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Three Mat Pours Blog Photo Collage - The Conco Companies

Saturday, August 24^th was not your typical day for Conco. While many projects are shutdown for the weekend, this Saturday was one of the busiest Saturdays in Conco’s 60-year history.

The activity began Friday evening in Southern California. Starting at 9:30 PM, Conco began to pump, place, and finish 10,400 cubic yards in downtown Los Angeles on a project known as The Grand. The Grand is a mixed-use project with retail, residential and a hotel across the street from the Disney Concert Hall. The developers for The Grand are The Related Cos. and CORE USA for this Frank Gehry designed structure.

The Grand Concrete Pour

The Grand 10,400 concrete pour was the second of three foundation pours for the structure. Eight concrete pumps were positioned around the foundation to receive concrete at the scheduled delivery rate of 750 cubic yards per hour. In order to supply concrete at this rate, Calportland, with the assistance of Associated Concrete, utilized five batch plants and over 120 concrete mixer trucks.

In addition to the work performed on The Grand, Conco had another large concrete pour on this day in downtown Oakland, CA. Working for the Holland Partner Group, the project located at 24^th & Harrison, site of the old Acura dealership, will comprise of luxury apartments with retail and other amenities.

Before placing the concrete, Conco was responsible for fabricating and installing all the rebar. Comprised of mainly #11 bar, more than 4.1 million pounds were needed for the entire mat foundation.

24th & Harrison Concrete Pour

The 24^th & Harrison project by the Holland Group was the second of two foundation pours at the site, requiring 7,300 cubic yards of concrete supplied by Central Concrete out of five concrete batch plants. Prior to pouring the concrete, Conco provided the fabricated rebar and installation. The challenging site necessitated that six concrete pumps (five were active at any given time) be used with a scheduled delivery rate of 600 cubic yards per hour being delivered by 120 concrete mixer trucks. The concrete pour began at 1:00 AM.

950 Market Street Concrete Pour

Furthermore, in addition to the Los Angeles and Oakland pours, a mat foundation pour also took place simultaneously in San Francisco, CA. The project at 950 Market Street will be a mixed-use development consisting of housing, a hotel, retail, and a dedicated non-profit space. This project is being developed by Group i, a San Francisco-based real estate development company. Working for the general contractor, Pankow Builders, Conco also fabricated and installed the rebar for the foundation. More than 1.7 million pounds were needed to be put in place prior to concrete placement for the entire foundation.

The mat pour for the 950 Market Street project was the first of two for the site and was supplied by CEMEX out of three concrete plants. A total of 3,195 yards of concrete was pumped, placed and finished by Conco through three concrete pumps that were supplied at a scheduled rate of 300 cubic yards per hour.

For the activity in three separate markets to transpire, multiple internal and external meetings were held to discuss every facet of activity associated with making each concrete pour a success. For Conco, success comes from developing the proper plan and executing that plan. Items such as safety, concrete mix designs, pump placement, street closures, individual company responsibilities, and contingencies are just a few of the details that must seamlessly be ironed out.

The resources that were used and vital statistics for Saturday, August 24, 2019 were:

	The Grand Los Angeles	24 & Harrison Oakland	950 Market San Francisco	Total
Concrete Placed	10,400	7,300	3,195	20,895
Concrete YPH Placed	750	600	300	1,650
Square Feet Finished	41,000	44,800	18,000	103,800
Mixer Trucks Used	120	140	60	220

With the combined effort of Conco, our customers and suppliers, all three projects finished on time with only 5 extra yards of concrete for all three projects combined. More importantly, all were completed without so much as a first aid claim.

Large mat foundation pours require extensive planning and collaboration with customers, suppliers, public agencies and various other third parties. Conco’s success is dependent on everyone doing their part and we at Conco are thankful to work with great customers and suppliers day in and day out, who give us the opportunity to succeed.

Marin General Hospital - The Conco Companies — Design rendering from http://mgh2.org/.

The Conco Companies is providing concrete services for the Marin General Hospital Project in Greenbrae, CA. The modernized four-story, 260,000 sq. ft. replacement building will offer 114 private rooms and 6 new operating suites. The $535 million, state-of-the-art project is being developed by the owner Marin Health Care District and is designed by Perkins Eastman Architects, DPC. The general contractor on the project is the San Francisco based McCarthy Building Company and the structural engineer is KPFF. The SWA Group, also based in San Francisco, is the landscape architect.

Conco was selected for the project due to a longstanding relationship with the general contractor, McCarthy Building Company who is familiar with our extensive experience on hospital projects as well as our understanding and commitment to the project. We began work on the project in February 2017 and will complete our responsibilities in July of 2018. Some of the special challenges of working on the replacement project entail constructing an OSHPD project that when complete, will meet or exceed the latest state-mandated standards for earthquake safety. The new building is also being constructed as a best-practices environment to provide the community with an updated hospital building that will have the ability to improve patient outcomes.

Each hospital room is designed larger than normal to accommodate state-of-the-art imaging equipment and robotics. In addition all of the 114 private rooms, including the 19 intensive care units will have floor-to-ceiling windows made from high performance glass and sunshades. Amenities such as rooftop gardens, balconies, and the natural light in all of the patient rooms are designed to support a healing environment for both the patients and their families. The building will be open to patients in 2020 and is expected to meet LEED Silver standards.

At The Conco Companies, we are one of the leading concrete contractors in the Western U.S. and offer a wide range of quality services and products. Our experience includes providing services for commercial, educational, parking and other construction development as well as public works projects. We serve California, Washington State, Oregon, Colorado and Nevada.

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The Conco Companies are busy finishing up work on a new 11-story hotel in downtown San Francisco. The 701 3^rd Street Hyatt Place project is near AT&T Park and is being developed by its owner, the Four One Five, LLC c/o Stonebridge Companies. The general contractor is Charles Pankow Builders and the architect is Stanton Architecture. DCI Engineers is the project’s structural engineer. The 230 room, 103,000 sq. ft. hotel is expected to receive LEED Platinum certification for features that include a grey water system, vegetated roofs, and highly sustainable mechanical systems.

Conco began work on the project in May of 2017 and expects to finish in January, 2018. Our job responsibilities included providing concrete reinforcement, pumping, formwork, finishing, shotcrete and Design/Build services. We were selected for the job due to our understanding and commitment to the project as well as our longstanding relationship with the general contractor, Charles Pankow Builders, who is familiar with our high standards. The project has provided challenges along the way due to the logistics of its close location to AT&T Park as well as its aggressive schedule; and we are proud to say we have been more than able to meet all of the challenges.

The building will offer a landscaped public courtyard at ground level as well as a terrace on the 9th floor and a vegetated rooftop terrace that are reserved for hotel guests. In addition there will be approximately 2,000 gross square feet of ground floor retail space and 15 below‐grade off‐street parking spaces. As the majority of construction in San Francisco recently has been office buildings and apartment towers, hotels are in high demand and a new hotel development will be most welcomed.

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The Conco Companies is providing a full range of concrete services on the 4th & Madison apartment project currently under construction from the San Francisco based owner and developer, Carmel Partners. The builder on the 90,000 SF project is CP Construction West, Inc., and the architect is KTGY Architecture + Planning. Located in Oakland’s Historic Jack London Square Waterfront Warehouse District, the project consists of two buildings directly across the street from one another.

Building “A”, which will be seven stories and offer 240 housing units, is within the Historic Warehouse District so it was designed with “boxcar-like” elements that evoke the district’s activities. It will also have a total of 3,000 square feet of retail space with each of the building’s corners flanked by a shop or restaurant. Building “B” is not required to conform to the historic guidelines so KTGY designed it with a more contemporary look that “references a dynamic stack of shipping containers and the “boxcar” look of Building A.” It will offer 90 housing units that include configurations such as an extra loft and two-or three bedroom floor plans.

Conco’s responsibilities on the project include providing concrete pumping, reinforcement, formwork, finishing, shotcrete, and Confoam™ services. During the course of the project we expect to place 19,000 cubic yards of concrete as well as shotcrete and Confoam™. We are also providing 1,050,000 pounds of rebar and PT reinforcement.

The residents of 4th & Madison will have a full array of amenities available including a fitness center, pool and spa, demonstration kitchen, multipurpose room, media room, sky terrace and BBQ area, and much more. In addition the new buildings are conveniently located approximately a half-mile from the Lake Merritt BART light rail station.

The architect, KTGY Architecture + Planning, has already won a Gold Nugget Merit Award for the project in the category of “Best on the Boards Multifamily Community.” Additionally Conco is excited to be working with Carmel Partners, a company “focused on sustaining a culture committed to the principles of responsibility, integrity and alignment of interests.”

Conco is one of the foremost suppliers of concrete services for the Western U.S. We got our start in 1959 in the Bay Area by offering clients the best value on a broad range of concrete services and products. Since that time, we have taken a leading role as top concrete contractors in the region. We have regional offices serving California, Oregon, Nevada, Colorado and Washington.

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Just one year ago, on November 8, 2015, The Conco Companies completed the 12,000 cubic-yard mat pour for the new Salesforce Tower and set a record for the largest continuously pumped foundation in San Francisco’s history. Now one year later, Conco is proud to report that we successfully completed the final core wall pour and have topped off the concrete portion of the 1,070’ office high-rise to officially make it the tallest building in San Francisco.

The video above is a timelapse depiction of the last full core wall lift. The self-climbing form system used at Salesforce Tower in San Francisco is a unique construction method that has allowed for a pour cycle, also known as a “lift”, to be completed once every 3 days. This self-climbing form system is secured to the existing concrete wall below. It then raises itself in increments of 15 feet. Each section of this system, exterior and interior, move independently of the others. The less complex exterior sections take 20 minutes to complete a jump and the larger, more complex, interior system takes roughly 45 minutes to jump. When the jump is complete, the panels are aligned and secured allowing for the walls to be closed and a pour to take place. Due to a combination of characteristics from the concrete being poured and from the system itself, the cycle is able to begin again just 6-8 hours after the pour takes place.

Accomplishing this tremendous feat required exceptional organization, management and execution on the part of the entire Conco team from the very top, right down to our dedicated rebar, formwork, pump operators and placement crews. The support, partnership and collaborative effort of Clark/Hathaway Dinwiddie, a Joint Venture, the project’s general contractor, further contributed to our success. We also acknowledge the cooperation of our other trade partners, our concrete supplier CEMEX, and the project owner, Boston Properties.

To effectively and efficiently pump concrete to the upper floors of the Tower, we used the most powerful concrete stationary pumps in the industry. Furthermore, the fast-paced schedule required us to complete two floors a week, which meant a 3-day work cycle for each floor. The accelerated pace left no room for error and took the efforts of our whole team.

The building’s 14-foot 9-inch floor-to-floor heights allow for approximately 13-foot unfinished ceilings. Conco’s crew used high-strength self-consolidating concrete inside the core walls and lightweight deck-fill concrete on all floors.

Last November’s massive 12,000 cubic-yard mat pour produced a foundation that rests on 42 load-bearing elements (LBE’s) drilled 265 feet down into bedrock. The extensive site work also required more than six million pounds of reinforcing steel, mostly consisting of #18 bars (2.25 inch diameter), woven into the 14-ft. thick mat.

In addition to our extensive concrete services for the Salesforce Tower, Conco topped off the 73-story Wilshire Grand in Los Angeles earlier this year as well as placing the building’s 21,200 cubic-yard foundation in February of 2014. Conco is honored to play such a significant role in these remarkable skyscrapers that will be the tallest structures in their respective cities and the two tallest buildings west of the Mississippi River.

Salesforce Tower Conco Companies Concrete Construction

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Salesforce Tower San Francisco - Conco Companies

Conco is a leading supplier of concrete services for the Western U.S. We got our start in the Bay Area in 1959 by offering clients the best value on a wide range of concrete services and products. Since that time, we have taken a leading role as one of the top concrete contractors in the region. We have four regional offices serving California, Nevada, Washington, Oregon and Colorado.

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