can’t possibly be experts on everything. Therefore, we have put ourselves in the role of concrete experts. We know all about these minute details and are in a position to tell them what is possible with each type of concrete.”

Green by Example

Although several ready mix companies in the area supply concrete with fly ash, fewer offer slag as an alternative; however, no other ready mix company in Indianapolis can boast about having their own reclaiming system for concrete, storm water runoff and waste water.

The Soldiers Memorial at Washington Park Cemeter y contained various t ypes of decorative concrete.

Decorative Concrete was used at this roundabout in Avon on Dan Jones Road .

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Our Indianapolis and Franklin Facilities have unique concrete reclamation systems that allow us to recycle leftover material for re-use benefitting the customer and the environment.

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Gre ystone and Shelby Materials teamed up to complete the Beilouny, luxur y condo living in downtown Indianapolis.

“When our owners came to this site [Beech Grove] in 1999, they spent a lot of money to clean it up to be good citizens,” recalled Wolf. “People had been dumping back here forever. This land is bound on three sides by railroad and other properties so we couldn’t get the typical utilities. That is when we decided to be a clean producer and develop a clean site. Our Beech Grove location is a zero discharge site.”

Because of the municipal storm water mandates, water run off has to be carefully monitored and controlled at the site. Shelby Materials developed a reclamation system that keeps all of the rainwater and sewage on the property and reuses all of the returned concrete. When trucks return from a job with unused concrete, Shelby makes barriers or concrete blocks with the bulk of it, but there is always some unused amount.

“When concrete comes back, we put it into a machine that separates the sand and stone. They go back into a stockpile that is then resold and reused as a fill product,” explained Wolf. “The hazardous part of concrete is the actual cement that is in the water because of its very high pH. We capture the gray water, and we reuse it in our concrete.” Using the reclamation system, Shelby Materials has achieved a “zero production waste stream” at the Beech Grove location. Shelby also utilizes the same system at their Clermont and Franklin plants.

“The benefits are that it gives us one more tool that we can provide to our contractors who want us to adjust the mix for whatever specific conditions they are facing,” said Richard. “In winter, contractors may need the mix to set faster or attain early strength in order to remain on schedule. Gray water, which is allowed by ASTM C-94 specification, makes the concrete easier to work with and clearly gives our contractors advantages. The product really helps. It’s like having another tool in our belt to make the concrete better for a particular situation.”

workability. Alternatively, plasticizers can be used to reduce the water content of concrete (and have been called water reducers due to this application) while maintaining workability. This improves its strength and durability characteristics.

•Corrosion inhibitors are used to minimize the corrosion of steel and steel bars in concrete.

All of Shelby Materials plants have state-of-the-art facilities capable of automated order entry, batching, and moisture control to ensure that each load is batched to meet exact specifications.

Beyond Concrete Aggregates

While concrete is the main product produced by Shelby Materials, it is not the only one. Two sand and gravel plants produce aggregates that are used in the ready-mix concrete business. The sand and gravel plants also provide various fill materials for all types of construction.

Making Concrete Work for you

Slag, fly ash, pigment and gray water are not the only tools Shelby Materials has to increase the productivity of concrete. Chemical admixtures are materials in the form of powder or fluids that are added to the concrete to give it certain characteristics not obtainable with plain concrete mixes. Admixtures are added to the concrete at the time of batching/mixing. The most common types of admixtures (2) are: •Accelerators, which speed up the hydration (hardening) of the concrete. Typical materials used are calcium chloride (CaCl2) and non-chloride accelerators.

•Retarders slow the hydration of concrete, and are used in large or difficult pours where partial setting before the pour is complete is undesirable. A typical retarder is glucose (C6H12O6).

•Air entrainments add and distribute tiny air bubbles in the concrete, which will reduce damage during freeze-thaw cycles thereby increasing the concrete's durability. However, entrained air is a trade-off with strength, as each 1% of air may result in 5% decrease in compressive strength.

•Plasticizers (water-reducing admixtures) increase the workability of ‘plastic’ or fresh concrete, allowing it to be placed more easily with less consolidating effort. Superplasticizers (high-range water-reducing admixtures) are a class of plasticizers that have fewer deleterious effects when used to significantly increase

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Shelby Materials’ sand in gravel mine in northern Shelby Count y

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“We feel it gives us an advantage to control our own aggregate sources,” said Gregg Hebbe, Vice President in charge of the aggregate division. “Obviously, the strength and durability of our concrete are two of the most important properties with which we concern ourselves. However, we feel the consistency and finishability of our concrete are also very important to our success. Our ability to control our aggregates to a greater degree than what is required by specification is an important factor in maintaining that control.”

Shelby Materials typically takes six to eight gradation tests a day, whereas the state only requires one every 2,000 tons. “We’re testing approximately every 500 tons which allows us to have a little more consistent product, and we can tailor it more to what our customers want,” Hebbe explained.

In fact, Shelby Materials is part of Indiana’s stringent CAPP program (Certified Aggregate Producer Program). CAPP designates specific quantities of material to be tested, material test values, test equipment calibrations, and statistical concepts to be applied to control aggregate products at the producer level. In the past, Indiana’s Department of Transportation required that aggregates be tested before each shipment to verify compliance with specifications. This pass/fail specification procedure could delay or even stop shipments to active job sites. The state developed the CAPP program so that producers like Shelby Materials, which meet rigorous requirements, can ship their aggregates out the same day the orders come in.

Athletic and Specialty Products

chemical usage, more days of cart traffic, and potentially even fewer days when the course is closed. “We’re right at that size where we’re still small enough that if a guy wants something that’s a little bit different, we can work with him to get it right, and we are also big enough to have the resources to provide what he needs,” said Hebbe.

Shelby Materials provided the sand needed at The Legends and shortly thereafter to the Brickyard Crossing Golf Course, launching their reputation as central Indiana’s premier supplier of golf course materials. Since then, they have delivered golf course mixes and sand to approximately 100 courses around Indiana and surrounding states. They have also expanded to produce products for other athletic fields such as the practice field of the Indianapolis Colts and the outfield at Victory Field, home of Indianapolis Indians AAA baseball team.

The next challenge for Hebbe and Haehl involved creating a mix for the “green roof ” in use at the Marion County Library. Green roofs are covered with vegetation and soil, or a growing medium, planted over a waterproofing membrane. In this case, the roof was actually at street level and covered the parking garage below.

A mix of drainage aggregate and organic soil was engineered to achieve the specific percolation rates that the designer required.

trucking

In order to haul all of the aggregate material, Shelby owns a fleet of trucks they utilize for deliveries.

When those trucks are not in service for Shelby, they can frequently be seen delivering product for other companies. “We have six regular dump trucks, three conveyor trucks, three semi-tractor trailers, and we maintain a working relationship on a daily basis with other trucking companies. We feel that having direct control over our deliveries helps us insure that our products reach the customer on time,” Hebbe said. “The dump trucks equipped with conveyors have become popular because they are able to place material where a contractor wants it, very close to grade, versus just dumping it in a pile.”

The newly completed Blue River Park provides Shelby County with all sorts of activities. The softball diamonds contain our field

When two of Shelby Materials’ largest aggregate customers near Edinburgh went out of business in the early 1990’s, Shelby needed to find new uses for their products. At the same time, Indiana was experiencing a boom in golf course construction. The Legends of Indiana Golf Course had a specification that required very precise sand for construction of their greens and tees.

Shelby Materials examined the specifications and determined that they could produce the sand needed.

“There’s a lot of science involved in getting the right mix,” said Matt Haehl, sales representative for Shelby Materials at their Shelbyville location. “Most of the golf course superintendents are very well educated; they work hard and do their homework.”

Superintendents have discovered that with sand-diluted thatch and sand accumulation over heavy topsoil, water percolates through the soil profile quicker and more efficiently. Less water is held in the thatch layer, which means less disease and in theory, part of the extra cost of fairway topdressing can be offset by less

Our shooter trucks help spread the aggregate material saving contractors time and money on jobs.

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Septic tanks and Systems

Another service Shelby has developed that people might not associate with a ready mix producer is the manufacturing and installation of septic tanks. Septic tanks are made of concrete so it was actually a natural fit for Shelby to purchase tank molds and fabricate them at the Nashville, Indiana plant. “We load the tanks on boom trucks that go out and just set them in a hole,” described Billy Kirkby, another sales representative.

“Using the boom truck, we can place them in the ground and then the plumbers take it from there.”

When Kirkby became involved with the septic tank division, he soon discovered that some areas of Indiana were not right for the traditional finger system filtration. In places where the soil contains clay, the inability to use traditional septic systems became prohibitive for people wanting to build homes. Kirkby began researching other methods of filtering wastewater and discovered a system being used successfully in West Virginia, a re-circulating sand filtration system. “You can actually clean the water crystal clear and put it right back in the ground,” Kirkby explained.

These re-circulating septic tanks are now used all over the state for residential applications and have started to be used for commercial applications as well. Shelby Materials believed so strongly in the system that they used it at their Beech Grove location, making it the first non-residential system in Indiana. The Beech Grove site had no access to city sewers, and the ground was not suitable for a typical septic system when Shelby bought the land. They installed a re-circulating sand filtration wastewater system, pumping water continuously over a sand bed until the water is safe to recycle. Once cleaned, the water is pumped through ultraviolet light, which kills any remaining bacteria. The water is then sent to the reclaiming system for use as production water as part of their zero discharge program.

Newly constructed Walker Street in Shelbyville Indiana will last at least 20-30 years.

fast, and economical. Today, RCC can be used for any type of industrial or heavy-duty pavement.

Joint-free is a new process that eliminates the need for expansion joints in concrete floors.

“Everybody understands that the concrete will crack, so we’re just trying to control it by increasing the amount of fiber per yard,” sales representative Dustin Hartman provided. “You end up with some very small hairline cracks that you virtually cannot see. Stress is relieved throughout the slab, concrete curling and crack repair is significantly reduced, and the construction schedule is accelerated.”

A joint-free concrete floor is just what was needed at St. Luke Catholic Church gymnasium because a high tech synthetic rubber floor was to be installed on top of it. “We needed to be sure the concrete would be free of curling and cracking as much as possible. That’s when we proposed a high tech fiber product for the 12,000 square-foot slab. This product was designed to almost eliminate actionable cracks without crack control joints,” said Robert Haehl, sales representative for Shelby. “We measured the floor flatness/floor levelness of the slab right after the concrete was poured and again four months later before they installed the synthetic floor. No additional curling had taken place after the moisture in the slab was reduced to specification levels for the flooring. It turned out just as we had hoped.”

taking Care of Customers, Start to Finish

A reticulating sand filter in use.

“In West Virginia and Pennsylvania, small municipalities are using the sand filtration systems as part of a public utility in residential sub-divisions,” Kirkby added. “This application is perfect for vacation and lakeside properties that aren’t appropriate for finger systems.”

the Shelby Difference

“We like to be a very hands-on company,” said Philip Haehl. “I expect our sales people to provide the product that the customer wants and solve any of the customer’s problems that come about. It is more than just selling a product. We make sure that our concrete sets in a certain way, that it fits their construction schedule, finishes the way their people like it to finish and provides the end product the way they want it to be.”

It is because Philip and his brother Richard speak from experience that they truly understand the customer’s needs. “We batched concrete, we drove ready-mix trucks, we sold material, and as you go through those things you kind of see what the demands are, what the difference is between doing a good job and a bad job,” Philip continued. “And you learn from that experience. Now we feel like we have a pretty good understanding of what it takes to do a good job.”

“We call ourselves salesmen, but we’re really project managers in this company. We follow the project and are on-the-job representatives,” Ross added in describing his role as sales representative. “We’re usually on the job making sure the logistics are correct, the trucks are on time, and the product is delivered according to specifications. Instead of calling the salesman to get your bid numbers, then the internal QC center to get mix designs, then somebody else if there is another issue, we are a one-stop shop. You have one phone number to call for everything. We have found that this works really well in terms of customer satisfaction.”

“Because we are on the jobsite, if we see something, maybe not even a problem, we can make a suggestion or small change that streamlines things,” continued Matt Haehl. “If they’re successful, we’re successful and that’s what is important.”

Shelby’s sales representatives have the confidence to handle issues in the field because they have been exposed to the resources and the latest information available. Shelby Materials spends time and money on training and development. “We review new products, techniques and procedures. If there is a technical issue, we’ll do the research, capture the consensus, inform, and coach the salesman about the specifics of concrete.

We will review the things that go right and wrong on jobs to help us understand the effectiveness of our decisions,” Wolf explained.

Whether it is joint free floors, roller compacted concrete or any of the more traditional methods, Shelby Materials enjoys educating their customers about their products and processes. Shelby’s primary customer is the contractor who purchases and installs concrete. It is important they understand how concrete reacts to changing conditions. “Weather plays a huge role in how concrete behaves, it is very temperature sensitive,” Richard advised. “When it’s hot, you have to be ready to place it because it’s going to set fast. Some people love that because they want to go faster and get another job done. In the winter, it is exactly the opposite.

Humidity and wind also contribute to how concrete handles.”

By understanding how the concrete will react in different situations, Shelby can advise contractors on admixtures and give them tips on how to get the best finish. Some of those decisions, however, are made even earlier in the process, during the design phase of the project. “We’ll also work with an architect or engineer to find the proper mix designs,” said Ross. “We’ll let them know if we find a specification that isn’t what the rest of the industry typically does.”

“Sometimes, we’ll go back to the specifier for clarity, asking them what they’re trying to achieve and advising them of what is possible” commented Wolf. The desire to work with and help the customer is not just talk. Shelby Materials has spent a great deal of time and consideration in making sure that they are providing the best possible service to customers. They understand keeping the job on schedule is one of the most important concerns their contractors have. “If a contractor has a six-man crew that has to leave in two hours to go do another job, we better have the concrete there on time. If the concrete is not up to strength, and the contractor cannot begin the next phase of construction, other steps in the building process cannot begin and that’s another costly delay,” Richard explained. “Everything about this has to be choreographed well.”

understanding the Future

“We spend a decent amount of time looking at new products and trends that come down the road and try to determine if they fit into our industry and our business,” said Philip. Some of the new trends that Shelby is currently evaluating are roller compacted concrete (RCC) and joint-free floors.

“Roller compacted concrete is hauled on dump trucks, placed in a spreader like asphalt and then it’s compacted with a roller, like asphalt,” explained Richard. Unlike conventional concrete, it is a drier mix – stiff enough to be compacted by vibratory rollers. Typically, RCC is constructed without joints. It needs neither forms nor finishing, nor does it contain dowels or steel reinforcing. These characteristics make RCC simple,

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Shelby Materials provided the concrete for F.A. Wilhelm at the State-of-the-Art Indiana Live! Casino in Shelby County.

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Brickyard Crossing, a premiere golf course used Shelby Materials green and tee mix.

technologically Advanced

To help choreograph the delivery, Shelby has state-of-the-art systems in place including wireless communication between plants and GPS truck tracking. Dispatching of ready-mixed concrete trucks occurs out of Indianapolis, Shelbyville, Columbus and Nashville, and aggregate dispatch occurs in Edinburgh and Shelbyville. The locations can communicate with each other via a wireless communications system engineered

by Aaron Haehl, a recent graduate of Purdue’s Computer Information Technology Department. “One of the trades I learned at Purdue was point-to-point wireless technology. It’s a lot like the wireless network you might have in your house but uses panels that have a focused radio wave, which only talk to each other. We have dishes on top of several 180-foot towers or on top of the silos at our plants, and they are really focused, pointing right at each other to give us the bandwidth we need for communicating securely. We bought the equipment, put it up there, and have no recurrent costs. It has saved us a lot of money and has proven to be much more reliable.”

With this system, the dispatch locations can easily see what each has scheduled and move trucks around if necessary. The coordinated delivery helps insure that trucks are where they need to be when they need to be there. Another way of doing that is through the GPS truck tracking system that has been installed on all trucks. Dispatchers are able to follow trucks along their route and communicate with the customer if any trouble arises. Hartman cited an example of a recent job where that ability came in very handy. “We were pouring one truck at a time and it was going nice and smooth. I had one truck at the concrete pump and another one pulling in as the first one finished. It was perfect, one after another. Suddenly they disappeared, so, of course, I am on the phone. The dispatcher discovers they are all lined up at a railroad crossing, and a train has them stopped. Things like that happen, but the ability to tell the customer why it is happening is extremely important. We have the ability to do that. ”

the Shelby Advantage

Not only does Shelby Materials have the ability, but they also have the desire to take care of the customer.

That attitude starts right at the top with Philip and Richard Haehl and is shared by every member of their team. The Haehls have given their employees the information and tools to make good decisions and count on them to do so. “We like people to be able to perform on their own, without someone questioning their decisions all the time,” Philip commented. “We talk and discuss how we’re going to approach things, but I also think that it’s important for us to hire people that understand our product and can function and make decisions for the betterment of the customer or the betterment of the company.”

The employees appreciate having that confidence in their abilities. “Being able to work for two gentlemen that I feel carry the same attitude that we hold towards our customers means a lot,” said Ross. “It’s not a show. It’s not something we came up with in a board meeting one day, that we want to be a homegrown company. We are. We’re treated that way as employees, and when we’re out in the field, we’re trying to carry on what we get inside to the outside customer. I think it shows. Our customers appreciate that.”

“We want the project to be done and done correctly the first time,” he continued. “It’s the best way we have found to form a good relationship with our customers – provide them with the means necessary to get their project done on time and the way it was supposed to be done. So as far as a business strategy goes, it’s pretty simple at times, but you know the golden rule: treat them as you want to be treated yourself, or in our case, as we are treated.”

With another generation of Haehl children working alongside everyone else and learning the business from the ground up, it appears that Shelby Materials is poised to remain a homegrown business that takes care of customers. They are devoted to their role as an environmental steward, and they are committed to continuing to provide exceptional customer service while advancing the industry with innovative techniques and products.

This home made from concrete survived the devastation of Hurricane Katrina.

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2.

Portland Cement Association, http://www.concretethinker.com Cement Admixture Association. "CAA". www.admixtures.org.uk.

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The Concrete and Aggregate Experts

PO Box 280 Shelbyville, Indiana 46176 Phone: (800) 548-9516 Fax: (317) 398-2727 www.ShelbyMaterials.com

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