Crews with Ivan Rice & Sons typically see daily pours in the range of 20,000 to 30,000 square feet. But things got a little heated on the jobsite recently when owner Randy Rice decided to push his employees to complete a 60,000 square foot pour in one day. "A pour like this needs to be coordinated right to the finest detail," Rice says. "Coordination starts with making sure you are ready to pour - you have the proper amount of ready mix based on yards per hour and you have enough people and equipment on hand."
The Ivan Rice & Sons crews had been working on a 7-inch-thick slab at a 250,000-square-foot manufacturing and warehouse facility for a few days, going about with their average pours. A few things came together toward the end of the project, however, that led Rice to push his crews to finish up the job's remaining 60,000 square feet in one shot. First, his second crew was coming off another job so those men were available for the large pour. Second, time deadlines for the job were starting to tighten and Rice was feeling pressure to finish the slab as soon as possible.
The Ivan Rice & Sons supervisors coordinated with the concrete supplier to haul concrete from two plants to ensure they had the 150 to 170 yards an hour they needed to keep things rolling. They started the pour at 4 a.m. Rice had about 10 guys finishing the slab, and saw cutting started by 2 p.m. Crews were heading home by 8 p.m.
Rice had his second laser screed on the job as backup, knowing this piece of equipment was key to attaining this sort of productivity. "We couldn't have done a job of that size in one day without the laser screed - it saves a lot on labor," he says. "It probably would have taken us three days to lay that amount of concrete without it."
Despite the long hours and need for acute planning, Rice says more pours like this may be in his company's future. "With the lead people and employees I have, I would not hesitate to make pours of this size again," Rice says. "The pour could not have gone any better."
Ivan Rice & Sons is a commercial flooring contractor in Milton, Wis. Ninety percent of its work is floors, while the company also performs exterior flatwork, sidewalks, concrete paving, aprons and loading docks. It also has the equipment and skills to execute superflat floors.
The company has 23 employees and runs two flooring crews. Rice does all the estimating and has a two-person office staff.
Ivan Rice & Sons wasn't always a commercial flooring contractor. Rice's father started the company in the 1950s as a residential foundation contractor. In the 1980s, when the residential market dropped off, Ivan Rice & Sons took a turn toward light commercial work and flatwork and found it an easy sector for growth. It took the company about 10 years to transition into a commercial flatwork company at a level where Rice was comfortable with the client base and his crews' familiarization with the work.
Rice says once you start working in the commercial realm, you get caught up in a snowball effect and growth comes naturally. "When you hit the commercial market you start buying more equipment, and bigger equipment, and then it becomes a necessity to keep that equipment busy. You start growing and growing," he explains.
But jobs just don't fall into contractors' laps for no reason. "Over the years, we've built up customers and worked to keep them happy," Rice says. "They've remembered us and we get phone calls from those customers coming back to us when they have some work. They call me up, let me know about a new project they have and ask me to bid."
Rice has always believed in keeping up with technology in order to keep his crews productive and offer a finished product that customers remember. In the early 1980s he started working with lasers for leveling and finding grades. He says in some cases that type of equipment can allow one man to do the work of three. In 1989 Ivan Rice & Sons bought its first laser screed. "That piece of equipment allowed us to take a lot of the labor out of pouring concrete," Rice says. "And it allowed us to pour more on a per-day basis." Today Ivan Rice & Sons has two screeds, one for each of its crews.