Oldcastle Infrastructure provided an innovative pedestrian tunnel solution for International Speedway Corporation’s Richmond Raceway Reimagined project. The $30 million infield redevelopment will consist of modern attractions and amenities that complement the racing experience for which Richmond Raceway is known.
The new and improved design of the pedestrian tunnel is wider, providing fans with a more comfortable way to access the updated infield. The new tunnel also includes an elevator for added convenience and ADA accessibility.
Recognizing the benefits of precast, the project team selected precast concrete box culvert segments as the best solution to construct the pedestrian tunnel.
The General Contractor Barton Malow contracted Oldcastle Infrastructure’s Fredericksburg, VA, location to design, engineer and manufacture the 49 precast concrete box culverts used to create the 415-foot tunnel. Of the box culvert segments produced, three were designed to elevate the walkway upward to get the tunnel back to the concourse level.
“Precast concrete culverts can be used in countless applications. They install fast, provide the highest level of strength and durability, are less dependent on backfill, require little to no maintenance, can withstand more aggressive compacting and are manufactured locally,” said Doug Bruhns Regional Manager at Oldcastle Infrastructure. “The use of precast tunnel segments provided Richmond Raceway an efficiently constructed tunnel that saved both time and money and was constructed in just five days. In addition, the structure will last and perform well for years to come.”
To construct the pedestrian tunnel, a portion of the racetrack was removed, the area was excavated, and the foundation was prepared for the installation of the precast concrete box culvert segments.
President of Alpine Construction Corporation Scot Hawthorne remarked, “All went very smoothly. We could have set all the box culvert in three days if we had to, it went that well. The Oldcastle Infrastructure dispatcher was fantastic and stayed on top of everything, calling every day to check progress.”
The final assembly of the 10×10 precast box culvert segments is comprised of 6,506 cubic yards of concrete, 220,326 square feet of slab, and 256,000 pounds of rebar. It measures 415 linear feet and weighs 1,100 tons.
Construction continues at the Richmond Raceway, which is expected to be completed by September 2018, in time for playoff races for the Monster Energy NASCAR Cup and XFINITY Series.
General Contractor: Barton Malow
Architect of Record: DLR Group
Civil Engineer: Richmond-based HG Design Studio
Site Contractor: Alpine Construction Corporation
Precast Provided By: Oldcastle Infrastructure Fredericksburg, VA location
Link to Video: https://www.youtube.com/watch?v=QHicBIQolcU
About Oldcastle Infrastructure
Oldcastle Infrastructure, A CRH Company, is the leading provider of building materials, products and services for infrastructure projects to several market sectors nationwide, including: Building Structures, Communications, Energy, Transportation and Water.
For more information, visit www.oldcastleinfrastructure.com
About CRH
CRH (LSE: CRH, ISE: CRG, NYSE: CRH) is a leading global diversified building materials group, employing c.85,000 people at c.3,600 operating locations in 32 countries worldwide. With a market capitalisation of c.€23 billion (April 2018), CRH is the largest building materials company in North America and the second largest worldwide. The Group has leadership positions in Europe as well as established strategic positions in the emerging economic regions of Asia and South America. CRH is committed to improving the built environment through the delivery of superior materials and products for the construction and maintenance of infrastructure, housing and commercial projects. A Fortune 500 company, CRH is a constituent member of the FTSE 100 index, the EURO STOXX 50 index, the ISEQ 20 and the Dow Jones Sustainability Index (DJSI) Europe. CRH’s American Depositary Shares are listed on the NYSE.
For more information, visit www.crh.com
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Bridge substructure is composed of all precast concrete bridge components for fast‐track construction
Partnering with the Massachusetts Department of Transportation, engineering firm McFarland Johnson and general contractor Clayton D Davenport Trucking, Oldcastle Infrastructure Rehoboth, Mass. provided the precast concrete bridge components for the entire substructure, besides the footings, to replace the Savoy Road Bridge over the Chickley River. The MassDOT project consisted of replacing the existing bridge with a new bridge using concrete NEXT beams and precast concrete substructures. The bridge carries a 17‐foot vehicular roadway, with curbs on both sides of the bridge. The project limit extends approximately 200 feet north and 250 feet south of the bridge. Approach work consisted of reconstruction of the roadway guardrail.
In all, Oldcastle Infrastructure Rehoboth manufactured ten abutment stems ‐ (5′ x 4′ x 11’‐6″ tall); four abutment caps ‐ (12′ x 4′ x 2′ tall); four curtain walls ‐ (5′ x 4′ x 18’‐9″ tall); and eight wingwalls‐ (5’‐6″ x 3’‐ X 18′ tall) to construct the replacement bridge on Savoy Road.
The use of precast concrete bridge components allowed for the rapid construction of the bridge substructure. The bridge abutments were delivered, installed, and grouted over a 2‐day span.
Accelerated Bridge Construction (ABC): ABC is bridge construction that uses innovative planning, design, materials, and construction methods in a safe and cost‐effective manner to reduce the onsite construction time that occurs when building new bridges or replacing and rehabilitating existing bridges.
ABC improves site constructability, total project delivery time, and work‐zone safety for the traveling public. In addition, ABC reduces traffic impacts, onsite construction time, and weather‐related time delays.
A common reason to use ABC is to reduce traffic impacts because the safety of the traveling public and the flow of the transportation network are directly impacted by onsite construction‐related activities.
About Oldcastle Infrastructure
Oldcastle Infrastructure is the clear choice for building products and services for North American infrastructure projects. We are a leading provider of engineered product solutions nationwide to a number of market sectors including: Water, Communications, Energy, and Transportation.
www.oldcastleinfrastructure.com
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Oldcastle Infrastructure Idaho Falls teamed with Bonneville Power Administration, HK Contractors, and Bryant Greene Concrete to replace the bridge at the entrance to Pine Basin Camp in Swan Valley, Idaho. Condemned in the fall of 2016, this bridge serves as the only access to the popular boys and girls camp and a valuable access to many of the electrical systems running through the canyon serving Victor, Driggs and Swan Valley.
As the best way to proceed, the Bonneville Power Administration reviewed their options for rebuilding this bridge and selected the use of precast concrete bridge components for the deck.
The new bridge was designed with a span of 45‐feet. Due to this span length, not being conducive to standard precast slabs, Oldcastle Infrastructure engineers partnered with VSL Structural Technologies to create a custom precast solution. Oldcastle Infrastructure and VSL decided to install post tension cables in the slab during the precasting process.
After manufacturing the custom post tensioned bridge slabs, measuring 5‐4’‐wide by 2’‐thick by 45’‐long, Oldcastle Infrastructure Idaho Falls shipped them to the Pine Basin Bridge site. Once delivered and installed on the cast‐in‐place bridge abutments, Oldcastle Infrastructure and VSL applied the post tensioning of the cables in the field for a fantastic forever bridge.
“Custom and standardized designs, accelerated construction schedules and pre‐ fabricated parts are key components of this project that allowed everyone to work quickly and efficiently,” said Dana Yost, Sales Representative for Oldcastle Infrastructure.
About Oldcastle Infrastructure
Oldcastle Infrastructure is the clear choice for building products and services for North American infrastructure projects. We are a leading provider of engineered product solutions nationwide to a number of market sectors including: Water, Communications, Energy, and Transportation.
www.oldcastleinfrastructure.com
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Oldcastle Infrastructure is pleased to announce their latest achievement, the 2016 Precast/Prestressed Concrete Institute’s (PCI) Design Award. The repair to Skilton Road Bridge in Watertown, Conn. was selected as the Best Rehabilitation Bridge winner.
“Thankful to the PCI Design Awards’ panel of judges, we are honored to be the recipient of this award,” said Chris Fowler, Regional Manager‐Engineering of Oldcastle Infrastructure. “As a pioneer in developing innovative concepts for our clients, this bridge structure is just one example of Oldcastle Infrastructure’s ingenuity when it comes to creating high quality precast resolutions. We look forward to using our innovative precast concrete technology in future projects.”
The new Skilton Road Bridge design had to bring the bridge up to code and extend its life without sacrificing the historical character of the original structure. The designers decided to install a new superstructure consisting of precast, prestressed concrete slabs that would span over the existing arch bridge, thus preserving and protecting the entire historic structure.
Oldcastle Infrastructure designed, engineered and manufactured the precast bridge slabs at their Rehoboth, MA facility.
The use of precast concrete deck slabs allowed the bridge designers to repair the historic masonry bridge while maintaining its aesthetic appeal. Additionally, the designers were able to expand and widen the bridge with minimal impact on the existing bridge structure.
A widely‐regarded industry program, the PCI Design Awards (https://www.pci.org/)) honors design excellence and construction quality in buildings and transportation structures that use precast concrete.
VIDEO: https://www.youtube.com/watch?v=GuaV__a_w30
About Oldcastle Infrastructure
Oldcastle Infrastructure is the clear choice for building products and services for North American infrastructure projects. We are a leading provider of engineered product solutions nationwide to a number of market sectors including: Water, Communications, Energy, and Transportation.
www.oldcastleinfrastructure.com
Download Full Press Release
Oldcastle Infrastructure, a nationally recognized precast concrete manufacturer, announces that their Interstate‐10 Tex Wash Bridge Emergency Replacement Project received a 2016 Design Award Honorable Mention from the Precast/Prestressed Concrete Institute (PCI).
During the 54th annual PCI Design Award Program, twenty‐six awards were presented to projects across North America, including best‐in‐class awards for both transportation structures and buildings, as well as special awards for industry advancement, sustainable design, and all‐precast concrete construction.
Recognized for its innovative precast solution, the Interstate‐10 Tex Wash Bridge Emergency Replacement Project was constructed using Oldcastle Infrastructure Perris, California’s innovative precast concrete bridge elements that met the stringent requirements of the California Department of Transportation.
Speed was critical for this emergency project, and designers took advantage of the many benefits of precast concrete to meet the rapid delivery goals. Using precast concrete girders eliminated the need for temporary falsework, which accelerated girder placement and limited the environmental impact on the channel area. Precast concrete segmental abutment and wingwall elements were used to accommodate a staggered construction schedule. In addition, an adjacent precast concrete girder arrangement meant the project did not require deck forms, which further shortened the timeline.
The PCI Design Awards recognize design excellence and construction quality using precast/prestressed concrete. The program demonstrates how designers are continuing to use precast/prestressed concrete construction to achieve sustainable, cost‐effective, resilient and aesthetically versatile projects.
“The innovation of design, speed of construction and the functionality of precast/prestressed concrete are just a few of the qualities that made this year’s PCI Design Awards an outstanding competition,” said PCI President, Bob Risser.
About Oldcastle Infrastructure
Oldcastle Infrastructure is the clear choice for building products and services for North American infrastructure projects. We are a leading provider of engineered product solutions nationwide to a number of market sectors including: Water, Communications, Energy, and Transportation.
www.oldcastleinfrastructure.com
Download Full Press Release
The newly rehabilitated Skilton Road Bridge in Watertown, Conn., designed to bring the bridge up to code and extend its life without sacrificing the historical character of the original structure, selected precast concrete bridge slabs to accomplish this task. The designers decided to install a new superstructure consisting of precast, prestressed concrete slabs that would span over the existing arch bridge, thus preserving and protecting the entire historic structure.
Oldcastle Infrastructure designed, engineered and manufactured the precast bridge slabs at their Rehoboth, MA facility.
The use of precast concrete deck slabs allowed the bridge designers to repair the historic masonry bridge while maintaining its aesthetic appeal. Additionally, the designers were able to expand and widen the bridge with minimal impact on the existing bridge structure.
“As a pioneer in developing innovative concepts for our clients, this bridge structure is just one example of Oldcastle Infrastructure’s ingenuity when it comes to creating high quality precast resolutions. We look forward to using our innovative precast concrete technology in future projects,” said Chris Fowler, Regional Manager‐Engineering of Oldcastle Infrastructure.
About Oldcastle Infrastructure
Oldcastle Infrastructure is the clear choice for building products and services for North American infrastructure projects. We are a leading provider of engineered product solutions nationwide to a number of market sectors including: Water, Communications, Energy, and Transportation.
www.oldcastleinfrastructure.com
Download Full Press Release
Lincoln County and Nicholls/Kovich Engineers specified an optimized girder shape, known as a “Super‐Girder”
As part of the Lincoln County Bridge Replacement Program, Oldcastle Infrastructure of Spokane, Washington fabricated 136.8‐foot‐long prestressed concrete super‐girders for the new Miles Creston Bridge in Lincoln County, Washington.
The term “super‐girder” resulted from the efficient shape of this new bridge girder family, which utilizes high strength concrete and .6” diameter prestress strand to maximize span length and minimize the number of girders.
Precast, prestressed concrete girders have been used in bridge construction for over 65‐years and have proved to be economical and durable across the U.S.
In many states, especially Washington, prestressed girders, combined with a cast‐in‐place deck, or an all prestressed girder including precast deck, constitute the superstructure system of choice for bridges that span to over 200‐feet.
As has become customary, Lincoln County Public Works Department, working with their consultant Nicholls/Kovich Engineers of Spokane, WA, specified WSDOT WF 58 optimized girders, known as “Super‐Girders”, for the replacement of the existing Miles Creston Road Bridge Over Hawk Creek in Lincoln County, due to its substandard load carrying capacity, thus requiring a high priority replacement bridge.
General contractor Wesslen Construction, Spokane, Wash., the low bidder on the project, awarded Oldcastle Infrastructure‐ Spokane the contract to manufacture and haul the wide‐flange super‐girders for the new Miles Creston Bridge.
At 125,438‐pounds each, Oldcastle Infrastructure manufactured five, wide flange “Super‐Girder” bridge beams, measuring 58‐inch‐tall by 136.8‐feet‐long. The bridge girders were used to build the bridge superstructure, with a conventional cast‐in‐place concrete deck.
Accordingly, the optimized girders were designed with a 49‐inch wide top flange and a 38‐inch wide bottom bulb. These wider flanges give much more lateral stability during transport than the shapes they replaced, and utilize a much larger prestress force to increase spans and minimize the quantity of girders. In this case, spanning 136.8‐foot with only a 58‐ inch depth of girder provides an aesthetically pleasing profile as well as providing adequate clearance above the river for 100‐year flood passage.
Each “super‐girder” is custom manufactured in Spokane and transported on trucks specially‐designed to hold the weight. Due to their size, the girders must be transported to the construction site on steerable rear supports. Once the girders arrive on site, crews used two cranes to set them on top of the new bridge abutments.
Oldcastle Infrastructure Sales Manager Chuck Prussack stated, “Long‐span precast, prestressed concrete girder standards have allowed WSDOT and other bridge owners to extend the span capability of the construction material they prefer to use. Using long‐span precast, prestressed concrete girders can eliminate the need for falsework, reduce on‐site construction activities and schedules, reduce environmental impacts at water crossings, and minimize hazards, delays and inconvenience to the traveling public.”
Miles Creston Road Bridge Replacement project consisted of the following steps: 1) Install a temporary detour; 2) Remove the existing bridge, abutment walls and footings; 3) Install piling and pile cap abutments; 4) Install precast superstructure with cast in place deck and bridge rail; and 5) Install bridge approaches with approach steel rail to match up to the existing roadway width.
Several years ago, the “super‐girder” family of girders originated when WSDOT worked with the industry to create an optimized family of girder shapes that would be capable of longer spans, have more stability during shipping, present a shallow profile for stream clearance and aesthetics and fully utilize High Performance Concrete (HPC) with its higher strengths by using .6‐inch diameter prestressing strands.
As one of the leaders in the use of the new optimized girder shapes, the Northwest has been using the “Super‐Girder” shape at a 100‐inch depth on spans more than 200‐feet for many projects, with many more structures in this span range being designed!
About Oldcastle Infrastructure
Oldcastle Infrastructure is the clear choice for building products and services for North American infrastructure projects. We are a leading provider of engineered product solutions nationwide to a number of market sectors including: Water, Communications, Energy, and Transportation.
www.oldcastleinfrastructure.com
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Precast concrete highway pavement slabs are increasing in popularity for use in rapid highway construction. This is, in part, the result of many state departments of transportation recognizing the efficiency of the precast slab method and selecting it for use on an increasing number of state projects.
The California Department of Transportation (Caltrans) has specified precast concrete pavement slabs for one of the largest projects of this type in North America, the Pavement and Slab Replacement Project on the Foothill Freeway (I‐ 210). This transportation project, approximately 12 miles north of Los Angeles, begins at the Dunsmore Avenue undercrossing in La Crescenta‐Montrose and extends to the North Los Robles Avenue overcrossing in Pasadena.
Flatiron West of Chino Hills, California, has appointed Oldcastle Infrastructure of Fontana, California to supply several thousand precast highway pavement slabs for this $148 million project.
As a national precaster who has embraced this technology, Oldcastle Infrastructure, a leading provider of engineered building product solutions for North American infrastructure projects, received the contract to manufacture 6,500 precast concrete pavement slabs. Each slab measures 12.5‐foot ‐wide by 11.33‐foot‐ long by 12‐inch‐thick, for the 9.7‐mile segment of I‐210, and will be used to replace sections, that have undergone erosion and deterioration due to years of exposure to heavy traffic.
Site installation of the pavement slabs is occurring as an overnight process. The highway is closed at approximately 9:00 pm, the deteriorated sections are cut out, and a lean concrete base is placed into the opening. After the concrete base achieves the required strength, approximately 1 hour later, the precast concrete pavement slabs are installed and the highway is reopened for full traffic by 5:00 am the next morning. This method reduces impact to the public, especially to commuters.
Regional General Manager ‐ Southern Calif. Todd Ebbert remarked, “Our team took an innovative approach to this project, drawing on our many years of experience, which resulted in a successful outcome for all. This product offers a solid solution to improving our highways while creating little impact to the public.”
As has been seen over the years where precast pavement slabs are used to repair damaged highway lanes or upgrade older lanes, Precast Concrete Pavement Systems (PCPS) promote construction methods that reduce traffic congestion, reduce project duration, increase safety, and produce durable repairs. Not only do the highway slabs install quickly, minimizing closures and exposure of crews to live traffic, they can be installed in any weather and last a long time, an estimated 50 years, according to Caltrans.
This project started in April of 2015 and will continue through mid‐2018. The work will include both day and night operations. When completed these highway improvements will enhance safety and meet current Caltrans standards.
Length of freeway segment: 9.7 miles
Total amount of concrete: 200,000 cubic yards of precast and cast in place.
Avg. number of slabs set per week: 280
Avg. distance of slabs set per night: 630
Linear‐Feet Manufacturing time: April 2016 through March 2017
Avg. slabs cast per day: 30
About Oldcastle Infrastructure
Oldcastle Infrastructure is the clear choice for building products and services for North American infrastructure projects. We are a leading provider of engineered product solutions nationwide to a number of market sectors including: Water, Communications, Energy, and Transportation.
Download Full Press Release
