Concrete Make with Arcosa Lightweight Lifts Chicago’s River Point Tower

• Teaser:River Point, a 52-story skyscraper soaring 730 feet (213 meters) above Chicago’s West Loop, stands as a testament to the strength and versatility of lightweight concrete. Completed in 2016, the building features 1 million square feet of office space and is located at 444 West Lake Street, between Canal Street and the Chicago River. The building’s iconic parabolic arch at the base is a result of angled support columns designed to accommodate the unique site.
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  The construction of River Point dispels a common misconception about lightweight concrete: that it is difficult to pump at great heights. Despite the challenging task of delivering concrete 52 stories above the city, crews encountered no issues placing Arcosa Lightweight’s structural concrete across the tower’s floors.

“Lightweight concrete has been pumped some pretty far distances,” says Clint Chapman of Arcosa. “This project is a great example of how, when proportioned and pumped correctly, it can reach impressive heights without difficulty.”

In high-rise construction, each floor must not only support the loads imposed by the levels above, but also meet strict fire-resistance requirements.

“Most lightweight concrete has a built-in fire rating, so it eliminates the need for spray-on fireproofing on the backside of the deck,” explains Chapman. “That’s one of the key benefits to designing with structural lightweight concrete.”

For River Point, Ozinga Chicago supplied lightweight concrete for the building’s slab on metal deck floor system. The mix was specified to reach a compressive strength of 4,000 psi at 28 days and maintain a maximum equilibrium density of 115 pounds per cubic foot. Thanks to its lower heat conductance, lightweight concrete delivers the necessary fire resistance with about one-third less thickness compared to normal weight concrete. Coupled with a density reduction of about 20%, the system reduced floor dead loads by approximately 45%.

The lightweight concrete used in the Lake Street project also incorporated a self-consolidating concrete (SCC) mixture, which employed a high-range water-reducing admixture, three additional chemical admixtures, and Class C fly ash. The purpose of using SCC was to create a concrete mix that could spread without vibration, making it fluid enough for easy placement at the pump discharge. To further reinforce the structure, steel fibers were added at a rate of 35 pounds per cubic yard.

Construction progressed at a rate of two to three floors per week, with an average of about 350 cubic yards of concrete per deck.

The configuration of the pumping system was a unique challenge. All lightweight, fiber-reinforced SCC was pumped using a stationary Schwing concrete pump. The operation required a 5-inch steel slick line with no reducers, but the route to the upper floors included 16 to 18 elbows, adding extra vertical height due to the bends. At the discharge end, a 5-inch rubber hose was used to direct the concrete into place.

“It was a pretty challenging pump configuration,” says Scott Kelly, Assistant Manager of Quality Control at Ozinga. “But it was the best option for going up 52 floors without losing too much slump—and for keeping the concrete workable and placeable.”

According to Kelly, the River Point project didn’t pose any unusual challenges for Ozinga, which has extensive experience working on downtown high-rises. “Staging trucks in congested areas, managing time constraints, and overseeing delivery logistics are routine for us,” Kelly says. “Everything went smoothly and according to specification.”

Designed by Pickard Chilton Architects, River Point earned LEED Platinum certification in 2018, further demonstrating the sustainability of the tower. The building is co-owned by Ivanhoé Cambridge, a global real estate investment firm. In addition to its iconic parabolic arch and striking riverfront location, the tower also features a 1.5-acre public park and a landscaped riverwalk—both open to the public—as required by the City of Chicago.

The success of River Point demonstrates the capabilities of structural concrete in overcoming logistical and technical challenges in skyscraper construction. With its strong fire resistance, reduced dead load, and efficient pumpability, lightweight concrete continues to redefine what’s possible for high-rise buildings.

HydroLite Lightweight Aggregate Plays Key Role in Record-Breaking Structure

• Teaser: Wilshire Grand Center, which stands at an impressive 1,100 feet, is recognized as one of the tallest buildings in the western United States. The project’s engineers needed to significantly reduce the building’s overall weight to achieve this height, which is why they opted for structural lightweight concrete.
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  With over 15,000 cubic yards of lightweight aggregate used in the concrete mix—10,000 cubic yards of which incorporated Arcosa’s HydroLite® vacuum saturated lightweight aggregate—the project achieved not only the necessary height but also critical fire resistance and improved pumpability, allowing for more efficient construction.

The structural design of the building incorporates multiple lightweight concrete slabs, with lightweight concrete poured on metal decking to form the floors and core, spanning over 1.2 million square feet across the entire tower.

Pumping No Issue for Lightweight Concrete

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The ability to pump lightweight concrete all the way up to project’s soaring height was key to the successful completion of the building, which now features 900 hotel rooms, a 70th-floor sky lobby, and 445,000 square feet of office and retail space.

According to Clint Chapman, Western Region Marketing & Technical Manager for Arcosa Lightweight, the lightweight concrete used for the project was pumped at heights of 1,300 feet, with 1,100 feet of that being vertical pumping.

“The fact that our HydroLite is presoaked made pumping it up to the building’s very high floors more efficient compared to traditional materials,” explains Chapman.

HydroLite® is a vacuum saturated lightweight aggregate produced by Arcosa Lightweight. This process allows the aggregate to absorb water, providing improved pumpability, reduced slump loss, and better consistency during placement. The vacuum saturation also enables the aggregate to maintain internal moisture, contributing to better curing and minimized cracking in the concrete.

Chapman also notes that the LWC used for the project also helped achieve the project’s strict fire rating requirements without needing additional fireproofing layers.

Wilshire Grand Under Construction

Placement Team

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Turner Construction, the general contractor, led the build, with Conco Cement Company handling the concrete pumping, and Catalina Pacific Concrete, a division of CalPortland, providing the ready-mix. Arcosa Lightweight supplied the lightweight aggregate for the concrete that was used on the metal decking surrounding the building’s core and elevator towers.

Arcosa’s structural lightweight aggregate was manufactured at its Frazier Park, California plant, with the ready-mix supplier replacing standard weight granite with the lighter HydroLite aggregate.

“The HydroLite reduces the concrete’s unit weight from 147 pounds per cubic foot to just 115 pounds per cubic foot,” Chaman notes.

Exceeding Expectations Through Teamwork

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The Wilshire Grand Center project is a prime example of exceptional collaboration among the general contractor, the ready-mix concrete supplier, the concrete placement subcontractor, the pumping subcontractor, and the lightweight aggregate supplier.

“This project showcases the value of a cohesive team,” says Chapman. “Everyone worked together seamlessly to ensure the success of this monumental build.”

• The Issue: Reducing the building’s overall weight to achieve the height of the tallest structure in the western U.S., while ensuring that the lightweight concrete could be efficiently pumped to extreme heights during construction.
• What Arcosa Did: Supplied HydroLite® Lightweight Aggregate to produce over 10,000 cubic yards of lightweight concrete.
• Why Lightweight Works: Lightweight concrete helped reduce the building’s overall weight, met fire rating requirements without additional fireproofing, and allowed for efficient pumping to heights of over 1,100 feet.
• Result: The use of structural lightweight concrete enabled the successful construction of the tallest building in the western United States, reducing material weight while meeting key fire safety and engineering requirements.
• Key Quote: “The fact that our HydroLite is presoaked made pumping it up to the building’s very high floors more efficient compared to traditional materials.” — Clint Chapman, Western Region Marketing & Technical Manager for Arcosa Lightweight
• Industry Context: Structural and fire safety requirements needed to be balanced with the demand for efficient construction.
• Lessons Learned: Lightweight concrete not only meets engineering needs but also improves project logistics by facilitating easier material handling and placement at extreme heights.
• Call to Action: Learn more about the use of HydroLite® Lightweight Aggregate in high-rise construction at Arcosa Lightweight.
• Project: Wilshire Grand Center
• Location: Los Angeles, CA
• Customer: Catalina Pacific Concrete
• Client: Hanjin Group
• Project Size: 15,000+ cubic yards of structural lightweight concrete on metal deck

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Structural Lightweight Concrete

Additional Case Studies

Sherwin-Williams’ Global Headquarters: Lightweight Concrete for a Landmark Project

• Teaser: Sherwin-Williams is constructing its new global headquarters in Cleveland, Ohio, a development that will feature a two-story pavilion, a 36-floor office tower, and a multi-level parking garage. The project, which will redefine the Cleveland skyline, benefits from the use of Arcosa Lightweight aggregate in the structural lightweight concrete floors of the office tower.
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  “Our lightweight aggregate, manufactured at our Brooks, Kentucky facility, has significantly reduced the building’s floor weight, lowering construction costs,” said Arcosa Sales Representative Jeff Hochendoner.

The expanded shale aggregate was shipped by rail from Kentucky to Arcosa’s Cleveland, OH terminal. Longtime ready-mix partner, Cuyahoga Concrete, a division of the Osborne Company, handled the transportation of the lightweight aggregate to their plant for wetting and stockpiling.

“Kurt Bell of Cuyahoga has closely collaborated with our sales and logistics teams to ensure smooth lightweight aggregate deliveries for this complex project,” noted Hochendoner. “He continues to stay on top of the project’s progress and the evolving material requirements.”

The aggregate was pre-wet and batched at Cuyahoga’s plant near the Cuyahoga River. After delivery to the job site, the lightweight concrete undergoes quality testing and is pumped by Hydracrete Pumping Company, which sends it up multiple stories for placement on the building’s metal floor decking.

Courtesy: Sherwin-Williams Company

Structural lightweight concrete (SLC) offers design flexibility and significant cost savings by reducing dead load, minimizing supporting steel, and allowing for smaller foundations. Arcosa’s expanded shale or clay (ESC) lightweight aggregate has a ceramic composition, ensuring an excellent bond and elastic compatibility with the cementitious matrix of the concrete.

Compared to standard concrete, lightweight concrete using ESC offers superior thermal properties, higher fire ratings, and reduced autogenous shrinkage. It improves the contact zone between the aggregate and cement, reduces micro-cracking due to better elastic compatibility, and enhances sound absorption. It is also highly suitable for pumping applications, providing logistical efficiency on complex projects.

Sherwin-Williams chairman and CEO, John G. Morikis, described the new facility as “a next-generation workplace to serve our customers, retain and attract employees, and offer opportunities to celebrate the Sherwin-Williams brand, while acting as a catalyst for future development around our new campus.”

Cleveland Mayor Justin M. Bibb praised the decision, saying, “The city applauds Sherwin-Williams’ further investment in Cleveland and Northeast Ohio with world-class facilities designed for the workforce of the future.”

The multi-phase move-in process is expected to occur in 2025, marking a major milestone for Sherwin-Williams and the city of Cleveland.

Structural Lightweight Concrete Elevates Houston’s Skyline

• Teaser: Market Square Tower, a 40-story residential building, rises 502 feet over downtown Houston, Texas and features 463 luxury apartments. The impressive height of the skyscraper was made possible through the use of structural lightweight concrete, which allowed the tower to reach its maximum height despite challenging geotechnical conditions.
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  Market Square opened in 2017 as the tallest residential building in downtown Houston. It remains famous for its Sky Pool—a glass-bottom pool that extends 10 feet beyond the building’s edge—offering both breathtaking and thrilling views.

Market Square Tower was designed by Jackson & Ryan Architects, with Guy Jackson, AIA, Principal Emeritus, leading the project. Jackson explains that geotechnical conditions at the site would have limited the building’s height if traditional materials had been used. “It’s a 40-story building next to a 12-story garage I did back in the 80’s and that presented some geotechnical issues with the foundations.”

“We couldn’t go as tall as we did go without using lightweight structural concrete for the frame. We’d be three or four floors shorter if we’d used conventional concrete,” he added.

By reducing the dead load, Arcosa Lightweight’s structural concrete made it possible to overcome these challenges, enabling the tower to rise to its full 40 stories.

Bill Wolfe, Marketing & Technical Manager at Arcosa Lightweight, explains that structural lightweight concrete not only solves geotechnical challenges but also offers design flexibility and substantial cost savings, including reduced dead load, improved seismic response, enhanced fire ratings, and less reinforcing steel. These combined benefits made Arcosa’s lightweight aggregate the perfect choice for Market Square Tower.

This project also dispels a common myth: that lightweight concrete can’t be pumped to great heights. “We have example after example of projects where we’ve done just that,” says Wolfe. “We’ve pumped concrete to over 50 stories in Chicago, and 60 stories in Los Angeles at the Wilshire Grand Project. These examples show that lightweight concrete can be pumped successfully to great heights.”

Wolfe emphasized that Arcosa’s lightweight concrete performs exceptionally well in high-rise applications, where both height and weight are critical factors. In addition to its pumpability, lightweight concrete provided other vital benefits for the Market Square Tower, such as improved fire resistance and reduced structural load, which allowed the building to be taller without increasing foundation stresses.

609 Main at Texas Under Construction, 2015 | Office Tower in Houston, TX

Wolfe also notes another Houston high-rise project, 609 Main at Texas, pumped lightweight concrete several stories and obtained an extra benefit from the use of the product: achieving high compressive strengths.

“What’s unique about 609 Main was the project’s specified compressive strength of the lightweight concrete,” Wolfe says. “It goes as high as 7,200 psi which dispels another myth about lightweight concrete that you can’t achieve high compressive strengths.”

As Wolfe explains, modern pumping technology, combined with a better understanding of how to use lightweight aggregate effectively, has made these advancements possible. Prewetting the lightweight aggregate is a crucial step, ensuring the material doesn’t absorb water during pumping, which helps maintain consistency and minimizes slump loss.

The Market Square Tower and other high-rise projects in Houston showcase the value of Arcosa’s lightweight aggregate in overcoming geotechnical challenges and allowing buildings to soar to new heights. With improved performance, enhanced fire resistance, and the ability to reach high compressive strengths, lightweight concrete continues to be a key material for innovative high-rise construction.