Concrete Mixing Plant in Queens, NYC, USA

The structural analysis and detailed design of the foundations for silos, gravel bunkers, dust extraction systems, and water collection basins was a complex task. The design of the columns for a conveyor belt system that had to be placed above an existing building was particularly challenging. The main foundation slab was reinforced with several layers of heavy reinforcement.

The most important challenge in the finite element analysis was to find a solution for the deep foundation for the heavy equipment (silos and gravel bunkers) that was not possible due to local conditions. The ground water level was too high, which would have required costly groundwater-related subsidence and retaining walls. Piles were not an option, as even micropiles could not reach the bedrock at this location. Furthermore, it was necessary to place the foundation directly next to an existing building, which would have required massive underpinning work for a deeper foundation.

To solve these problems, a shallower foundation concept measuring approximately 20 m x 15 m (65.6 ft x 49.2 ft) was developed that did not affect the neighboring structure. Nevertheless, it withstood very high vertical and horizontal seismic forces.