Construction Heat

Thaw and Cure - 500,000 Square Foot Commercial Warehouse

Challenge
Construct the $60,000,000.00, 500,000 square foot warehouse and distribution facility starting in November, with the majority of the project occurring as a winter build.

Objective
Fast-Track the project completion to 9 months. One of the major components of this build was concrete. Working with traditional winter construction methods meant delays and the possibilities of concrete carbonizing/dusting, cracking, or heaving. Ways of preventing these risks and to accelerating the project schedule needed to be explored.

Solution
ICS Group was brought in to review the project plan and schedule to propose a solution. ICS recommended a process utilizing Portable Flame-Free Climate Control Equipment that addressed the following objectives:
  • Control environment to accelerate schedule
  • Save fuel
  • Eliminate fire risk
  • Provide clean emissions free heat for workers
  • Eliminate concrete carbonizing/dusting
  • Reduce the possibility of concrete cracking or heaving
  • Allow overhead work during ground thaw
The project was separated into thirds with smaller sections within. This allowed the utilization of the walls, insulated roof and hoardings to contain heat during this three-phased progression. The central heaters were positioned around the perimeter of the structure and ground thaw hoses were connected. Upon completion of each ground thaw vertical tarps were fastened from the roof as a hoard to confine the area to hold heat. Then the ground thaw hose and tarps were moved to a new section, and fan forced heat exchangers were connected in place of the hose to supply heat for the groundwork, concrete prep, pour, cure and interior work. This process allowed simultaneous thaw, heat, and cure. Eventually the central heaters and heat exchangers were supplying heat to the entire 500,000 sf structure.

Result
ICS Group contributed significantly by providing a controlled environment to meet the aggressive Fast-Track project schedule of 9 months from what would have normally been 12 for this type of project.

See Ellis Don Reference Letter

Additional Resources