Case Study: Hankook Tire Expansion
EXCELLENCE IN CONCRETE CONSTRUCTION - OUR FOCUS ON THE MANUFACTURING INDUSTRY
Martin Concrete Construction Partnered with Clayco and Concrete Strategies on the Hankook Tire Expansion Project in Clarksville, TN. This manufacturing project involved heavy-duty concrete and meeting the specific needs of a manufacturing environment. Concrete scope included the construction of three deep pits, a multi-level pit and nine elevated concrete platforms all presenting unique technical challenges. The project was characterized by a fast-paced timeline and complex coordination requirements.PROJECT SCOPE: HEAVY CONCRETE
The project involved several unique and technically demanding aspects, especially the construction of the large pits. These pits ranged in depth from 14 to 20 feet and featured thick mat slabs (3 to 5 feet) while some areas near sump pits were up to 8 feet thick. Mass concrete was required for one of the pits, which necessitated temperature monitoring with sensors to ensure proper curing. Additionally, the pit lids ranged from 3in, 8in and 14in thick concrete, which also included integrated beams to handle varying load requirements.SUPPORTING EQUIPMENT NEEDS
In total, the project involved nine cast-in-place elevated mechanical platforms. These platforms, each with 3-foot thick slabs, were designed to support heavy industrial equipment and machinery. Another critical feature was a multi-level pit structure that connected to the existing facility. The bottom level of this pit was 25 feet deep, the middle level was 10 feet deep, and the top level was a slab on grade. Ensuring seamless integration with the existing building required careful coordination across multiple levels. In addition to the new construction, formwork was installed for an elevated mechanical platform within an existing pit inside the facility. This task demanded precision, as it involved working within an already operational space.
complex challenges
Several challenges arose during the project, the most significant being weather delays. Due to the deep excavation, much of the work was conducted in pits, and frequent rainfall turned these work areas into deep pools of water. This caused delays, as work could not proceed until the water was pumped out.
The project operated on a tight schedule, which required intense coordination and the use of multiple crews working on different shifts to keep progress on track. In response, the team implemented acceleration plans to expedite the completion of certain areas, helping to mitigate delays caused by weather and other factors.
Another major challenge was the constant design development. To date, 63 new drawing packages were issued, each requiring quick adaptations and revisions to the existing work plan. This added complexity and required diligent communication between teams.
Staffing and Coordination: The project was staffed with an Assistant Project Manager (APM), Field Engineer, and On-site Quality Representative who worked closely with the team to manage the daily workload. This on-site leadership ensured that the work was well-coordinated and that issues were handled quickly. Daily and weekly project meetings were held to review progress, discuss potential obstacles, and align the efforts of the entire team. These meetings, organized under the Safety, Schedule, Quality, Production Plan (SSQP), helped maintain momentum and ensured everyone was focused on common objectives.
Communication and Coordination: Concrete placement plans, pump placement plans, and Definable Work Phase meetings were coordinated with and communicated promptly to all parties, ensuring better coordination between subcontractors and general contractor, Clayco. The Finish Safe representatives played a key role in facilitating safety training across different trades, which helped improve collaboration and created a stronger team culture on site.
Strategies and Solutions
The Hankook Tire Expansion was marked by significant technical challenges, rapid design changes, and a demanding schedule. Despite these obstacles, the Martin Concrete project team successfully navigated these hurdles through effective leadership, detailed planning, and a collaborative approach to problem-solving.
Working side by side with the Clayco and Concrete Strategies teams proved to be a testament to the importance of proactive collaboration and communication. This project serves as a model of how large, complex industrial construction projects can be successfully executed.
