COMMERICAL CONCRETE CONSTRUCTION

At Concurb Concrete, industrial concrete construction requires more than just pouring concrete; it requires absolute precision, unwavering adherence to safety protocols, and a deep understanding of structural dynamics.

Free-standing bridge cranes exert immense dynamic loads, moment forces, and uplift on their foundations.We recently completed a comprehensive bridge crane footing installation for a major manufacturing client. We are proud to report that this complex project was completed one full week ahead of schedule, with a flawless safety record—zero injuries and zero near-misses.

Here is our step-by-step process for delivering a structural foundation that meets the highest standards of safety and engineering.

1. Pre-Construction, Engineering, & Code Compliance

Before a single cut was made in the existing slab, our team collaborated closely with structural engineers and geotechnical specialists. A free-standing crane relies entirely on its footings to resist overturning moments, making the engineering phase critical.

Code Adherence: The structural design was strictly engineered in compliance with the Ontario Building Code (OBC) Part 4 (Structural Design). Specifically, we calculated for dynamic loads and impact factors as outlined in OBC 4.1.5 (Live Loads Due to Cranes) and ensured foundation bearing capacities met OBC 4.2 (Foundations).
Material Standards: All concrete and reinforcing steel specifications were dictated by CSA A23.1/A23.2 (Concrete Materials and Methods of Concrete Construction).
Safety Planning: A site-specific safety plan was developed in accordance with the Ontario Occupational Health and Safety Act (OHSA). We established clear hazard zones, lockout/tagout procedures for nearby active facility operations, and daily Job Safety Analyses (JSAs).

2. Concrete Cutting & Excavation

Because this footing was installed within an existing and operational facility, dust control and vibration management were paramount.

Slab Sawing: We executed precision wet-cutting of the existing industrial floor slab to mitigate airborne silica dust.
Excavation: We excavated the soil to the engineered depth, ensuring the pit walls were safely sloped or shored depending on depth and soil conditions.
Subgrade Preparation: The exposed subgrade was heavily compacted to achieve the required soil bearing capacity (measured in kPa) specified by the geotechnical engineer.

3. Formwork & Steel Reinforcement

The structural integrity of a crane footing lies heavily in its steel reinforcement. The rebar grid must handle immense tension forces caused by the swinging loads of the crane above.

Forming: Heavy-duty wooden formwork was installed and braced to contain the high-volume concrete pour.
Rebar Tying: We constructed complex rebar cages using highly specified structural steel. The cages included heavy bottom mats, top mats, and vertical stirrups tied securely to prevent shifting during the pour.

4. Concrete Placement & Consolidation

With the rebar and anchor bolts inspected and signed off by the structural engineer, we proceeded with the concrete pour.

The Pour: We utilized a high-early-strength, heavily localized concrete mix designed to withstand industrial stresses.
Vibration: Using mechanical concrete vibrators, our crews meticulously consolidated the concrete. This process removes trapped air pockets (honeycombing) and ensures a tight, solid bond against the rebar and anchor bolts.
Finishing: The top surface was screeded and trowel-finished to a perfectly flat elevation to ensure the base plates of the crane columns would sit flush.

5. Curing & Quality Assurance

Concrete does not dry; it cures through a chemical reaction. Proper curing is essential for the footing to reach its designed compressive strength (e.g., 35 MPa or higher).

Curing Process: We applied a specialized curing compound to retain moisture and regulate the temperature of the concrete as it hardened, preventing surface cracking.
Stripping & Backfill: Once the concrete reached sufficient strength, forms were stripped, and the perimeter was backfilled and compacted.
Final Handover: Cylinder tests confirmed the concrete exceeded the required strength parameters. The site was cleaned, swept, and handed over to the steel erectors seven days ahead of our contracted deadline.

Commitment to Excellence

Delivering a heavy industrial foundation requires an unwavering commitment to quality. By strictly adhering to the Ontario Building Code, executing rigorous pre-task safety planning, and utilizing highly skilled tradespeople, we were able to deliver this critical infrastructure efficiently, safely, and ahead of schedule.

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