2025 DCC Award Winner
Legacy Builders - Rudolf Hanger, Carolina Bomanite Corportation, Whitsett, NC
First Place: Cast-in-Place - Stamped, Under 5,000 sqft

300 word Narrative - Legacy Rudolf project: This initial project meeting was during covid, over a video conference with the Designer and owner. An original layout for the hanger/barndominium was determined and samples produced. The scale and purpose of the project allowed for a modest budget. We were chosen for our attention to detail and craftsmanship. It was determined that a bonded topping slab was best, in order to allow for normal construction traffic prior to the finished pours. Random cracking of the structural floor slab created additional crack repair work for us consisting of epoxy injection and grinding prior to our scope. The site, situated back in a large wooded tract, allowed for easy access in dry weather, but difficult after rainfalls. Since this was a post covid build, availability of the special order aviation door caused significant delays. During initial conversations with the Builder and owner, there were concerns about the ability of a sophisticated remote controlled landing platform to easily navigate over the door threshold and over the slate textured surface without disruption to the helicopter. Attention was given to allow for a soft 'skip' trowel over the texture after imprinting in order to knockdown the high edges. The owner was instrumental in performing several rescue missions shortly after Hurricane Helene in WNC. He mobilized his helicopter to Asheville, NC to assist in locating missing members of a family after being moved by a friend's Facebook post. His initial flights not only inspired others, but created a landing zone used for months at a Harley Davidson location. This group of civilian and ex-military pilots were nicknamed the "Redneck Air Force"

Project Specifics: The concrete portion of the project was approx. 3666SF with 2791SF either imprinted or textured. The imprinted sections were as follows: Main storage area 2467SF - 3" bonded topping slab with a 3' ocew composite rebar grid poured using a 3600psi small stone mix. The concrete was colored using Davis integral 860 pigment at a rate of 5#/CY. The surface was textured using Bomanite Slate Texture skins using liquid release. The antiquing was Black EZTique at a 1oz per gal of water ratio. A saw cut pattern approx. 42" was used for structural as well as aesthetic purposes. This allowed for multiple contraction jointing thus eliminating post pour random cracking. The base sealer was a 20% solids solvent based acrylic with a 20% water based acrylic topcoat followed up with 2-3 coats of a sacrificial wax prior to owner occupancy. Woodplank Walkway 324SF - This area, which started at the front door and led to the owners retreat, was poured first in order to establish elevation and ease of detailing for the installation crew. Nail holes were added using the back of a marker in order to add detail. The coloring was Brickform Walnut and the imprint tools were Bomanite 12" Boardwalk Plank using liquid release. After cleaning the walkway received special coloring of Mojave, Mission Beige and Terra Cotta from EZTique. The overall wash was Brownston from Bomanite. The same sealing process was used as the Main areas. The perimeter joints were sealed with an urethane joint sealant to match. Auxiliary Area 875SF - It was determined from the owner that the remainder of the storage area needed to be a nicer finish. An 800 grit grind and polish w/densifier was used in this space to compliment the entire space. General Contractor - Legacy Building Group Designer - Carolina Bomanite Corporation, John Fletcher Concrete Supplier - Chandler Concrete, Burlington, NC Submitted by - John Fletcher, President Carolina Bomanite Corporation