When the Frederick News Post located in Frederick, Maryland built a new three-story office building and newspaper production facility, a site analysis concluded that the soil conditions were not adequate to support the weight and size of the 100,000 square foot printing and distribution facility, while maintaining the settlement design tolerance. To support the foundation, Menard provided an innovative design-build solution for Controlled Modulus Columns (CMC)® rigid inclusions as an alternative to compaction grouting and piles for foundation support.
The site analysis showed that the site had poor soil conditions with very soft layers of compressible fill and soils on top of karstic limestone commonly found in the area and characterized by sinkholes.
Menard proposed an innovative CMC rigid inclusions solution to support the building columns and the slab-on-grade floors, as well as cap grout the top of the karstic limestone.
Menard designed a ground improvement program utilizing on-board monitoring to cap grout the fractured layers on top of the limestone while simultaneously creating 12.5-inch diameter CMC Rigid Inclusions. The automated system — installed on the pump and inside the rig — guaranteed the constant monitoring of the grout pressure and volume, ensuring the filling of any voids and openings in the upper rock surface and reducing the risk of sinkholes.
More than 2,200 CMC rigid inclusions were installed at a maximum depth of 40 feet for a total of over 30,000 linear feet. Menard completed the installation in a 38 day production schedule.