Case Farms Protein Conversion Plant

Case Farms Protein Conversion Plant, Winesburg, Ohio

LOCATION

Winesburg, Ohio

Project Highlights

28,000 sf state-of-the-art protein conversion facility
Site excavation and the concrete grade beam/concrete wall construction
124 precast concrete wall panels
8,000 cy of concrete pavement
200,000 sf area of heavy-duty concrete pavement
20,000 lineal feet of underground utilities
Fire and domestic water, sanitary sewer, storm sewer, electric and communication lines
170 augercast piles

Project Description

Facing an aggressive 7-month schedule, Construction Manager at Risk Beaver Constructors, Inc. assembled a team to design, engineer and construct a new 28,000 sf state-of-the-art protein conversion facility for Case Farms Chicken that converts chicken processing remains into animal food, feed or fuel.

Pre-planning of work activities began 6 weeks prior to construction to meet the aggressive schedule. As plans progressed, early soils reports indicated the site was sitting on mine spoils up to 40 feet deep, meaning the foundation system had to be modified to include augercast piles. Constructors self-performed all 170 augercast piles while simultaneously performing site excavation and the concrete grade beam/concrete wall construction.

For the building phase of the project, Constructors set more than 124 precast concrete wall panels. With some as tall as 36 feet, the erection process had to be coordinated daily with other trades performing work. While setting panels, Constructors also installed the precision equipment foundations to support the processing equipment. Exterior building construction included over 8,000 cy of concrete pavement with a 200,000 sf area of heavy-duty concrete pavement surrounding the new facility. Site infrastructure improvements included more than 20,000 lineal feet of underground utilities including fire and domestic water, sanitary sewer, storm sewer, electric and communication lines, and hot water insulated return lines.

Constructors successfully finished erecting their largest precast structure in company history before the scheduled deadline and was asked to remain at the site to construct a 2,800 sf office building and a 3,000 sf maintenance building for Case Farms.

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