LP2 Project Team Executes Monolithic Concrete Pour Over 13 Hours With Zero Injuries

December 11, 2023

In late October, Messer successfully executed a monolithic mat slab concrete pour for the foundation of a new pharmaceutical manufacturing building located within the LEAP District in Lebanon, Indiana. Two shifts of self-performance teams pumped, placed and finished 5,548 cubic yards (24 million pounds) of concrete over 13 continuous hours with zero injuries.

The effort required 584 concrete trucks (roughly 44/hour) from five batch plants, as well as 1,070 tons of rebar.

Leaders from Operations, Craft and Safety collaborated with key partners to coordinate and plan the pour—resulting in zero injuries not only on the day of the pour, but also for all of the work leading up to it. Ongoing quality inspections also proved valuable for the proper installation of the mat slab foundation.

Technology bolstered the hands-on work through modeling how the pour would unfold with the placement of each of the trucks, as well as creating an app to log concrete trucks’ arrival onsite and their turnaround time at each pump. We also utilized a third-party mass concrete expert to help monitor and control internal concrete temperatures to prevent excessive surface heat loss and achieve more uniform curing results.

Once complete in 2026, the building will manufacture cutting-edge gene therapy treatments. Check out more of Messer’s Science and Technology market segment experience.