Industrial

Ridgeway Gold Mine

600

acres of re-spread topsoil and stabilization

2M

cubic yards earthwork to complete reclamation

1.5M

cubic yards of embankment construction

Ridgeway, SC

KRMC constructed and operated the largest precious metal (gold & silver) mining operation east of the Mississippi. Morgan Corp. was instrumental in the initial development, ongoing operations, and final reclamation of the facility.

In 1987 Morgan Corp. was contracted for the initial site preparation work which included over 1.5 million cubic yards of embankment construction required for the 250 acre Tailings Impoundment. This impoundment is covered with an impermeable clay liner and 60 mil HDPE synthetic liner. Subsequent to the initial phase of construction, Morgan Corp. contracted directly with KRMC for Phases 2, 3, 3A, and Phase 4 projects which incrementally raised the elevation of the impoundment from Phase 1 elevation of 470 to the final, Phase 4 elevation of 560. This increase required in excess of 24 million cubic yards of embankment material, of which Morgan Corp. placed approximately 10 million. The impoundment presently encompasses over 365 acres of area, is approximately 14,000 feet in length, with a maximum height of 190 feet.

In October of 1999, KRMC contracted with Morgan Corp. for final reclamation of the facility after the conclusion of active mining operations. This work included the hauling, placement, and compaction of over 1 million cubic yards of inert armor material for the 365 acre impoundment. It also included the construction of passive wetlands and a one-mile water conveyance channel connecting the North and South Pits. The total earthwork volume required to complete this reclamation project was approximately 2 million cubic yards. Additionally we re-spread topsoil and permanently stabilized 600 acres of disturbed area, placed 11,000 tons of Rip Rap, 71,000 square feet of AB matting, and established the final contours on the two 180 acre mine pits.

Bridgestone Tire Plant

38.5k

square yards of RCC

7.5"

RCC surface layer

Aiken County, SC

This Bridgestone Tire project is a new manufacturing plant located in Trenton, Aiken County, SC. Construction of the facility started in 2011 and included 2 phases. The owner and the design team selected RCC as the pavement of choice for the access and haul roads in and around the plant. Placement of approximately half of the RCC pavements was included in each of the two construction phases.

Gresham Smith & Partners designed the pavement section, which consisted of a 6-inch aggregate base layer and a 7.5 inch RCC surface layer. The base layer was placed by others and served as a temporary construction road. The RCC for the first construction phase was also placed by others. Morgan Corp., working as a paving subcontractor to Kajima Design and Building Group, constructed the RCC for the second phase of the project. This phase of the work encompassed 38,500 square yards of RCC.

Morgan Corp. evaluated several sources of aggregates available nearby and chose materials different from what was used in Phase 1. An RCC mix design meeting the project requirements was selected based on laboratory testing and field performance during the first day of placement. The project was completed within the contract time and within budget. Owner, General Contractor, and the Architect/Engineer of record all expressed great satisfaction with the quality of the RCC placed by Morgan Corp. during the second phase of the project. When asked about the pavement, the project engineer stated, “The current RCC job being done by Morgan Corp. has shown Bridgestone what RCC could be.”

South Carolina Inland Port

57k

cubic yards of RCC paving

30k

cubic yards of cement-treated base

Greer, SC

The South Carolina Inland Port extends the Port of Charleston’s reach 212 miles inland and provides shippers with access to more than 95 million consumers within a one-day drive. The inland port boosts efficiency for international freight movements between the Port of Charleston and companies located across the Southeast.

Morgan Corp. work included mixing, transporting and placing more than 57,000 cubic yards of RCC paving and 30,000 cubic yards of cement-treated base. Approximately one half of the pavement area (97,000 square yards) was 13 inches thick placed in 2 lifts and the other half (85,500 square yards) was 9.5 inches thick placed in one lift. Work also included subgrade lime modification to render the silty subgrade manageable after frequent heavy rain events. RCC was mixed in a RapidMix 600 continuous pugmill mixer and placed with two Volvo high-density paving machines. A three bin blending hopper was used to convey the predetermined aggregate proportions to the mixer hopper. Cement was supplied from two silos feeding directly into the mixing chamber.

In addition to the RCC, CTB and lime modification operations, work included ancillary conventional concrete; railroad crossings, and underground utilities.

Value–Engineered Approach for Fast Construction and a Better Product at No Additional Cost

The subgrade soils at the site consisted of silty Clay and clayey Sand. The pavement design grade was 0.5 percent. The original designs consisted of (1) 14-inch RCC over 3-inch dense graded aggregate base for craneways and handling of loaded containers area and (2) 10-inch RCC over 3-inch dense graded base elsewhere. Based on Morgan Corp.’s extensive experience in grading and sitework, the design posed a major constructability problem because of the pavement design slope, expected rain fall in the area, and the soils encountered at the site. There was no chance for the 3-inch base layer to remain stable under construction traffic after rain events. To have a much better chance of completing the project with a reasonable time frame, Morgan Corp. designed new pavement sections of equal or higher structural capacity at no additional cost. These value engineered pavement sections included a 6-inch cement stabilized soil base layer instead of the 3-inch aggregate base. The RCC thicknesses were reduced from 14 and 10 inches to 13 and 9.5 inches, respectively. The soil base layer allowed placement of RCC within a few hours after rain events as compared to waiting days after rain events had the “as designed” base was installed.

Vogtle Electric Generation Station Units 3 and 4

670

acres of clearing, grubbing, grinding

45

acre parking lot

25%

cost savings in suggestions

60%

increase in structural capacity

Waynesboro, GA

Morgan Corp. provided a total site preparation and pavement package for construction of two new AP1000 Model, 1100Mw Nuclear Power Generating Units, covering over 1,000 acres of land disturbance. The project included laydown areas, craft and management parking areas, access roads, cooling towers, on-site batch plant area, and future switchyard.

Work performed included clearing, grubbing, and grinding of 670 acres; design, construction, and maintenance of a 50-acre multi-staged surface and subsurface dewatering system for two 90-foot-deep nuclear island excavations, as well as construction of 70 acres of roller-compacted concrete pavements over soil-cement pavement base layer.

Notable Details

RCC construction at Vogtle started in 2011 to build an approximately 45 acre parking lot. The original design called for a flexible pavement section consisting of 2 inches of hot mixed asphalt over 6 inches of graded aggregate base. Morgan Corp. proposed a value engineered RCC pavement section consisting of 4 inches of RCC over 6 inches of cement treated soil (CTS) base course. This value-engineered option was approved and used to build the parking lot pavement.

The RCC/CTS pavement section offered the following benefits:

  • 60% increase in structural capacity
  • 25% cost savings
  • 50% reduction in illumination power
  • Fast construction-sometimes opening the pavement to traffic one day after placement
  • Low maintenance and long service life
  • Many sustainability attributes by using in-situ soil for the base instead of mining, processing, and transporting aggregates that are not locally available

Building on the success of the RCC at the parking lot, all remaining parking and laydown areas, access roads, heavy-haul roads, etc. were built with RCC over a CTS base layer. RCC thicknesses used on this project for various loading and traffic conditions included 4, 6, 7, 10 and 18 inches.

Grant Clarendon OSB Plant

850k

cubic yards of excavation

200

acre site development

150k

tons of base stone placed

Alcolu, SC

This was a 200-Acre Site Development for a new OSB Manufacturing Facility. Morgan Corp., with the assistance of subcontractors, installed a 4-stage dewatering system to perform a 45-foot excavation, of which 40 feet were below the ground water table.

This project involved a total of 850,000 cubic yards of excavation. Morgan Corp. placed 150,000 tons of base stone, 8,000 linear feet of storm drainage (18”-42”), and 60,000 linear feet of silt fence. 16,000 linear feet of waterline (4”-16”) were installed. Installation of an on-site septic system included 2,000 linear feet of sanitary sewer lines, along with three lift stations. Morgan Corp.’s sub grade treatment utilized 35,000 square yards of soil cement.

Notable Achievements

Morgan Corp. was able to complete this project, which was contracted for nine months, in less than eight months.