Casey’s General Store | Crawfordsville, IN

ECI Construction Services

General Contractor > Commercial > Commercial

Overview

ECI Construction Services completed one of the largest Casey’s General Stores & Truck Stops to date in Crawfordsville, Indiana, from November 23 to April 24. The 4,569 sq. ft. facility, located at 5139 E. State Road 32, was celebrated with a ribbon-cutting ceremony hosted by the Crawfordsville/Montgomery County Chamber of Commerce. The store oƯers convenience items, fresh bakery goods, pizza, & sandwiches, operating 24/7 to serve the local community. The project totaled 16,080 man-hours with zero safety incidents, with a total contract value of $6,305,527. Of the work, 13.6% (2,187.75 hours) was self-performed by ECI, including site supervision, trim carpentry, & finish carpentry. Despite significant construction challenges, including winter conditions and the need to increase the site elevation by 4 feet, the project was delivered on time and under budget. The project was led by ECI’s Vice President & Site Superintendent, Jerry Tadlock, who has over 10 years of experience working with Casey’s General Stores. His established relationships streamlined communication, expectations, and ensured smooth project execution. His leadership was integral in navigating the challenges and confirming the project’s success.

Innovative Programs: Quality Control

ECI implemented quality control measures for the self-performed portions of the project, including site supervision, trim carpentry, and finish carpentry. ECI ensured consistent quality by conducting pre-installation meetings for each critical task and closely monitoring work as it progressed. For site supervision, Jerry Tadlock coordinated with subcontractors to ensure their work exceeded standards and adhered to Casey's high expectations. His seasoned understanding of the owner’s requirements allowed for proactive adjustments, keeping the project on track.

Innovative Programs: Scheduling

Due to the fast-tracked nature of the project, ECI implemented a dynamic scheduling system to keep the project on track. A key example of this was the delivery of 1,200 truckloads of dirt for site elevation. This phase required precision coordination to avoid disrupting other construction activities.

Value Analysis/Engineering

Value engineering played a critical role in optimizing project outcomes. ECI worked with Casey’s design team to optimize the layout of underground utilities. By simplifying the routing of utilities, the team reduced labor costs and long-term maintenance needs, providing long-term value without compromising functionality. An unexpected challenge arose when the original plans had to be modified to accommodate a larger well and relocate it due to road construction. These changes required ECI to construct a new pump house. Despite the scope change, ECI managed to complete these tasks without extending the project timeline.

Special Obstacles Overcome

As previously mentioned, the 8 acre site needed a significant portion increased in elevation. Meticulous planning was used in order to achieve a 4’ elevation and maintain schedule for an 18 week completion timeline. ECI in conjunction with site contractors delivered over 1,200 truck loads of dirt every 7 minutes for two weeks. Over the course of that two week period all construction activities continued from tank installation to foundation and building pad preparation. Harsh winter conditions forced ECI to ensure concrete curing met specifications. ECI’s leadership team and subcontractor implemented innovative techniques to ensure proper curing. Ground heaters, concrete blankets, calcium, hot water, and cold-weather additives were all used to maintain quality products and installation were achieved.

Difficulties and Extenuating Circumstances

The fast-track schedule required intense coordination among 18 subcontractors. Winter weather also added complexity, particularly for site work and foundation tasks. These conditions required adaptive scheduling and creative problem-solving to avoid delays.

Innovative Programs: Productivity

ECI implemented a real-time productivity tracking system that monitored task completion rates and adjusted resources dynamically. This system allowed supervisors to assign labor to critical tasks when delays occurred in other areas, optimizing productivity across all phases of the project. A labor optimization program also increased flexibility. Workers were cross-trained to perform multiple tasks, enabling the team to adjust to changing conditions. For instance, during periods when exterior work was paused due to cold weather, labor was reassigned to interior tasks to keep the project on track. The site supervision team, led by Jerry Tadlock, worked closely with subcontractors to ensure that any productivity issues were addressed immediately. This embedded approach ensured that potential delays were mitigated before they could impact the project.

Conclusion

The Casey’s General Store and Truck Stop in Crawfordsville, Indiana, is a remarkable achievement for ECI Construction Services. Despite the challenges of winter conditions, significant site elevation work, and a fast-tracked schedule, the project was completed on time, under budget, and with zero safety incidents. Under the leadership of Jerry Tadlock, whose extensive experience with Casey’s General Stores was invaluable, the use of innovative scheduling, productivity programs, and value engineering ensured a successful outcome. This project stands as a testament to ECI’s ability to manage complex construction projects eƯiciently and qualifies for national recognition.