Cell-Crete Corporation

JF Shea Construction, Inc. was contracted by the San Diego Water Authority to rework the San Diego #28 Flow Control Facility. This project had several underground pipes to be taken out of service. Plans called to fill the pipes with a low-sack sand slurry. These mixes needed additional mix water to be made flowable, and that extra water causes separation to occur (sand would fall to the bottom and water would rise to the top), maintaining a void.

Cell-Crete’s Engineered Fill Division submitted Class II cellular concrete, a very pumpable mix that does not separate. The picture to the left demonstrates the ability of this material to fill a large diameter pipe void-free. Cell-Crete’s abandonment material is being used to backfill the pipe. This abandonment of the underground pipes currently in place would help save the costs of removal in the overall project.

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Located south of the ArcLight and Cinerama dome on Sunset Boulevard, this 3.5-acre project will include a 20-story tower with 193 residential units in addition to office and retail space. Netflix has signed a lease to utilize the office space between three buildings, once construction has been completed. Thus, this will become one of Netflix’s new Hollywood residences.

Cell-Crete had to pour Lightweight Insulating Concrete (LWIC) through and over multiple pieces of conduit lying on the existing deck, but we still were able to manage creating a positive slope to the drain. Originally, this project would have taken weeks to complete with a typical polyiso roofing system, but with our crews, we were able to complete this project within only two days of pouring.

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In the heart of the Las Vegas Strip, Caesars Entertainment continues to reinvent this Nevada city with their newest addition: the 550,000 sq. ft. Caesars Forum Conference Center, featuring the two largest pillarless ballrooms in North America. Countless preparations are being made before this officially opens in 2020. This new convention center required a new plaza requiring up to 12’ of imported soil to match new proposed elevations. However, an existing 11’x7’ double precast RCB would have potentially failed under new fill loads.

Cell-Crete was subcontracted under the general contractor to fill this area for the outdoor plaza right by the new center. Cellular concrete was the chosen material for this gap because it was much lighter than filling the space with dirt. 4’ of (e) fill 120 PCF+ was excavated to expose the top of the RCP and replaced with 12’+ of 30 PCF class II cellular concrete. The lower density of the material reduced/eliminated the added fill loads due to a 12’ increase in fill material over the culvert. The project was originally supposed to take place over a two-year construction, but the timeline was condensed to 18 months, so our team had to work quickly in order to meet the deadline for the grand opening in March of 2020.

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The Orange County Transportation Authority (OCTA), in cooperation with the California Department of Transportation (Caltrans), is widening the I-405 freeway between the SR-73 freeway in Costa Mesa and the I-605 freeway near Long Beach. The project includes making improvements to freeway entrances, exits, and bridges as well as adding one regular lane in each direction from Euclid Street to I-605. New express lanes from SR-73 to I-605 are also being constructed. The roadway pavement design standards being implemented would help produce high-quality pavement. The ultimate goal is to provide shorter commute times and improve traffic congestion in these areas.

Cell-Crete has been subcontracted to fill approximately 52 retaining walls along the I-405, including sections for on- and off-ramps. Lightweight cellular concrete (LCC) is much lighter than typical soil backfill, so this material was chosen to help reduce or eliminate the anticipated settlement of the large fill areas, especially underneath the roadway approaching new bridges. Once the area was excavated and cleaned up, we were able to start pumping and pouring the cellular concrete material. These are being done in 3’ lifts, with the height of the walls being about 20’–30’ high and approximately 525’ from wall to wall with a volume of about 200,000 cubic yards (CY) of the material in total. The density of the cellular concrete is Class II material with the last two feet being Class IV. Lanes will be extended (laterally) about 30’–40’ and ultimately add an additional two lanes (one on each side) to create a total of 6 lanes to help meet traffic demands.

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SchoolsFirst Federal Credit Union

Mask and protect all work areas, spray-on Fireproofing, and clean-up any messes to leave clean areas once our job is complete. Ensure our work meets and exceeds standards by passing all required testing of products thickness, density, and bond strength.

We got the job done in a timely, professional, and clean manner. For this spray-on fireproofing project we used Monokote MK-6. This cementitious fireproofing product has significant advantages, including proven in-place performance and fast, efficient application.

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The Stanford Hospital is currently under construction in Palo Alto, CA. A large portion of the structure features green roofs, specifically the garden roof sections of the building.

Cell-Crete developed and installed the lightweight insulating concrete (LWIC) and paired Insulfoam EPS lightweight roof insulation with concrete to provide thermal insulation. This also reduces the weight from the roof system, which helps prepare for the garden components to be added. The load for the roof garden was supported with the concrete portion of the LWIC, forming a flat concrete deck. The custom-tapered insulation blocks to provide the slope for the drainage. After it was cured, a quarter-inch cement board was installed over the LWIC.

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This residential building in Downtown San Jose has 2 high-rise towers: East and West, each with 23 floors. Cell-Crete installed Siplast Insulcel with Insulperm board. We sloped the flat structural concrete deck 1/4” per foot fall, with an Average of R30 R-value.

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Next door to the new outdoor soccer stadium in San Jose, CA, we recently completed 1, 2, 3, and 4 building exterior walkways using Siplact Insulcel RT and Insulperm board for the Coleman Highline.

Cell-Crete sloped the flat structural concrete decks 1/4” per foot fall. The deck will support a raised pedestal paver system for outside seating and passageway between the 4 buildings.

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The Escondido Village Graduate Residences consisted of 4 buildings with a roof square area of approximately 196,000 sq. ft.

Cell-Crete was brought in by the roofer, ALCAL, as a Value Engineered change to the tapered insulation originally specified for the project. We installed Elastizell Lightweight Insulating Concrete with stepped EPS for sloping and average R30 R-Value. The Elastizell LWIC is the perfect material for the new single-ply roof membrane being installed.

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Siplast Insulcell was installed over a flat concrete deck at 875 California Street in San Francisco. The project was on top of a hill with cable cars going from both north/south and east/west directions. This was a challenge because the job had to be completed without disrupting the cable-car service.

Our equipment setup was complicated because it was only a few feet away from the cable cars on the hill. Fortunately, Swinerton Builders, the general contractor, worked with our crew to provide support and direction that made the job a success without any disruptions.

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