Cell-Crete Corporation

Cell-Crete has participated in various stadium projects, including the SoFi Stadium in Inglewood, CA and the Chase Arena in San Francisco, CA. Currently, Cell-Crete is also working on the new and upcoming stadium in Las Vegas, NV. It’s expected to seat 65,000 people and will have a roll-in natural grass field with artificial turf placed directly on the stadium’s concrete floor.

Cell-Crete performed work on a plaza of a stadium using a hybrid solution of cellular concrete and expanded polystyrene (EPS) board to fill in the interstitial space from a structural concrete metal deck substrate that required a lightweight fill with variable depths. A topping slab will be placed after the hybrid system has been installed. This solution offers a combination of a lightweight solution and rapid construction as the cellular concrete can easily be sloped to finish to achieve the required final elevations without the need to cut custom pieces of EPS board.

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Sunset Las Palmas

Sunset Las Palmas Studios has designed a collaborative office space for creatives right next to their studio in the heart of Hollywood. We were contracted to ensure that their project met building fireproofing codes. Known for our solid reputation, we also deliver the best customer service and help clients meet their fireproofing design requirements.

Blaze-Shield, a Portland cement-based Spray Applied Fire Resistive Material (SFRM) was used to fireproof the structure. Known for its environmentally friendly characteristics, Blaze-Shield’s inorganic material formulation does not promote mold or fungal growth. Other benefits include excellent thermal and acoustical insulation properties. We finished the job in a timely, professional, and clean manner.

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US 89 Farmington to I-84

As part of an initiative to improve Utah’s infrastructure, for the US 89 Farmington to I-84 project, a 54’’ pipe was inserted into a culvert under the U.S. Route 89 Highway. The culvert was over 40 years in age. Lightweight cellular concrete was used to fill the area between the pipe and the culvert to lock it in place.

Our Cell-Crete team had to overcome the challenge of an elevation change of over 10 feet. Multiple lengths of PVC pipes were run along the ceiling of the culvert to fill the annular space. This method helped guarantee that all voids were filled. Our crew worked diligently and successfully accomplished the project in less time than the contractor had allotted, saving the project time and money.

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ESR Ridge Oak Drive

Contact grouting is the process of filling or sealing voids between two surfaces in contact with each other. These voids are often created unintentionally during a tunnel or shaft excavation and need contact grouting to achieve a tight contact between the structures to help prevent ground settlement.

For this project in Los Feliz, Cell-Crete performed contact grouting on the outside perimeter of the shaft. We used lightweight cellular concrete (LCC) to fill this space between the outside the dirt. LCC was a solid choice for this type of project because in addition to filling the void, we were able to create ground stabilization around the shaft as well.

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Tahoe Echo Summit

Caltrans was tasked with repairing and rehabilitating the bridge at Echo Summit in late 2019. The project included removing the bridge deck and replacing it with a new, reinforced section as it winds around the bend at the summit. Before the bridge deck was removed, the abutments that held the bridge deck up needed to be reinforced and filled in. Reinforcement came from rock anchors drilled into the mountain side as well as cellular concrete poured into the voids all around to hold the abutments in line. Cell-Crete installed material for 3 days pouring in 38-degree weather, with overnight temperatures reaching as low as 9 degrees. With our extensive knowledge and expertise, we were able to install the material while also weather protecting our equipment against low overnight temperatures.

The entire project footprint was limited to the roadway along the summit with a couple of small yards to store material up the road. Using cellular concrete was the only way to bring in a material that would be strong enough and self-compacting without needing a lot of space for mobilization. Cell-Crete set up in one lane and installed approximately 300 cubic yards (CY) of material into the voids. The material was strong enough to hold the abutments in place while work was completed on the bridge deck the following spring.

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The Pier Plaza project in Pismo Beach is a $6 million project that will update the plaza surrounding the pier. The new space will extend the plaza into what used to be a parking lot as an area for a stage. This outdoor section will be reserved to hold future concerts and special events. Other new features for this exciting project will include new bathrooms, a children’s play area, and even a slide that extends directly from the plaza into the sand, as there is a need for ADA compliance ramps.

Cell-Crete Corporation is building the slide portion with lightweight cellular concrete. Essentially, we are filling in the dead space to place concrete over our material reaching from the deck out onto the sand. With our plan, we are able to create a slope of 25%, and we can finish a total of approximately 1500 cubic yards (CY) within only 12 days of pouring. Cellular concrete reduces the overburden pressure on the existing subgrade with poor bearing capacity, eliminating the need for traditional ground-improvement techniques.

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This project is a rehabilitation of a portion of the Joint Outfall “F” Unit 3, a reinforced concrete pipe by constructing concrete encasements around the existing siphon structure. The trenchless rehabilitation will help provide the ideal flow capacity for many years.

Cell-Crete was contracted to fill this annular space for the 72” fiberglass pipe involving 143 linear feet (LF), which approximates to 40 cubic yards (CY) of lightweight cellular concrete (LCC) in total. LCC is a great choice for annular space grouting because it protects against shock and corrosion, but it can also be easily pumped through small openings and long distances at lower pressures due to its lightweight nature. Another benefit to using this material for filling annular spaces is because of its ability to reduce buoyancy, decreasing the chance of pipe damage.

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About The Resorts World Las Vegas Project

PROJECT LOCATION

Las Vegas, Nevada

Resorts World Las Vegas

Along the Las Vegas Strip, this multi-billion-dollar project was previously the site of the Echelon Place construction and the Stardust Resort and Casino. Construction for the Asian-themed Resorts World Las Vegas project is planned to feature a 3,500-room property, a 5,000-capacity theater, 350,000 sq. ft. of meeting and event space, and much more.

The Solution

The Resorts Project opened its doors in June 2021. Cell-Crete has poured approximately 1,000,000 total sqft of Lightweight Insulating Concrete (LWIC) Roofing system which helped keep the GC and our customer Eberhard Roofing right on schedule for the project’s upcoming opening which is a great example of how LWIC can give back time on construction schedules.

For Eberhard Roofing, Cell-Crete is installing Elastizell Lightweight Insulating Concrete to help create a slope to drain while also providing the customer with an R-value. We are installing Elastizell Lightweight Insulating Concrete on most roof decks around the tower and the tower roof. Our company was chosen because by using our system and our foamed concrete, in addition to providing slope, R-value, and the lasting lifetime of the building, we are able to install at a much quicker rate than the standard roofing/waterproofing installation. This ultimately gives the customer added time on their schedule.

Since this was previously the site of the Echelon Place that stopped construction, there were many areas on the existing deck that were left uneven and depressed. We are able to flatten and infill by installing Maxxon’s Duracap and Commercial Topping Gypsum product as a way to provide the GC with a flat surface to set the framing on or to leave exposed with the installation of various floor coverings and an epoxy over the top of our finished surface.

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About The Project

Initiated in 2014, this design-build construction project took place at a grade-separated interchange. This helped to improve the efficiency of the Bangerter Highway and Redwood Road corridors by helping reduce the traffic volume and delays at this intersection.

For this job, fill heights reached up to 25 feet and the lengths of the walls were up to about 500 feet. This project’s main purpose was to reduce load/vertical effective stresses below the yield stress at depth in fine-grained layer(s). Sites were over-excavated, and Cell-Crete replaced the native deposits with lightweight cellular concrete (LCC) below mechanically stabilized earth (MSE) walls. As a result, the construction schedule was accelerated and long-term settlements were reduced. The design approach for this project included treating LCC as an embankment material and the structure needed to be designed as a traditional/typical length of MSE wall reinforcement. Ribbed metallic straps was the type of reinforcement used for this project, and there have been no reported performance issues or concerns to date.

About The Project

This design-build construction project was initiated in 2015. This transportation project involved widening the roadway near a large existing/historic utility vault. Overall, it helped improve mobility and reduce congestion along the I-15 freeway.

For this job, fill heights reached up to 12 feet with the length of the wall up to approximately 100 feet. Similar to the SR-154 at Redwood Road job, the site was also over-excavated and replaced the native deposits. We constructed mechanically stabilized earth (MSE) walls with lightweight cellular concrete (LCC). As a result, the reduced load and earth pressures on the existing utility vault eventually reduced costs because it eliminated the process of vault/utility line replacement and relocation, involving simplified utility agreements and coordination instead. As a design approach, this job included treating LCC as embankment material and designing a traditional/typical length MSE wall reinforcement and segmental retaining wall. The biaxial geogrid was the type of reinforcement used for this job, and no performance issues have been reported or observed for this project.

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Home Depot – Pasadena

The home improvement store chain Home Depot is opening a new retail location in Pasadena. We were contracted to fireproof the building to ensure the store met fireproofing building codes.

Our team sprayed Cafco 300, a Wet Mix Spray-Applied Fire Resistive Material (SFRM). Cafco 300 is designed to provide up to 4 hour fire resistance ratings. This material is commonly used for commercial construction projects and exceeds industry in-place physical performance standards.