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Seafrigo Cold Storage Warehouse

Elizabeth, NJ

DESCRIPTION

The Seafrigo Cold Storage Warehouse consists of a 175,000 sf refrigerated warehouse.  The site was the location of a 170,000 sf FedEx Distribution Center constructed in 1967, which was demolished to make way for the new warehouse.

CHALLENGE

Fill and Organic Soils – The geotechnical field investigations revealed a 2 to 12 ft thick layer of uncontrolled sandy fill underlain by a 2 to 12 ft thick layer of organic marsh deposits. Below the marsh deposits at a depth of 10 to 14 ft is a loose to medium dense sand layer.  Shale bedrock is ultimately encountered at a depth of 40 to 55 ft below the ground surface.

High Ground Water Table – Groundwater is encountered at a depth of 3 to 6 ft below the ground surface.

Building Loads –  200 kip column loads and 550 psf refrigerated floor slab loading.

Settlement Tolerances – The refrigerated floor slab was the critical element on the project with total settlement criteria of less than 1 inch and differential of 0.5 inches.  Due the random nature of the uncontrolled and undocumented fill and the high compressibility of the organic marsh deposits settlements up to 7 inches were estimated without ground improvement.

SOLUTION

Grouted Impact® Rammed Aggregate Pier (RAP) elements were installed to provide foundation and slab support for the 200 kip column loads and 550 psf refrigerated slab loading.  This rigid inclusion system eliminated the need for a structural slab, saving the client both time and money. The rigid inclusions were selected since the thick organic soil layer posed the potential problem for long term bulging of a conventional aggregate pier system.  The grouted RAP’s were founded in the medium dense sand layer.  In order to transfer the load from the rigid inclusion to the slab, a load transfer platform (LTP) was used which consists of a 2 to 3 ft thick layer of crushed recycled concrete grade raise fill with a 6 inch gravel pad.  A LTP consisting of a 12 inch thick ungrouted RAP was also used for footing support. (see sketches below)

Grouted Impact Pier - Slab Support - Seafrigo

A Load Transfer Platform approximately 2 to 3 ft thick of recycled concrete fill to raise existing grades overlain by 6 inches of base course well graded gravel was used for grouted RAP’s under the slab.

Ungrouted and Grouted - Footing Support Detail - Seafrigo

 

A Load Transfer Platform consisting of a 12 inch thick ungrouted RAP was used below footings.

A total of 2,900 Grouted Impact RAP elements were installed to a depth of 18 to 20 ft to provide control total and differential settlements for the slabs and footings.

Owner

Seafrigo USA, Inc

General Contractor

Campanelli Construction Company

Architect

RKB Architects, Inc.

Structural Engineer

Langan Engineering & Environmental Services (Civil Engineer)

Geotechnical Engineer

Langan Engineering & Environmental Services

Product

Geopier Impact® System

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