Beyond The Fence - Episode 4 - Concrete Cake - Austin Texas Construction Documentary

In episode 4 of Beyond the Fence, we tag along with Flintco and Keystone Concrete to learn what it takes to form, pour, and finish the final concrete slab of the project, the roof slab. Learn what it takes to get concrete poured 535 feet above the Rainey District of Austin, Texas.

Join us next time for a look into the extraordinary topping out celebration at 44 East Ave!

BTF Ep.4 “Concrete Cake”

There’s just something dramatic and satisfying about building a skyscraper.

Especially when you get to the top.

It starts with a soaring vision, a striking design, a set of blueprints, and a well-orchestrated construction plan.

It takes a special breed of men and women, working dawn till dusk, day in and day out, to build the extraordinary.

We’re taking you Beyond the Fence, 535 feet sky high with Flintco and Keystone Concrete to show you what it takes to form, pour, and finish the level 50 roof slab at 44 East Avenue.

CONCRETE CAKE
Pouring a concrete slab and baking a cake have a lot in common.

Both require a special batter.

Specific ingredients and other additives.

Plenty of mixing.

A pan or form to achieve the desired shape. And time to bake the cake or cure the slab.

But that’s where the analogy ends.

COLUMNS
Before the team begins work on level 50, the supporting columns are framed and poured.

Planning, prefabrication, and experience keep the process moving quickly.

A vibration tool helps the concrete batter settle, adhere to the steel bones inside, and deliver an appealing finish.

After the columns are poured, the framing crew install the falsework - the temporary structure that supports the pan, and stripped away once the concrete is cured.

SHORING
Activity on level 50 is fierce.

Banging hammers and ripping saws are like a rock and roll rhythm section with a beat that drives the team as they frame, deck, and form the structure.

Unique to the roof slab, prefabricated steel beams are embedded in the deck to support the building’s massive cooling towers.

PREFABRICATED STEEL
With the bottom of the formwork complete, and the steel beams placed according to the drawings, edge forms create the sides of the “cake pan” and keep the heavy concrete batter – weighing in at 150 pounds per cubic foot – contained.

After edge forms, steelworkers, also known as rodbusters install the rebar.

REINFORCEMENTS
With the late afternoon sun kissing the Austin skyline, Keystone Concrete is driving toward final inspection, and placing the concrete batter into the buildings “cake pan” for the final slab.

THE FINAL POUR
Typically, a high-rise uses an 800-horsepower pump system to deliver wet concrete at a rate of 50 cubic yards per hour.

However, the complex logistics of the level 50 pour dictated a safer approach: bucket the concrete to the top, but at half the speed.

The team starts pouring at midnight to avoid traffic, keep the concrete flowing, and avoid impacts to construction progress in other areas of the building during the day.

Fifty-nine buckets and eleven hours later, the team successfully delivers 176 cubic yards of concrete to the top of 44 East Avenue.

As the final concrete slab cures, post tension cables are stressed, and the ring beams at levels 51 and 52 are poured.

The building is officially topped out.

And that's how you get to the top of 44 East Avenue – level by level, 50 times over – tying 5.6 million pounds of rebar supporting 157 million pounds of concrete.

That’s a lot of cake.

Join us next time to celebrate Topping Out with the men and women of 44 East Avenue who show up everyday, with their passion, vigor, and talent to build the extraordinary.

Because without them we would never leave the ground.

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Beyond the Fence Ep. 4
“Concrete Cake”
Credits

Executive Producers
Flintco Residential, LLC
Intracorp Homes (Texas)
Urbanspace

Producer & Narrator
Tim Garbutt
Flintco Residential, LLC

Director, Cameraman & Editor
John Whitton
Steadybuilt Productions

Script
John Whitton
Tim Garbutt

Music by Vallejo
All tracks from “Brother’s Brew” Used with permission ©2013 Vallejo
“Euphoria”
“Free”
“Better Days”
“Waiting on You”
“Running”

Huge thank you to the Flintco project team and Keystone Concrete for your cooperation and site access.

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