Renowned engine manufacturer Cummins embarked on an 85,000-square-foot expansion of its Rocky Mount Engine Plant in Whitakers, North Carolina, USA. The project required a 16-inch thick slab to support heavy machinery and withstand extensive use. Initially designed as a jointless floor with a double rebar setup, Layton Construction proposed an alternative solution using Dramix® steel fibers that would save time and money, while providing a high-performance floor for years to come.
One major challenge presented by the project was the need to pump concrete over a distance of 800 feet (243 meters) with a heavy dosage rate of fibers. This long-distance pumping could lead to concrete segregation, slump loss, potentially preventing successful of pumping of such distance and compromising the slab’s quality. More importantly, the project called for a jointless slab with heavy machinery loading, which required an efficient and robust reinforcement method.
Bekaert enlisted in a third-party consultant experienced in pumping steel fiber concrete to modify the mix for long distance pumping. To achieve time and cost savings, Bekaert proposed an innovative solution using Dramix® 4D 65/60BG to replace the double mat of rebar. Despite initial reservations from the owner, Cummins decided to proceed with the steel fiber solution. The resulting reinforced slab displayed enhanced structural integrity to successfully withstand the demands of heavy machinery used in engine production. Dramix® reinforcement cut project time by 20%, reduced costs, and delivered durable floors, earning positive feedback from Cummins. Indeed, the owner decided to use Dramix® on another expansion at the site. Moreover, the local Layton Construction team was so impressed that they are promoting Dramix® solutions to their other offices throughout the USA.
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