Supplied to Fowler-Flemister Concrete, the ready-mix producer for the project, and produced at Arcosa’s Livingston, AL plant, the expanded clay material provided designers flexibility, the necessary strength, and reduced weight. The end result is a more durable and versatile performance space designed to meet the demands of a state-of-the-art facility.

The NewDay USA Center of Leadership, located on the campus of Georgia Military College (GMC) in Milledgeville, Georgia, is a 28,937-square-foot facility that brings world-class learning and performance opportunities to both the college and the local community. The center features a 753-seat theater with Broadway-level production capabilities, a full orchestra pit, and classrooms designed to foster dialogue with leaders from various fields, including business, public service, the military, sports, and the arts.

Concrete for the Stage and Orchestra Pit

According to Alan Deariso, vice president of sales and technical service at Fowler-Flemister Concrete, the elevated stage and lower pit area is comprised of metal decking and approximately 17 yards of lightweight concrete.

“The architect specified a semi-lightweight concrete with a plastic density of 120 pounds per cubic foot,” he says.

“In terms of constructing a suspended slab, the steel framing must be able to support the weight of the slab plus the live load, which in this case includes performers, props, and other stage needs.”

This was the first time Fowler-Flemister used Arcosa’s lightweight coarse aggregate. “In the past, we used a different lightweight aggregate that was not as light as the Arcosa product,” Deariso notes.

The Mix Design

The mix design for the project included Arcosa’s structural coarse aggregate, which is heated in a kiln to about 2,000°F and then graded to meet the ASTM C330 3/8” by #8 grading specification. The aggregate is then pretreated with sufficient water to achieve a saturated surface dry (SSD) condition. While the material is not completely saturated, the permeable voids inside the aggregate particles are filled with water, necessary to make the concrete pumpable.

The day before the pour, prewetted material was delivered late afternoon to Fowler-Flemister’s ready-mix plant. This minimized drying of the aggregate prior to batching. The next morning, the concrete was batched, a minor slump adjustment was made, and the final product was delivered to the site.

At the job site, the concrete was tested for slump, density, and air content, and compressive strength test cylinders were prepared before the concrete was released to the contractor. The concrete pumped smoothly with a 5-inch slump and a density of 121 pounds per cubic foot at the time of placement. The project was completed in four hours.

Fowler-Flemister Concrete

Just-in-Time Inventory

Arcosa’s lightweight structural coarse aggregate was delivered to Fowler-Flemister using the Just-in-Time (JIT) Inventory method. This means the aggregate was delivered pre-soaked with water, alleviating the time and expense for Fowler-Flemister to prepare the aggregate before batching the concrete.

“It’s extremely important for lightweight aggregate to be properly saturated,” says Paul Altznauer, technical sales representative for Arcosa Lightweight. “Aggregate that is not delivered in a pre-wet state will take time to properly prepare as the stockpile must be watered, soaked, and turned to get sufficient water into the aggregate. But with the Just-in-Time method, the aggregate can be used the day it is delivered.”

Because the material was properly saturated ahead of time, Fowler-Flemister produced concrete with less slump loss. This method also provided cost savings, as it reduced labor costs needed to water and turn the stockpile, as well as minimizing the need for water, storage, sprinkler systems, and cleanup associated with runoff.

“We eliminated that timeframe and labor. The soaking process was already taken care of by us,” Altznauer said. “We do the work for you. It’s a simple process that can make a big difference in the ready-mix plant and on the job site.”

A Major Community Investment

On September 12, 2024, General James N. Mattis, the 26th United States Secretary of Defense, headlined the grand opening of the NewDay USA Center of Leadership. The NewDay USA Foundation, the largest donor to the facility, is dedicated to supporting leadership development for military families and the broader community.

The center’s state-of-the-art theater and performance space are a testament to the collaboration between Arcosa Lightweight, Fowler-Flemister Concrete, and the project’s architects and engineers. The use of lightweight concrete allowed the construction team to meet the project’s demanding specifications while delivering a durable and versatile venue for future performances and events.