The Client
The Walsh Group
The Project
As one of the ten largest construction companies in the United States, the Walsh Group undertook a time-sensitive project at the Detroit International Airport. The project called for reconstructing and, when possible, repairing the airport’s taxiways and 21 apron gate areas at the McNamara Terminal. Plus, the reconstruction of the surface area over the underground Light Tunnel that connects the Terminal’s three concourses. To accomplish this, they needed to demolish 1.1 million SF of 17’’ concrete, equaling 46 Linear miles of saw-cutting concrete to depths of 17’’ thick. While also green-cutting control joints, joint widening, and beveling an additional 40 linear miles of newly poured concrete. All of this needed to be completed without shutting down the airport operations or terminals. At the start of the eight month project, 75,000 linear feet (14 miles) of saw-cutting 17’’ thick concrete over the Light Tunnel had to be saw-cut into 5-foot x 5-foot squares for easy removal. The cutting had to be accomplished in five days.
The Plan
To meet the Walsh Group schedules, Diamond developed carefully thought-out short- and long range plans. The short-term plan addressed the five-day window for saw-cutting of the Light Tunnel surface, while the long-range plan was coordinated to meet the eight-month needs and schedule of the Walsh Group as their work progressed through the airport.
The Process
Diamond deployed 20 saw-cutting techs and 14 high-power slab saws to implement the shortterm Light Tunnel plan. The techs were divided into two 10-man crews, each working 12-hour shifts for five days. In addition, after calculating the blade wear rate, Diamond stored sufficient 20” to 42” diamond-tipped saw-cut blades on-site to ensure timesaving, worn blade quickreplacement turnaround. Working around the clock, Diamond met The Walsh Group’s schedule by saw-cutting 14 miles of 17’’ thick concrete in five days. Over the next eight months—from April to November, Diamond deployed additional crews and equipment to meet the Walsh Group timelines for the entire duration of the project.
The Outcome
By the project’s end, Diamond saw-cut 242,600 linear feet (46 miles) of concrete to depths of 17’’ thick while also green sawing control joints, joint widening, and bevel sawing an additional 210,255 linear feet (40 miles) of new concrete. “This was a very large and logistically difficult demolition, removal, and reconstruction project,” said Chris Reed, Assistant Project Manager at the Walsh Group. “We developed our plan and timeline, and Diamond worked alongside us to finish it on time.” According to Reed, the Diamond team knew what they were doing. “Their crews were professional, and while they worked fast, they did not sacrifice quality. They worked long hours, day and night around the clock, to finish on schedule. If another project needs what Diamond offers, I’d hire them again.”
