Micron MTV Expansion Plant 4 – 1,000,000-Gallon Liquid Nitrogen Storage Tank Foundation

Key Accomplishments

Johnston Construction Company

• Managed ground-improvement activities including engineering/design coordination, layout and oversight of aggregate pier installation.
• Coordinated installation of aggregate piers extending through controlled fill into underlying disintegrated rock to achieve required foundation bearing performance.
• Performed foundation excavation, dewatering, fill placement, backfill and grading associated with the LIN tank foundation.
• Constructed the specialized double-slab elevated concrete foundation supporting the cryogenic storage tank.
• Installed 46 anchor straps, 24 embed plates and 4 pipe sleeves furnished by others.
• Installed a 3-inch lean-concrete layer beneath the foundation.
• Completed bottom-slab backfill using approved onsite soils.
• Coordinated concrete, reinforcing steel, embedded items, QA/QC testing and foundation construction in accordance with CB&I and Air Liquide requirements.
• Provided engineered review of ground-improvement installation records and as-built pier documentation.
• Johnston Construction Company provided specialized civil and foundation construction services for the Micron MTV Expansion Plant 4 Liquid Nitrogen Plant in Manassas, Virginia. The project incorporated a new 1,000,000-gallon liquid nitrogen storage tank as part of the industrial expansion at Micron Technology's Blue Ridge facility. The project site is identified as 9600 Godwin Drive, Manassas, Virginia 20110.
• CB&I LLC entered into the project's prime contract with Air Liquide Electronics US LP and subsequently contracted Johnston Construction Company to perform the Ground Improvement and LIN Tank Concrete Foundation work.
• The overall tank foundation package was developed for a new 1,000,000-gallon LIN storage tank and included the design and construction of a specialized double-slab elevated foundation. The project incorporated coordinated requirements for earthwork, reinforced concrete and ground improvement beneath the storage structure.

Concrete Services Division

• Performed specialized concrete construction for the new 1,000,000-gallon liquid nitrogen storage tank foundation.
• Furnished labor, form materials, lumber, tools and concrete-related equipment required for CSD’s scope.
• Installed and stripped formwork for slabs, columns and supported slabs.
• Placed approximately 625 cubic yards of concrete across slab-on-grade, column and supported-slab foundation components.
• Finished concrete surfaces through screeding, troweling, pointing and patching.
• Performed concrete curing and associated protection activities.
• Installed approximately 556 dowels.
• Provided labor for setting sleeves and anchor straps as required.
• Coordinated concrete supply, testing laboratory services, concrete pumping and supporting equipment provided by JCC.
• Worked under CB&I, JCC and project-specific safety and quality-control requirements for the cryogenic tank foundation.
• The broader project involved construction of a new 1,000,000-gallon liquid nitrogen storage tank for Air Liquide, including a specialized double-slab elevated foundation.
• CSD's subcontract required the division to furnish the labor, materials and tools necessary for forming and concrete placement of the tank foundation in accordance with the project contract documents, CSD control estimate, CB&I specifications and CB&I foundation drawings. Its defined scope included forming, placing, finishing and curing of the concrete foundation components.
• A substantial portion of CSD's work involved form construction. The subcontract included approximately 425 square feet of slab-on-grade formwork, 3,225 square feet of column formwork, and approximately 3,744 square feet of supported-slab formwork. CSD furnished form-material rental, purchased form lumber and performed installation and stripping of the required forms.
• Concrete placement included approximately 309 cubic yards of slab-on-grade concrete, approximately 60 cubic yards of column concrete, and approximately 256 cubic yards of supported-slab concrete, representing roughly 625 cubic yards of concrete placement within CSD's contracted foundation work.