The Challenge
The new Fedex® Ground Distribution Hub in Middleton, Connecticut, would be one of the largest contruction projects in the state of Connecticut. The scope of the project included over 300,000 square feet of segmental retaining wall block built to maximum heights of 60 feet - making it one of the largest and tallest SRW projects in North America. "Due to the size, complex installation and overall scope of the wall project, we knew right from the start it would have to be a collaborative effort by all to be a success story." said Chip George, General Manager for Earth Retention Systems, LLC.
"The general contractor Manafort Brothers, Earth Retention Systems, Advantage Engineers and the ANCHOR DIAMOND℠ team all worked together to make that happen."
The project broke ground in May 2016 and according to representatives at FedEx, is part of a nationwide expansion resulting from the exponential increase in the number of daily packages shipped over the last 10 years. The 260-acre site would house a 525,000 square foot main hub building, alonog with a maintenance garage and salt storage shed.
The Solution
The project involved an astounding 2.5 million cubic yards of earthwork that required six retaining wall structures, encomopassing over 11,000 linear feet of SRW to re-grade, stabilize and optimize the site. The project also called for over 650,000 square yards of Mirafi geosynthetic reiforcement.
Oldcastle worked with the project's retaining wall design engineers during the design phase to secure the Vertica® Retaining Wall System with Mirafi geosynthetic reinforcement as the basis of the SRW design for the project.
"The design of the masive walls needed a proven system such as Vertica Wall with Mirafi georgrid reinforcement," said Scott VOllmer, SRW Market Manager for APG New England, an Oldcastle company. "Vertica's four degree batter was another advantage of the system and allowed for optimal site layout."
"Vertica Wall was shown to be a viable product that could hold up to the structural needs of the prpoject, look good for the client, and hit all of the other marks in terms of competitive price and a demanding square-foot per-day delivery timeline." said Joshua Krebs, Advantage Engineers/Project Designer.
The Results
APG New England, an Oldcast company, was selected as the exclusive provider of the retaining wall and geogrid materials using the Cranston, Rhode Island plant to manufacture the SRW units. "This selection was based on competitive price, proximity to the project, technical support , manufacturing capabilities, and the overall resources to supply a large project on a tight time frame." Vollmer said.
"We worked closely with BL Companies (site civil engineer) to help optimize the retaining walls in context with the overall site design. APG New England was helpful in providing technical resources and were very responsive to everyone's needs throughout the process." Krebs added. "From a delivery strandpoint, the materials were provided on the scheduled timeline that was needed.
As of July 1, 2018, the entire segmental retaining wall proejct was completed to the customer's satisfaction accomplishing one of the biggest and most complex SRW applications in North America. "I'm very proud of all the companies and individuals who helped make this one of the most successful SRW projects within the Oldcastle family," said Greg Piper VP of Sales for APG New England.
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