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Loudoun County Parks

Delivering Modular Durable Unit for a Loudoun County Park

Smith-Midland Corp. recently manufactured, delivered and erected an EASI-SET precast concrete modular restroom/concession building for Loudoun County at the Byrne’s Ridge Park in Aldie, VA. Loudoun County was searching for a durable, maintenance-free yet cost-effective solution to issues that are often associated with park sites; vandalism and maintenance challenges.

The first of several restrooms ordered was a 24 ft by 30 ft six-toilet restroom with concession area. The building was cast by SMC with split-faced block exterior wall and cedar shake roof finishes. The building was erected at SMC’s yards in three 24 ft by 10 ft modular sections. The modular sections were then outfitted with components including lights, breaker panel, water heater, hand dryers, grab bars, toilets, partitions, sinks, baby-changing stations, mirrors doors and a roll-up concession window. Stain and anti-graffiti control were added at the factory along with an anti-slip epoxy floor paint.

The modular sections were delivered on three separate tractor-trailers to the park site and were off loaded onto a level, compacted stone foundation using a 90-ton crane. The primary challenge during the installation was to ensure that the three modular sections lined up with one another within a tight ¼-in. tolerance. A feature of the EASI-SET precast concrete restrooms offer is that the roof and floor sections are post-tensioned longitudinally which ensures that the three modular sections are held together under constant tension. The roof and floor are, in effect, single diaphragms, eliminating the need for a roof membrane to prevent water infiltration, SMC tied the electric and plumbing between the three modular sections together at the site and hooked the building up to the site electric and plumbing systems. Loudoun County now has a restroom/concession building that offers it freedom from dealing with constant durability and maintenance issues.

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North Fork Pump Station

Building Codes and Budgets Converge

The challenge was to design a pump station that not only met tight budgeting and scheduling requirements, but also adhered to strict building appearance codes to conform to the guidelines of the gateway zone they are located in on the major approach road into historic Albemarle County.

As part of the $10.7 million North Fork Regional Pump Station project, Virginia’s Albemarle County Service Authority (ACSA) demolished the existing Camelot Wastewater Treatment Plant and their Research Park pump station. The construction of two remotely located regional pump stations replaced the out-going stations. The two are located across from each other on the busy Route 29 divided highway and are joined by 1,500 ft of 12-in. force main. Each pump station includes emergency standby generators, instrumentation and SCADA systems.

ACSA met their budget in part by specifying an Easi-Set precast concrete transportable building. The design called for a brick finish with a metal standing seam roof. Cost-savings in materials were achieved by using an Easi-BrickTM grid in the Smith-Midland Corporation precast plant to simulate brick on the 10 wall panels that comprised the 20-ft x 30-ft buildings. This method also produced savings by removing the cost of on-site masons. The design also called for a non-standard height of 13 feet. The use of 13-ft-high precast wall panels simplified construction and eliminated the use of a knee wall. Delivery and assembly of the wall and roof panels was completed in only two days, saving weeks over on-site construction methods.

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Wilderness Wastewater Plant

Smith-Midland Awarded $350,000 Contract Company to Provide Eight Precast Concrete Buildings to Improve Wilderness Wastewater Plant

SMC manufactured and installed eight precast concrete buildings as part of an overhaul of the Wilderness Wastewater Plant in Orange County, Va. Worth more than $350,000, the new buildings will allow the two million gallon-per-day plant to meet enhanced nutrient removal requirements.

“The buildings will serve a variety of purposes,” said Matthew Smith, Vice President of Sales and Marketing at Smith-Midland. “We will deliver five Easi-Set precast concrete buildings measuring 12 feet by 16 feet and 12 feet by 20 feet that will house pump stations and electrical equipment. Three larger Easi-Span buildings, measuring 14 feet by 30 feet and 30 feet by 40 feet will house a return sludge pump, administrative offices and restrooms.”

Easi-Set and Easi-Span precast concrete buildings have been manufactured by Smith-Midland Corporation for almost 40 years. Fabricated as separate wall, roof and floor panels, the buildings feature the patented Easi-Set post-tensioning system in the roof and floor, a turn-down roof that caps the walls, and a step-down floor panel to eliminate the possibility of water migration into the building along the bottom of the wall panels. Easi-Set buildings are virtually maintenance free, are available in a variety of sizes and finishes, and are fully customizable. They are typically assembled at the plant, delivered to the customer's site and installed on a concrete slab or gravel pad in a matter of hours.

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Department of Defense

12-Building order via GSA Contract

Smith-Midland Corp. recently delivered twelve 12’ x 20’ x 8’ Easi-Set Buildings to the Department of Defense (DOD). “After initially pricing the buildings with delivery to Blossom Point, MD, the DOD changed the location to Crane, IN. The job went to bid and SMC was awarded the order worth over $300,000 (12 buildings outfitted, delivered, and set)”, said George Sharikas, Sales Manager at SMC.

Six of the Easi-Set Buildings will be used as office space, for shop space, and two providing hazmat storage. All buildings incorporate epoxy coating on the interior surfaces as well as HVAC systems. Most contained a standard electrical package, some had roll-up doors, while the hazmat buildings included explosion-proof electrical packages. The buildings were assembled and outfitted in Midland, VA and delivered by truck in three shipments of four buildings each. The low-boy trailers required flag cars for the 650-mile journey. Harold Cross, a senior SMC truck driver made all three trips, oversaw the delivery, and assisted with the setting of all of the Easi-Set Buildings.

If not for SMC’s GSA contract, this job could easily have gone to a competitor. If you are an Easi-Set/Easi-Span Building producer and are not on GSA’s Schedule 56, you should look at the benefits of doing so. If you have any questions about the GSA process, give us a call and we will be happy to assist you in getting started.

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Lake Wappapello

Smith-Midland completes recreational lake restroom project in Missouri within a tight time frame and budget

The U.S. Army Corps of Engineers contracted precast concrete manufacturer Smith-Midland Corp., to complete a time-sensitive, 750-panel restroom project.

Smith-Midland Corp., has completed a restroom project at Wappapello Lake that truly showcases the beauty and adaptability of precast concrete. The $865,000 U.S. Army Corps of Engineers project in Wappapello, Mo., encompassed 750 architectural precast panels, multi-colored fieldstone, and batten board siding.

Nestled in the foothills of the Ozark Mountains on the St. Francis River in Southeast Missouri, Wappapello Lake offers activities for all walks of life. Completed in 1941, Wappapello Lake annually provides an estimated $3.9 million in flood protection to agricultural lands and developed areas along the St. Francis River.

The Wappapello Lake restroom project was fairly routine for Smith-Midland with one exception: all 15 restroom buildings had to be finished within 60 days or less due to the looming Labor Day holiday. “It was a pretty tight timeframe for the number of pieces and structural intricacies involved,” said Scott Fiore, the Smith-Midland sales associate who initiated and managed the U.S. General Services Administration (GSA) contract.

Up to the challenge, Smith-Midland developed five different floor plans and then began making the 750 24-foot by 20-foot precast panels in accordance with the project owners’ custom exterior finish requests. Fiore said Smith-Midland was selected for the Wappapello Lake project based on the company’s 50-year reputation in the precast business, commitment to quality, and reasonable pricing. “We have experience with these types of buildings,” Fiore added, “so the project owners knew that they were going to get exactly what they asked for.”

Sequoia Britton, Smith-Midland’s buildings installation manager, said the panels were installed by a local general contractor who was able to accommodate the short completion schedule laid out by the U.S. Army Corps of Engineers. Part of the challenge, said Britton, involved transporting the huge precast pieces from Virginia to Missouri. “There were a lot of unknowns and possible roadblocks that could have come up during the trip,” remarked Britton. “To make sure there were no kinks, we put a lot of time and effort into the scheduling and transportation arrangements.”

Once onsite at Wappapello Lake, the 750 precast panels were installed in three phases with most of the heavy rigging and lifting managed by a local crane operator. “One of our foremen and I went to the jobsite and oversaw the entire process,” said Britton. “Everything went very smoothly and the customer is pleased with the results.”

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