Cell-Crete Corporation

The Fontainebleau Las Vegas is a new hotel and casino currently under construction to be built on the North end of the Las Vegas Strip. Cell-Crete Corporation was tasked with the project to pour Lightweight Insulating Concrete across the roof of the tower. One of the highest pours we have done, the tower sits at 800’ in height and 600’ in length.

Due to shortages in construction and extremely long lead times of tapered ISO Foam board, we were awarded the project due to our ability to install at a fast rate while maintaining quality work with our lightweight insulating concrete.

The Fontainebleau Hotel and Casino is expected to open in 2023.

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How could you fill a void and ensure the material meets the compaction requirements without being able to get equipment under the approach slab? The answer is cellular concrete.

The plan selected by the contractor was to slide the bridge into place and use lightweight cellular concrete to fill any voids under the approach slabs. This pour required access for hoses to pump the material into the void space. The material would need to be flowable, self-compacting, and have some self-leveling properties.

The fill depth was deep enough to require two subsequent lifts. Cell-Crete coordinated with Wadsworth Brothers to open some cores for us to insert our hoses into the void space from the side of the wingwalls and top of the approach slab. These access points and vents were placed in a manner that allowed for our crew to pump the cellular concrete into place without having to incur any lane closures.

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The City Trunk Line South Unit 3 project required rehabilitation of an existing 100+ year old water line located along Whitsett Ave. between Vanowen St. & Magnolia Blvd. in North Hollywood, CA. Approximately 5,300+ feet of the 80-inch waterline has been relined with a new 60-inch steel line by open trench and pipe jacking construction.

The rehabilitation involved grouting the space between the new fiberglass slip liner pipe and the existing RCP with lightweight cellular concrete (LCC), also known as annular space grouting. The LCC helped stabilize the new slip-lined pipe, preventing future corrosion and completely filling the annular space.

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If you have recently driven through Farmington on I-15 or south of Farmington High School, you may have seen three new ramps for the West Davis Corridor. These ramps are formed by using MSE panels and using lightweight cellular concrete as the fill material behind the panels. The sites for the ramps on this project that require lightweight fill are due to the soil conditions. So far, we have poured over 20,000 cubic yards of cellular concrete on this project and the biggest pour is yet to come.

Each site has presented a different challenge, but it has been a pleasure to work alongside Farmington Bay Constructors. Our material has been poured around piles, MSE anchor straps, for manhole abandonment, backfill around pipes, etc. Lightweight cellular concrete (LCC) is being used as a solution for load reduction on the unstable soils, reducing the amount site traffic, allowing for multiple construction activities to continue while backfilling, and eliminating the need for compaction and compaction testing.

Where there are unstable soils that require load reduction, lightweight cellular concrete has been poured. 20,000 Cubic yards have been placed so far, completing our scope on three ramps on the West Davis Corridor. It has been a pleasure working with Farmington Bay Constructors and we look forward to even larger pours coming this fall.

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The City Trunk Line South Unit 3 project required rehabilitation of an existing 100+ year old water line located along Whitsett Ave. between Vanowen St. & Magnolia Blvd. in North Hollywood, CA. Approximately 5,300+ feet of the 80-inch waterline has been relined with a new 60-inch steel line by open trench and pipe jacking construction.

Cell-Crete Corporation was subcontracted to grout the annular space between the existing waterline and the new steel liner. Lightweight Cellular Concrete (LCC) compliments open trench and pipe jacking construction – it is lightweight and flowable which accelerates construction schedules enabling us to grout longer distances with fewer injection points. LCC also can be installed to prevent buoyant uplift and decrease hydrostatic pressure resulting in lower chances of damaging the new liner pipe.

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One of Utah county’s most well-known rivers is the Provo River. This mountain river flows down the valley into Utah Lake. Provo River Diversion is a project associated with water distribution to the public. To route the water to the pump house a new HDPE pipe was slip lined through a squash pipe culvert under 2230 North. Once the new pipe was slip lined into the squash pipe culvert, they needed to fill the annular space between the pipe and culvert.

Using LCC (Lightweight Cellular Concrete) for the annular fill was advantageous for several reasons. This busy street and local businesses remained open while we injected LCC into the annular space. The flowability of LCC allowed us to fill around the pipe to eliminate voids. Our crew was able to batch the material on-site and complete the pour before lunch!

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A historical house in downtown Portland has been slipping down a hill. To prevent future slippage, a retaining wall was required. Lightweight Cellular Concrete was installed to add support to the retaining wall and stop the erosion of the hillside. The location was a logistics challenge. We maneuvered through winding and narrow streets to setup our equipment and pump truck 250’ away from the pour site.

The project required the installation of a retaining wall supported with LCC to prevent the home from further slipping down the hilltop.

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The lower headworks facility in South San Francisco is always growing to support the demand of the metropolitan area it serves. Part of the work involved installing low strength and low-density material in the lower sections of the headworks facility to abandon the structure in place. The area was difficult to reach and required a low temperature installation to protect adjacent structures and utilities.

Our low-heat LCC mix proved to be an excellent solution to backfill and abandon this 40-foot pit section in San Francisco. The abandonment in place saved on demolition costs and will ultimately assist in future expansion and construction of the facility. The LCC was placed in lifts and the low density ensured no adjacent structures were damaged during install.

Due to its high flowability, cellular concrete can travel longer distances compared to traditional concrete.

On this project, Cell-Crete was tasked to grout annular space between an existing casing pipe and newly installed carrier pipe which was put in place to serve the city of Chandler.

Emergency projects to rebuild and repair the water delivery system after the Caldor Fire. The Caldor Fire overtook more than 220,000 acres of area, some sections of El Dorado Canal that delivers water supplies from high elevation lakes, specifically Flumes 4, 5, 6 & 30, were destroyed.

It was very tight access to the job site. The engineer was looking for a lighter and stronger fill material to prevent the landslide. The plan was to have the material exposed permanently. We proposed our class II material with fibermesh and concrete sealer in order to prevent cracking and to prevent any water to penetrate the LCC.