Hospital Expansion is a Milestone for City and Pumper
The Order of St. Francis (OSF) has a long history in Peoria, Illinois going back to 1876 when six Franciscan Sisters established a hospital in a two-story frame house under the direction of the local parish. Today OSF Healthcare is a multi-state corporation still under the auspices of the Sisters of the Third Order of St. Francis. Their Milestone Project is a 440,000 square foot expansion of the OSF St. Francis Medical Center which qualifies it as the single largest construction project ever undertaken in Peoria and one of the biggest contracts Midwest Ltd. Concrete Pumping Service, Rock Island, IL had ever received.
Beginning in August of 2007, General Contractor, Mortenson Construction, Minneapolis, MN initiated site work for the ten story main structure. By the time Midwest came on the project in October of 07, “All we faced was a big hole in the ground according to Beth Langhauser, sales person for the pumper. She would be on the project 2-3 days per week for the next 12 months which was integral to the success of the concrete pumping. “An important consideration is always the level of service from a concrete pumping subcontractor,” according to Dan Sizemore, assistant superintendent for Mortenson, “Beth’s routine presence on the job ensured that she had a personal understanding of the Project. Having a pumping contractor that is involved in the details and logistics of the Project is key to working through challenges that arise.” Mortenson self-performed the foundation and footing concrete work.
Some of the challenges for the pumper included completing foundation pours during one of the tougher winters in Central Illinois, according to jobsite personnel. The Peoria Journal Star newspaper documented it as the second wettest in the City’s history. Additionally, because there was very little space between footing structures it was usually more efficient to form several footings at once. Midwest’s Schwing S 47 SX proved ideal for the task, according to Langhauser. “We needed the 140-foot reach and the ability to set-up where the truck mixers had access. Between the foundations and the decks the 47 pumped 90 percent of the project.” The pump was assisted in its ability to set-up in the crowded areas inside the hole by the Super X outriggers, “ Langhauser stated, “And the tight front outrigger spread (27’3”) lets us use all of the horizontal reach which helped with pouring multiple footings from one set-up.”
Some of the foundation walls were 49-feet high and were pumped with Self Consolidating Concrete (SCC). This material was instrumental in completing the 30′ to 49′ tall walls in single full height pours. SCC eliminates the need for vibrating concrete within the forms which makes placing walls of this size a much more efficient process and offers a high quality finished product. However, along with these benefits comes other areas of concern. Because SCC is a relatively new mix design there is still much to be learned about its use. One specific area that was studied on this Project in conjunction with the University of Illinois, was the increased formwork pressures encountered because of the material’s above normal fluidity. In order to ensure a safe and successful pour, formwork pressures were monitored during several of the foundation wall pours in order to develop a model of the pressures within the formwork. “Midwest’s ability to adjust the pumping rates according to feedback we received from the formwork pressures was a key to ensuring the pours were completed safely,” Sizemore stated. The S 47 SX is equipped with Vector controls which allows the operator to communicate with the pump through the remote box. This exclusive feature helped Midwest’s operator to control the pump’s output during the SCC pumping and form pressure monitoring.
Pumping more than 3,000 cubic yards of the SCC walls often required 10-12 hour non-stop operation. “When you are two hours from the shop, it is real peace of mind to have confidence in your pump’s reliability during these non-stop
pours, “ Langhauser noted. She also credited Midwest owner and ACPA Board member Ed Bauersfeld for providing high quality pumps in excellent condition. “It makes my job easier when I sell a project knowing I have the equipment to back me up,” she adds. The company also owns two Schwing KVM 32-meter boom pumps and a KVM 34 boom pump that were used on the project. “We used one operator for the majority of the pumping on the project,” Langhauser said, “It helps a lot with communication when an operator is familiar with the site and the personalities on the project.”
By April of 2008, all of the 10,000 cubic yards of concrete for foundations and foundation walls was in place and steel erection was completed by August. Scurto Cement Construction Ltd, Gilberts, IL, specializing in industrial and commercial concrete projects, was chosen to place and finish the decks for the eight main stories. A penthouse and a helicopter pad complete the structure. Midwest was again chosen as the pumping contractor. Scurto superintendent of flatwork Randy Aevermann, explained their portion of the project, “The hospital floors are 6-1/4-inch thick concrete decks on metal floor pans. Each tower floor was approximately 37,000 square feet and we chose to pour them roughly one-half at a time.”
For Midwest, it was their S 47 SX that was again called upon to pump the 9,662 yards of lightweight concrete for more than 490,000 square feet of decks and placement of nearly 84,000 square feet of slab on grade with hard rock concrete. The operator placed the tip of the boom on the deck and the crews tied into as much as 200-feet of four-inch system.” The 4,000 psi lightweight concrete with 3/8-inch aggregate was “workable,” according to Aevermann. The finishing crews used a 16-foot strike-off and riding trowels to achieve the correct flatness and finish. “Midwest was very consistent providing the mix when we wanted and at a rate the finishers could keep up with,” he added.
One other member of the Midwest fleet made it to the site. The company’s Schwing BPA 750-18 trailer pump was put into service to pump an elevator core that was boxed in by the steel. The 100-horsepower trailer mounted unit with up to 70-yard per hour output and 1100 psi capability pumped 200 yards of structural concrete over the period of several days. More than 200-feet of system was used which the pump handled with no problems according to Langhauser.
Juggling pumps and handling challenges is all in a days work for a woman who has been travelling four days a week selling and supervising concrete pumping for the past 15 years while also serving on various ACPA committees. Some days are easier than others, Langhauser notes, but the OSF St. Francis project has been a pleasure. “I have so much respect for Mortenson – the superintendents, the project managers and the owners of the company are so professional. This has been a very good job. The pumps did what they are supposed to do and everything fell into place.”
Scheduled to be completed in 2010, The Milestone Project received overwhelming support from the City of Peoria and one its largest employers. A $5 million direct grant from the Caterpillar Foundation was announced at the topping off ceremony. Another $5 million matching grant from the employees and retirees of Caterpillar could generate a total of $15 million for the OSF Saint Francis Medical Center that is committed to the disadvantaged and continues to fulfill the mission begun 132 years ago by six Franciscan Sisters.
Project: The Milestone Project, Peoria, Illinois
Owner: OSF Healthcare System, Peoria, Illinois
Architect: O’Donnell Wicklund Pigozzi & Peterson, Chicago, Illinois
General Contractor: Mortenson Construction, Minneapolis, Minnesota
Concrete Contractor: Scurto Cement Construction Ltd, Gilberts, Illinois
Pumping Contractor: Midwest Ltd. Concrete Pumping Service, Rock Island, Illinois
Pumping Equipment: Schwing S 47 SX boom pump, KVM 32 boom pump, KVM 34 boom pump and BPA 750-18 stationary pump