Loading Dock Apron Modification

Project Details

FedEx Freight contracted with Millstone Weber (MW) when it's 209-bay service center located in St. Charles, Missouri, experienced settlement of the concrete approach aprons around the perimeter of the facility. The entire 40 ft. wide perimeter ribbon of concrete was to be removed and replaced in 11-bay increments to avoid impacts to FedEx daily operations. After removal of the existing pavement, the site was undercut and stabilized with a large stone section. A perimeter trench drain, incorporating the existing roof scuppers, was installed to capture storm water sheet flow and divert the runoff through a series of manholes and storm sewer pipe to the existing lagoon. The new pavement section consisted of base aggregate and 8" reinforced concrete. During the modification process, MW discovered the T-Dock portion of the facility had experienced footing settlement and was shearing the interior reinforced concrete slab. A relief section of the interior slab was removed, and the footings were pinned and jacked using helical anchors and hydraulics to ensure no further settlement could occur. Despite challenging subsurface conditions and adverse weather, this project was completed 1 month ahead of schedule and under budget, with no interruptions to FedEx daily operations.