Stephens & Smith Foundation and Flatwork recently joined Ultimate Thermal Contractors to construct a large cold storage private warehouse in Omaha.

Work on the 55,000-square-foot Omaha warehouse facility began in October and has since entered the completion stage. Quick thinking and communication between parties expedited the project significantly and decreased contractor overlap, according to Ultimate Thermal Project Manager Ron Callahan.

He praised the Stephens & Smith team that completed the work one month ahead of schedule and also the precise flatwork that met stringent flatness specifications. Callahan said, “the flatwork crews achieved an overall FF 98 / FL 57, nearly perfectly flat. “Flatwork hit an accuracy mark that was almost unachievable,” he said. “We couldn’t have asked for anything more.”

The floor was 9 inches thick on low density Styrofoam with two layers of reinforcement. All slab concrete had to be pumped/placed through a hose system through an overhead door. Utilizing a laser screed was the only way to achieve “Superflat” strict flatness specifications. In order to utilize a laser screed with the two layers of reinforcement in place, an aluminum bridge system had to be used along with a lot of pre-planning and coordination amongst the crews and other trades. Gary Ebert, Flatwork Division Manager said, “the project’s success can be directly attributed to much of the pre-planning and organizing in pre-pour meetings. Flawless execution of the pour plans by the crews paid off with a finished slab that met the owner’s high standard of expectations.”

Project Manager Ryan Sadil said grade beams were originally scheduled to be completed after the steel was erected and the building was enclosed, but it would have required placing all concrete through an overhead door. As a result, the team worked with the contractor to find an alternative plan. “Ultimate Thermal allowed us to place the majority of the interior grade beams ahead of the steel work,” he said, “completing a quadrant of the building while the steel was installed in another.”

Sadil said about 2,700 cubic yards of concrete was used for the footings and foundation walls, with 93 pile caps and approximately 2,600 cubic yards of concrete was used for the structural slab, elevated slabs, curbs, and paving. 

A well-done joint effort by S&S crews!