MARTINSBURG WV    -     On Friday, October 10, 2008, a part of the Essroc New Line Coal Clinker Storage Hall project required a single pour floor slab of 5370 cubic yards of 4000 psi concrete. A lot of planning went into pulling off the largest pour in Potomac Construction Industries, Inc. history. Plant staffing for 25 consecutive hours had to be scheduled including concrete mixer drivers, plant operators, loader operators, quality control staffing and yard laborers. The scope of work was to provide 220 cubic yards per hour for 25 hours. To do this, PCI used two dry batch concrete plants, Martinsburg (Plant 5) and Williamsport (Plant 7), to accomplish the hourly production rate. PCI was able to rent trucks and drivers from other area concrete companies, Valley Quarries, Titan and DuBrook. Also, some temporary employees with CDL licenses were contracted for the pour. A total of 29 mixer trucks per hour were needed to accommodate the production rate.

On the jobsite, entry and exit routes were determined weeks in advance to help expedite the delivery of concrete to two 47-meter concrete pumps. The prior planning helped make each truck round trip time more efficient during the pour. Keystruct employees had clearly marked the entry and exit routes and helped with traffic control for the PCI mixer drivers.

Also, raw material inventories were built up over a one-week period and staged at both plants. Approximately 1800 tons of cement was used for the pour and South Berkeley Hauling was very instrumental in keeping the cement flowing through both plants for the duration of the pour. Over 5000 tons of coarse aggregate was used and over 3000 tons of fine aggregate was needed for the pour.

This was a major accomplishment for PCI and its employees. It showed what proper prior planning and a whole lot of teamwork could accomplish. PCI is very proud of all the people that were involved in making the pour a success.
A photographer captured a few of the moments here.