In response to a catastrophic failure on the Teton Pass Highway due to a massive landslide, Oldcastle Infrastructure partnered with the WYDOT and Avail Valley Construction to construct an emergency detour. This project aimed to restore connectivity between Idaho’s Teton Valley and Jackson, Wyoming, ensuring safe passage for commuters and tourists. The urgency of completing this project before the upcoming 4th of July holiday imposed significant time constraints
CHALLENGE
The project presented several critical challenges. To begin with, a swift turnaround was essential, with the detour needing completion in under 15 days to minimize disruption and restore this vital transportation route. Logistically, transporting 120-feet worth of box culvert from Oldcastle’s Nampa, Idaho, plant to the project site required meticulous planning and coordination due to the distance and logistical constraints.
SOLUTION
Oldcastle Infrastructure responded to these challenges with decisive actions. Engineers quickly produced and obtained approval for CAD drawings to expedite the manufacturing processes. Leveraging our facilities, Oldcastle Infrastructure promptly cast 19 box culverts, meeting project specifications and timelines. Collaboratively, Oldcastle Infrastructure partnered with other CRH companies and WYDOT to seamlessly integrate the box culvert into the detour construction, ensuring efficient project execution and compliance with safety standards.
BENEFITS
The completion of the emergency detour yielded several key benefits:
Timely Restoration:
The detour opened before the 4th of July weekend, enabling uninterrupted travel for over 15,000 daily commuters and tourists.
Enhanced Safety:
The new detour, featuring a bidirectional roadway with concrete barriers, ensures safer passage.
Community Impact:
Oldcastle Infrastructure demonstrated a commitment to supporting local communities in times of crisis. Shorter Onsite Construction Time: Oldcastle Infrastructure’s efficient processes reduced onsite construction time, minimizing disruption to traffic and local businesses.
Resilience:
The robust design of the detour ensures long-term durability against natural elements, providing a reliable transportation route for years to come.
Oldcastle Infrastructure’s rapid and collaborative efforts with WYDOT and a One CRH approach exemplify effective crisis management and community service. By swiftly addressing the challenges posed by the Teton Pass landslide, Oldcastle Infrastructure not only helped restore a critical transportation link but also ensured the safety and convenience of thousands of commuters and tourists. This project underscores Oldcastle Infrastructure’s commitment to resilience, innovation, and community support, reaffirming their role as a leader in delivering timely and impactful infrastructure solutions.
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The Nevada Street and Commonwealth Avenue Apartments in Chandler, Arizona are newly constructed multifamily apartments that needed a solution to address both stormwater detention and deep infiltration.
With our full solutions approach to stormwater management, Oldcastle Infrastructure looked to modernize this community with the use of the brand new MaxCapture®, combining Oldcastle Infrastructure’s StormCapture detention modules and MaxWell® drywell solutions into a single system, all while saving the owner and contractor time, costs, and land space.
CHALLENGE
Addressing the need for both detention and deep infiltration, while cutting down on the costs, installation time, and land usage that is typically required. Generally, two separate products from two separate companies are needed, if detention and deep infiltration are both required on a site. Solving both issues with a single product, one that had never been installed before, required a comprehensive approach ensuring this groundbreaking project ran smoothly and set the precedent for future projects.
This implementation project required the coordination of all parties involved so Torrent, Oldcastle Infrastructure, and the contractors could work seamlessly together. With nearly 50,000 ft3 of storage volume installed, it was also necessary for the city of Chandler to approve the use of the drywells.
SOLUTION
This project showcased Oldcastle Infrastructure’s turnkey solutions by leveraging the first-ever installation of MaxCapture, an innovative, one-of-a-kind combined detention and drywell system. While detention and drywell system installation is typically costly, labor-intensive, time consuming, and usually requires a very involved design process, Oldcastle Infrastructure’s ability to create comprehensive solutions that address core needs alleviated those hurdles.
BENEFITS
Land Allocation
Utilizing MaxCapture allows for land space to be saved and allocated for other revenue-generating purposes thanks to its stacked design.
Cost Efficiencies
Since MaxCapture is self-contained, the design and installation process required less excavation and fewer materials than a traditional two-product system.
Accelerated Timeline
Oldcastle Infrastructure’s engineering and design resources, streamlined the design process for specifying engineers.
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In a landscape where success is measured by innovation and overcoming challenges, our partnership with Toyota of Lewisville stands as a testament to hard work and adaptability. This project involved the installation of 86 – 4.5’ SC-1 modules with 50 link slabs and 50 grade slabs aimed at providing 75,000 CF of storage. The undertaking was not without obstacles, but our commitment to excellence facilitated success.
CHALLENGE
The project presented exciting opportunities paired with unique challenges. We quickly realized that this site posed constraints regarding the amount of space available, and the clock was ticking to find a solution with delivery timing at the forefront. The site constraints and the urgency of delivery timing added an extra layer of complexity to the installation, shipping, and arrival of the units. However, these challenges were approached as steppingstones to creative solutions.
SOLUTION
Enter StormCapture – a groundbreaking concrete detention system that not only met project requirements but also provided a solution to enhance detention capacity and expand the size of the parking lot. The decision to opt for StormCapture was driven by its quality and alignment with the dealership’s needs. The installation process, spanning 45 days with 1 crane, unfolded seamlessly, conquering the challenges of limited space and tight timelines.
BENEFITS
Increased Detention Capacity
StormCapture facilitated the addition of detention capacity without compromising the parking lot size, optimizing the use of available space.
On-time Delivery
Despite the challenges in logistics, the project maintained an average of 10 trucks per day, ensuring timely delivery that adhered to the contractor’s timeline.
Unique Concrete Detention System
The product’s special features, designed specifically for detention, showcased its suitability for the project and contributed to its success.
Our partnership with this thriving dealership showcases our dedication to overcoming challenges, providing innovative solutions, and delivering results that go beyond expectations. As we continue to shape success stories, our commitment to our clients remains unwavering.
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The Cypress Street area of Tampa consisting of one residential street, two mixed-use streets, and one commercial street is in a low-lying area of West Tampa close to the central business district and Tampa Bay. With a patchwork drainage system added over the years, its design lacked cohesion and the capacity to deal with the level of stormwater runoff and persistent flooding caused by significant thunderstorms.
Oldcastle Infrastructure joined Woodruff & Sons Inc. and an engineering consulting firm to develop a drainage solution for the city of Tampa that was effective, efficient, and economical while increasing the sustainability, safety, and overall system longevity. This comprehensive, turnkey support and solution would be needed to modernize the community and transform the lives of its residents.
THE CHALLENGE
Frequent and excessive stormwater runoff was overwhelming the heart of downtown Tampa due to its outdated storm drainage system. As a result of this antiquated system, the city was having ongoing business and residential flooding, ongoing traffic delays, and disruptions.
Nearly 7,300 linear feet of box culverts and reinforced concrete pipe with precast catch basins and curb/throat inlets, dual vortex separators, Flogard® inlet filters, Nutrient Separating Baffle Boxes® (NSBB), and area drains were added to the existing system. This was necessary to reduce maintenance costs, and lessen the duration and depth of flooding. The system would require multi-stage filtration, hydrodynamic separation, and hydrocarbon absorption to achieve eco-friendly and sustainable benefits.
THE SOLUTION
This outfall project showcased Oldcastle’s ability to provide comprehensive, turnkey support and solutions that modernize communities and transform the lives of their residents. Oldcastle’s multi-solution systems offered an increased level of drainage, traffic safety, residential and business safety in a residential area that is historically prone to flooding. In addition to its handling of stormwater, the project:
| Enhanced pedestrian safety and mobility
| Created far less flooding in the area
| Reduced threats of road closures, flooded vehicles, traffic incidents
| Improved overall water quality with filtration and proper drainage
BENEFITS
SAFETY
| By eliminating business and residential flooding due to previous poor stormwater drainage, Tampa traffic safety has vastly improved.
SUSTAINABILITY
| The full stormwater management and drainage solution, including NSBB and curb inlet filtration, is significantly reducing polluted stormwater run-off to otherwise clean water sources. As such, it is largely improving Tampa’s overall water quality and green infrastructure.
“Previously, Willas at Rome and Fig was struggling with persistent flooding and had installed an aluminum sluice gate on their door to prevent stormwater from entering their business. Since the install of the new system, the business has not had any more flooding problems.”
Sunny Noland | Superintendent
Woodruff & Sons, Inc.
Owner: City of Tampa and the Southwest Florida Water Management District (SWFWMD)
Contractor: Woodruff & Sons
Distribution Plant: Cape Coral, FL
Solutions:
1,328 Box Culverts
3 NSBB Units
43 Access Risers
73 Curb Inlets
18 Storm Manholes
11 Grate Inlets
22 Sanitary Manholes
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Salisbury, MD
Up the creek. Without funding or a plan, that’s where a consortium of civic, corporate and volunteer entities found themselves back in 2009 when faced with a rather large clean-up effort of Hall Creek in Beaverton, Oregon.
Undeterred, the city of Beaverton started the process by applying for a capital grant with Metro, the agency that oversees the Portland metropolitan area. Created more than 30 years ago, Metro coordinates regional planning for managing growth, infrastructure and development, often crossing various jurisdictional boundaries while serving an area of some 1.5 million residents.
Beaverton, a community of some 92,000 people, is located about seven miles west of downtown Portland, Oregon. “We wanted to clean up an area of Hall Creek that had become known as the dirtiest section of the creek,” said Debbie Martisak, Project Manager in the Public Works Department in the city of Beaverton. “It was because of the big car lots and mechanics shops that are there,” she added.
In 2012, the city was awarded a significant grant from Metro in the amount of $354,000 to help fund a 650-foot section of Hall Creek. Officially known as the Hall Creek Water Quality & Pathway Enhancement Project, the plan was quite ambitious.
According to the Beaverton Public Information office, the goal was to “realign the creek and adjacent trail, reconnect the floodplain, remove invasive plants, stabilize banks with native plants, remove impervious surfaces and create swales for enhanced water quality.” Martisak noted that the Metro grant amounted to about one-third of the total estimated cost of the project. “This grant really sparked the design and made it possible to have this project happen,” she said. “Without that money, we wouldn’t have been able to afford it. So, with the grant in hand, we went through the design process.
MEDIA FILTRATION
“Putting a filter vault in wasn’t part of the original plan, but the design process indicated that this was the right step to take for our area,” Martisak said. “It became important to us once we went through the design process and began looking at hydrology, pervious and impervious surfaces, and what’s actually flowing into the creek to be treated by this vault.
“It’s a very substantial area, an area that’s highly industrial and commercial. It’s in the heart of what we call our downtown. So, we started talking to our agency called Clean Water Services about our plans, and what types of things that they would like to see. They’re a regulatory agency here in Beaverton that provides permits for this area of Washington County.
“They were also a big supporter of our plans, donating plants and their employees’ time. They recommended having a filter vault in this location, to collect all of the runoff on private property and a little bit of public property as well.
“Most of what we were doing was to improve the urbanized area, taking what was a poorly functioning creek and make modifications to the creek that would support the aquatic life and hydrology of the area. It’s a straight and narrow creek, with high velocities that was scouring out the banks by up to four feet. We had to do something.
“There’s quite a bit of area there that was not being filtered, and it was a very dirty area of the city because of the types of businesses that are there. So, we decided to add on a filter vault to our project.”
Martisak learned, however, that at that time there was currently only one approved supplier for these vaults. “So initially, we were only getting one bid, which isn’t the way that we do business. It’s not normally cost effective, especially when we’re talking about a $40,000 to $50,000 piece of equipment for our infrastructure.
“Therefore, we requested that they work out and approve another manufacturer and different design. This resulted in Oldcastle® Infrastructure getting their PerkFilter® vault approved in addition to a third manufacturer as well, so now there are more competitors in the area.”
Deon Lourens, Area Technical Manager with Oldcastle Infrastructure, explained that there are several advantages to the PerkFilter system. “Its cartridges have no moving parts and no cartridge hood, allowing for easier maintenance observation. In addition, its design allows for fewer cartridges than alternative models, and the bypass flow underneath the cartridge bay limits re-entrainment of pollutants.”
He noted that cartridge lifecycle can range up to three years, depending on the pollutant load. “The cleaner the influent,” he said, “the longer the duration between maintenance cycles.”
OLDCASTLE INFRASTRUCTURE’S STORMWATER
Martisak described the city of Beaverton’s relationship with Oldcastle. “We ended up hiring Oldcastle. They came in as the lowest bidder, and they came up with a design for us, together with our engineer who sat in with Cardno WRG, the engineering firm who did the design work. They approved our shop drawings and they made modifications as they saw fit, in consultation with Oldcastle.
“Oldcastle and Cardno WRG were very helpful in discussing exactly which area is being covered by the vault, how much water is being filtered, and the precise numbers for this creek enhancement project.”
Construction finally began in July 2015. “That’s when our contractor started excavation,” explained Martisak. “We’ve been working on it since, and our own city staff actually installed this vault. So, it was a cost saving to the city to purchase the vault, and our team of engineers worked with Oldcastle to see what we were going to get before it came onsite, to work with them regarding how it was going to be delivered, and how it was going to be set up.
“They were onsite with us when it came, and it was crucial to make sure that it was set up with the correct grade and level. Our city team could place and install the connections and everything that comes into this vault, as well as the pipes that come out of the vault.
“That saved us quite a bit of money, since our labor hours are much less than if we would have contracted it out to another contractor. That was a unique aspect to this project, having our city staff able to place and install the vault. This was a challenge that we overcame, and it came out perfect.”
Another issue the city encountered before the work could get very far along was a problem with what was found underground where the vault was to be placed.
“We ran into a situation with some contaminated soil,” explained Martisak. “When we were digging, we found oil sheens. We would dig a hole, and it would just fill up and have a sheen to it. We had it tested, and we had to reclaim everything that came out of that area, and send it to a specific location to be handled quickly.
“We’re talking very low amounts here. We did more than we had to, but when we found something in one small spot, we decided to treat the whole area. These oils we found are likely a direct result of the businesses that have been in that area for decades.” The oil contaminants weren’t the only underground problem. “When we started digging our test holes for this new vault, we found that some major electrical lines were in the way, so we had to move the location of the vault, in order not to have to go under or above the electrical transformers. You never know what’s underground until you start tunneling in.
“So, we had to do some adjustments with moving the vault’s alignment. The original design had one way for the pipes to go in, but now it’s turned and moved over so we can get a more direct shot without having to worry about a transformer.”
LOW-IMPACT DEVELOPMENT
The PerkFilter vault was just one element of this overall water quality improvement effort. In addition, the city installed new curbs, a landscaping planter and did some parking lot resurfacing. In the project area, they now have some pervious concrete, several plantings and a new boardwalk.
The plantings were part of a low-impact development effort. Martisak indicated that native plants, shrubs and trees have been newly planted along both sides of the creek. Local volunteers assisted in the plantings, conducted in October and November of 2015, and in January 2016. A final volunteer planting day took place in April 2016 on Arbor Day, in conjunction with a ribbon cutting ceremony for the new trail that was created in the area.
“This helps ensure that the area is going to eventually maintain its own water quality, as the planted trees get bigger, the shading of the creek increases, and as the stormwater is being treated by plants that were specifically chosen for this environment,” Martisak said. “It’s a low-impact development project.”
The Oldcastle PerkFilter vault is now in place, and is filtering the water and taking out the garbage that is collected from the storm system, including the runoff from the parking lot, before it goes directly into Hall Creek.
“The vault was operational through all the big winter storm events that we had,” Martisak said. “Beaverton has gone through some record storms, and it has performed really well.”
She explained some of the other elements in the local enhancement effort. “We already had plantings and water quality plants that went into this project. We also did mitigation upstream, to ensure that we’ve got good shading of the creek. We pretty much took out most the trees that were non native and invasive. When we cleared them all out, it left the area looking very bare, although it was nice to be able to see the aesthetics of what we were able to change in the channel.
“For water quality, we have a rain garden that is also part of the project. We have two swales that are part of this project, that are taking stormwater outfall from the parking lot at the car dealership. The filters we’re using are all from plants. We’ve also made changes to the creek’s alignment, to slow it down, and to give the channel and the area downstream a better chance to avoid flooding.
“The other stormwater work we have done is to install new catch basins in the parking lot for an apartment complex on the north side of the creek to handle the stormwater coming off these adjacent properties.” Additional details of the other stormwater aspects of the project were provided by Cedomir Jesic, an engineer with the consulting firm Cardno WRG. “There are two treatment trains. One is the filter vault, with catch basins clearing the stormwater of debris before it even reaches the vault. Then there is also a series of catch basins throughout the parking lot, with a water quality pretreatment manhole that lead into the swale.
“It wasn’t entirely clear what drains here, so with the catchment area it was assumed that it can either drain to this vault, or to the adjacent water quality swale. So, we have the vault, and we have a water quality planter, a swale, that treats another part of the catchment area.
“A part of the development drains directly to this water quality facility. So, on this project we are using both mechanical treatment, with the PerkFilter, and we’re also using vegetative treatment with the water quality swale.
“We were very fortunate that we were able to build this vegetative facility and call it a conveyance facility, but it’s planted as a water quality facility, so we know that some treatment will occur. This is with the swale.
“We’re doing as much water quality treatment as is feasible, with existing outfalls. There has been extensive landscaping. So, there has been stream restoration, enhancement and improvement of water quality.”
One of the problems that had been encountered prior to the start of this project was that there are five separate private property owners in this area of Hall Creek. As Martisak commented, it had become a case of “who’s doing what?”, with the result being nothing.
“There was a trail,” she said, “but it was a bit dicey, because it wasn’t maintained by these property owners. So, we took over responsibility not just for the installation of this filter vault on private property, but we will be continuing to do all the maintenance on it forever, changing all the filters forever. We will also be ensuring that these plants are maintained and nourished for three years. We did everything we possibly could to make this a very natural, established end product. We went the extra mile to get this filter vault. We had to get more money to do the right thing.
“That shows the city’s sense of responsibility for the creek and its integrity by actually paying some $40,000 for a piece of equipment that wasn’t initially planned. We didn’t have to do this, we weren’t required to; it was a matter of doing the right thing, and that’s what the city did. We were able to take all the issues that we saw, and make something that is not just effective, but is beautiful. The project turned out incredibly fabulous.”
Cardno WRG’s Jesic was equally impressed with the finished project. “The city crews did a really good job,” he said. “There were different groups working within the city – there were utility and pipe crews doing one thing, street crews doing another thing, and the landscape people working with volunteers to do all the planting.”
Martisak noted that without the Metro funding, this project might never have taken place, or would have been significantly scaled down. But the city of Beaverton didn’t sit idly by, waiting for a funding decision. They were incredibly pro-active.
“We got 26 big local supporters for this project – big players who came to the table and said at the beginning of the process that they like the idea, that there is a strong need here, and that they support this project.
“Because we had so many supporters that came to the Metro meetings, I think the grant committee was overwhelmed with the fact that there was so much support, it would have been difficult for them to say ‘no.’ But without that grant, I don’t think this project would have gone forward to the level that it did. We probably would have had to do a low maintenance project and just cleaned it up a bit.”
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The STAKKABOX Ultima Connect Chamber provided a transportation authority with an outstanding combination of durability, customization, and ease of installation for protecting sensitive railway components.
THE CHALLENGE
Commuter rail lines in densely populated areas rely on intricate communications and signaling systems for efficient and safe operations. The
infrastructure that protects those systems must be durable, reliable, and easy to configure for ongoing upgrades.
The transportation authority was in search of an alternative to the existing polymer concrete vaults to support the need to add capacity to the system (including additional fiber cables) in the Philadelphia area. Typically, polymer concrete boxes are used along with cable trench and conduit to protect transit signal and communications wiring.
The standard polymer concrete boxes are difficult to modify without compromising strength, especially when a large number of conduits must interface in a single box. The transit authority needed a solution that could accommodate a higher quantity of 6″ holes (cored-out conduit access holes or square cut-outs in the field) while maintaining the structural integrity of the chamber.
THE SOLUTION
Oldcastle Infrastructure provided one 4′ x 4′ x 4’ STAKKABOX Ultima Connect Chamber with Steel Frame and H20 Composite Covers, configured so the conduit-to-vault transition holes could be drilled on site.
Installation was simple and straightforward:
| An excavator was used to dig a hole in the ground.
| The excavator then lifted and set half of the body (a total of 5 rings), followed by the balance (an additional 3 rings) to create an entirely assembled chamber.
(Note: This configuration could also be built directly in the hole, one ring/layer at a time).
| Holes were cored out on opposite sides of the box (15 on one side, 8 on the other) and conduit access extensions were inserted.
| The area around the chamber was backfilled.
| The frame was placed on the body, and composite covers were secured to the frame with screws.
Total time for installation was approximately 3 hours.
“Everyone was extremely impressed with the ease of installation and accessing the conduit through the body.”
Cort MacLean | Transit Account Manager
BENEFITS
THE STAKKABOX PROVED TO BE AN OUTSTANDING SOLUTION FOR THE TRANSIT AUTHORITY’S REQUIREMENTS:
| Openings for cable trench or conduit can be pre-fabricated or cut on site without compromising the chamber’s strength and performance.
| Rings can be added or removed to reach a customized final depth as dictated by the site conditions, due to the Ultima’s innovative layered design.
| The Glass Reinforced Polyester Resin (GRP) components offer more durability and will not crack when placed close to vibrating rails.
| The body components and covers are lightweight, making it safer for the personnel installing the cables and providing easier access to the cables in the future.
GOLD STANDARD DURABILITY: THE “TRACK TEST”
After all tests, the STAKKABOX Ultima Connect Chamber met all form and function requirements. In fact, no sidewall flexure was observed in the chamber even with 15+ six-inch diameter holes cut on one side for conduit access. The box was left in the transportation authority’s main maintenance way next to the rail and will undergo a performance review for a period of 3-6 months. The installation crew was extremely impressed with the ease of installing the box and accessing the conduit through the body. A second unit (STAKKABOX Ultima Connect Chamber) is scheduled to be installed within the next few months.
www.OldcastleInfrastructure.com
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As part of a new Walmart build in Lake Elsinore, California, Oldcastle Infrastructure was awarded the contract to manufacture a sustainable biofiltration solution for the commercial development. Installing BioPod systems for this project paved the way for the largest individual units installed in Southern California and showcased Oldcastle’s ability to engineer an advanced, custom stormwater treatment solution that meets green infrastructure requirements.
THE CHALLENGE
Apple Valley Construction sought to install a sustainable stormwater treatment solution for a commercial development in Southern California. Oldcastle Infrastructure was instrumental in providing a large-scale solution with flexible designs that met site-specific needs.
Specific challenges the Oldcastle team faced during this project included:
| Introducing a new product to the Southern California market where other well-established products in the area are typically specified.
| Consolidating the number of originally specified units to meet site requirements.
| Adapting plans for the job site footprint and larger units.
THE SOLUTION
The Oldcastle Infrastructure team identified a unique opportunity to install three of its flexible BioPod systems in place of a competitive product previously specified, which would have required more units.
The three BioPod systems are the largest individual units designed and installed in Southern California to date. By collaborating with project engineers early in the design phase, Oldcastle was able to provide a premium yet simplified treatment solution that accommodated site specific stormwater treatment requirements in a cost effective package.
BioPod’s footprint allowed the contractor to utilize a smaller number of larger units to consolidate the stormwater treatment system into one area. This was beneficial in accommodating both treatment flow rates of 0.86 cfs and peak flow rates of 20 cfs.
BENEFITS
QUICK TO INSTALL
| Oldcastle Infrastructure’s BioPod was quick, easy and safe to install on-site for Apple Valley Construction. Using BioPod in place of the well-established competitor’s product allowed for all three units to be installed in just 13 hours, saving the contractor a significant reduction in labor time.
FLEXIBLE DESIGN
Despite site challenges and budgetary restrictions, BioPod was able to meet site-specific requirements for size, reducing the amount of materials and units needed for installation all while maintaining an aesthetically pleasing design for the end-user.
SUSTAINABLE SOLUTION
Fitting seamlessly into standard site drainage, BioPod serves as a long-lasting solution for this new Walmart build. Not only do the BioPod units create a more efficient installation process for the crew, but they also utilize an advanced biofiltration design for an environmentally friendly stormwater solution.
“In lieu of site challenges, the Oldcastle team designed an exceptionally large stormwater treatment devices that will provide the performance and reliability required for many years to come.”
Oldcastle Infrastructure
Owner: Walmart
Contractor: Apple Valley Construction
Consulting Engineer: Kimley-Horn
Solution: Three 11′ x 26′ x 8′ BioPod Systems
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As part of a soil investigation for the Westminster Presbyterian Church in Portland, Oregon, Torrent Resources, an Oldcastle Infrastructure company, was awarded the contract to develop and manufacture a storm water capture and infiltration system using the MaxWell Plus drywell. Oldcastle was able to showcase its ability to develop a greener and customized solution to converting the church parking lot using low impact development (LID) principles, that saves the client effort, time and money. Torrent Resources’ MaxWell drywell allowed the client to reinforce and improve their existing infrastructure for a reliable solution.
THE CHALLENGE
The soil investigation for the Westminster parking lot found that the site was underlain by at least 30 feet of clay and silt. As a result, this was creating unideal conditions for infiltration and LID designs.
Oldcastle was selected for the contract to complete the church parking lot update. A second inspection beyond 30 feet was required to gather new geotechnical information to ensure the MaxWell Plus drainage system was the right infiltration BMP.
THE SOLUTION
The client installed the MaxWell Plus drainage system to provide infiltration, citing a number of important factors:
| High storm water storage volume of 5,733 CF
| Ability to pre-treat storm water twice for constituent removal
| Field-proven efficiency
| High quality standards
Oldcastle was contracted to drill the MaxWell drywell to a depth of 57 feet, which was completed in a highly permeable layer of sand and gravel to make for a successful LID project.
The post construction percolation test yielded an in-situ flow rate of 0.46 CFS (206 gpm), which was more than 3 times greater than the design percolation rate.
BENEFITS
QUICK TO INSTALL
| Oldcastle Infrastructure’s BioPod was quick, easy and safe to install on-site for Apple Valley Construction. Using BioPod in place of the well-established competitor’s product allowed for all three units to be installed in just 13 hours, saving the contractor a significant reduction in labor time.
SUPERIOR QUALITY
The Westminster Presbyterian Church parking lot update was an excellent example of robust pre-treatment for influent storm water. As materials become permeable, a deep infiltration system from MaxWell drywell systems is key to a reliable solution.
A RELIABLE SOLUTION ON A TIGHT TIMELINE
Oldcastle exceeded performance expectations for the client and the job site. The MaxWell Plus system was installed and tested in less than one week so as not to impact the project schedule, making it the most feasible, constructible, and cost effective solution.
“The product offers field-proven efficiency and is the overwhelming choice of specifying engineers in the private sector.”
VLMK Consulting Engineers
Jurisdiction: City of Portland DES
Developer: Westminister Presbyterian Church
Civil Engineer: VLMK Consulting Engineers
Solution: (2) Maxwell Plus – Double Wall
Stormwater Volume: 5,733 CF
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The all-new Seattle Waterfront is set to change the entire landscape of the city, finally connecting the downtown and historic piers into one single, cohesive system. In addition to completely reimagining the flow of the city, the development will provide new protective infrastructure, including a seismically stable seawall (another Oldcastle project) as well as a green stormwater management system to maintain runoff along the entire development.
The systems had to meet regulatory requirements for basic treatment with GULD approval by the Department of Ecology as well as the City of Seattle (both Seattle Public Utilities and Seattle Department of Transportation). Systems were all sized using City of Seattle Stormwater Design Manual for multiple drainage areas and corresponding treatment flow rates.
THE CHALLENGE
The challenges with this project were primarily found in the coordination of multiple stakeholders and navigating the complex infrastructure below street level, working with both to tie in new construction for multiple utilities. The existing Alaskan Way Viaduct had required full demolition as we looked to build the new Alaskan Way within the very same footprint. Numerous moving parts resulted in a vastly complex schedule for installation, demanding precision in execution on every phase of the project.
Specific challenges the Oldcastle team faced during this project included:
| Meeting the HS-25 traffic load rating for all structures included.
| Redesigning pedestrian and vehicular traffic to include PerkFilter systems for stormwater treatment.
| Ensuring the approved inlet vane grating was on all CB units.
| Providing stamped structural design calculations and drawings for every unit on the project.
THE SOLUTION
When matched against competitor solutions, Oldcastle Infrastructure’s PerkFilter stood out among the competition. Both catch basins and vault units were used in the design of the project, as the City of Seattle sought the longevity of a solution that can only be found in precast concrete. In addition, the PerkFilter product had been used in jobs for the City of Seattle previously; this familiarity and trust with the product helped reassure the project’s success. All systems used were sized according to the City of Seattle Stormwater Design Manual to include multiple drainage areas and corresponding treatment flow rates.
BENEFITS
LONGEVITY
| Thanks to precast concrete, PerkFilter offers more reliability than steel when used in a marine climate. The long term durability and service life of concrete is unmatched, and provides a better solution for sustainability of the infrastructure.
SECURITY
| Compared to other products, PerkFilter stands up to vehicle traffic better due to its stronger top lid design. PerkFilter lids fasten securely so that they remain resistant and largely clatter-free when subject to standard vehicular traffic.
TIMELY
| Product delivery was done in phases, ensuring that units were available whenever needed. This delivery phasing allowed Oldcastle Infrastructure to supply units early and in greater supply, allowing for on-site storage until it was time for installation.
“The City of Seattle is a huge fan of the PerkFilter® system. Its advanced filtration matches perfectly with their transition to new, modern infrastructure both in this, and other developments around the city”
Owner: The City of Seattle
Contractor: Gary Merlino Construction
Consulting Engineer: WSP | Seattle
Solution: 49 PerkFilter Catch Basins | 3 PerkFilter Valuts
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During the development of a large commercial warehouse, tight site constraints made it nearly impossible to install a standard configuration stormwater treatment system. Replacing the existing design required a new solution that met site requirements and could be delivered on schedule. As part of the development, a custom underground BioPod™ biofiltration system was designed.
THE CHALLENGE
Having previously worked with Oldcastle Infrastructure, the contractor reached out seeking an economic alternative that would satisfy the treatment requirements and meet site specifications.
This installation provided a number of challenges along the way:
| Accommodating a tight right of way at the development site.
| Customizing a solution that eliminated a multiple unit design configuration and a number of flow splitter manhole hydraulics.
| Reducing the lead times and installation window with a more economic product.
| Ensuring design approvals and delivery were within the project timeline.
THE SOLUTION
The Oldcastle Infrastructure team identified a unique opportunity to design and install a custom BioPod system to replace the originally specified units. The Oldcastle team’s ability to deliver a solution on time while meeting site constraints was crucial in being awarded this project.
Designing the custom BioPod required a new 15×51 layout to achieve a high treatment flow rate and an expedited process to ensure delivery times. The new unit was successfully installed within 8 hours, saving the contractor time and money.
BENEFITS
ENVIRONMENTALLY-FRIENDLY
| The BioPod system delivered a low-impact development solution that meets green infrastructure requirements and offers a reduced footprint compared to traditional stormwater treatment systems.
TIME-SAVING
| Oldcastle Infrastructure was able to work swiftly and precisely to present and submit designs in 2 weeks, with the system ready to deliver in just 7 weeks after approvals. And with a perfectly executed delivery and installation, the custom BioPod was delivered to the exact project specifications.
FLEXIBLE
| From design to installation, the Oldcastle team offered an experience tailored to the contractor’s need, and BioPod’s unique design allows for seamless integration with other stormwater systems in the future.
“The BioPod was the most cost effective solution for this project applicatio. Large treatment requirements, tight site constraints equals perfect solution.”
| Contractor
Miles Resources
| Consulting Engineer
Barghausen Consulting Engineers, Inc.
| Solution
BioPod Underground
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Title of the document
Thriving and bustling Harris County is the most populous county in Texas. To plan for continued growth and increasing water management needs, the county required an expanded water line system to run under Beltway 8, part of an 88-mile freeway around Houston. Oldcastle Infrastructure was chosen for the job because of their ability to meet the specification requirements, operate within the required budget parameters, and complete the project by the deadline.
CHALLENGE
This was a highly complex project in many ways, as it required Oldcastle Infrastructure and the contractor to overcome a series of unique and difficult circumstances. These included:
• The waterline went through a fault line.
• Extensive tunneling was required underneath the busy Beltway 8 Freeway.
• The project location was in close proximity to high voltage transmission lines.
• The size and weight of the required concrete pipe made installation challenging.
• Hydraulics were required to jack the pipes in place.
• The pipe jacking machine required constant monitoring and maintenance.
SOLUTION
Oldcastle Infrastructure, working in tandem with Harper Brothers Construction, designed, manufactured, and installed 17 pieces of 108” concrete pipe as a Tunnel Liner or Jacket around the 84” water line. Normally, a trench would be dug to install the concrete pipe underground and the trench would be backfilled after the pipe was installed. Conditions in this case, however, called for a trenchless installation. The contractor had to tunnel under the Beltline 8 Freeway and hydraulically jack the 108’ diameter concrete pipes into place. This had to be done one after the other – and all from one location at the side of the freeway. The hydraulic jacking required 12 hours to push each pipe into place.
This was a highly specialized application at a fault line crossing – and only the second time Harper Brothers Construction has used concrete pipe as a tunnel liner. After two months, the project was completed on time. The waterline was well-supported and protected across the fault line and the entire installation went smoothly without disrupting freeway traffic.
BENEFITS
Oldcastle Infrastructure’s Concrete Pipe will provide a long-term, high-performing, and sustainable water management solution for the North Harris County Regional Water Authority.
Highest Built-in Structural Strength
The strength of the Oldcastle Infrastructure’s concrete pipe contributes to its resiliency. It is particularly resistant to damage from external forces; therefore, it was selected to support the water line across the fault line protecting it from damage due to earth movement.
Highway Service Uninterrupted
The Beltline 8 Freeway was not disrupted during the pipe installation.
• Tunneling prevented the digging of a trench through the freeway.
• Traffic flowed normally on the freeway during the installation.
• The freeway did not need rebuilding after the installation.
“Oldcastle Infrastructure was always on time and easy to work with. They understand tight timelines and deliver with great dependability and reliability. Plus, their engineers were always available for questions or to resolve any issues. Overall, I was thoroughly impressed.”
Miguel Garcia
Project Manager
Harper Brothers Construction
| Owner
Harris County
| Contractor
Harper Brothers
| Distribution Plant
Houston, TX
| Featured Products
17 Joints of 108” concrete pipe
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The EV Cabinet Base System has been specified by MFG to aid and enhance the installation of Power Cabinets, required at an EV Charging Bay, located on a gas station in Leyton.
SOLUTION
Designed to simplify the installation and maintenance of switch gear power/comms cabinets which allows for streamlined upgrades, additions and replacements. This modular base system is significantly faster to install when compared to traditional methods as initial installation requires no concrete, removing significant delays attributable to weather constraints. Comprising of a STAKKAbox™ ULTIMA Connect Access Chamber, onto which cabinet modules are bolted and secured, the system facilitates a positively connected duct network directly into the cabinets.
Upon completion of civils installation and, if preferred at a later stage when ready for use, power cabinets are simply lowered onto the cabinet base via a truck crane and bolted into position.
In this instance, contractors were able to install the cabinet base prior to the delivery of power cabinets eradicating the risk of potential and costly damage to equipment while work continues. Additionally, this installation allows for civils and electrical works to be carried out independently, guaranteeing no time is lost due to conflicting schedules.
Providing open cable access between cabinets, the Cabinet Base System is fully future proofed to allow the addition of cables (should advancements in technology dictate) while affording a simplified process in terms of maintenance, removal and replacement.
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Transport for London (TfL) has invested in EV charging infrastructure to support the UK government goal of cutting 68% of UK greenhouse gas emissions by 2030.
SOLUTION
The implementation of EV infrastructure aims to encourage the transition to electrical vehicles. However, this rapidly evolving technology could potentially prove costly to many local authorities as they try to make their towns and cities cleaner. We have utilized our experience providing future-proofed solutions to develop the Universal EV Charger Foundation to accommodate changing EV technologies.
The system is composed of a Shallow Foundation Retention Socket, which is ideal for installing around existing underground services. Another advantage is that the Retention Socket and ducting can be installed and left sealed with a pedestrian plug until the expensive EV charger unit is available for installation at a later date. The second component of the system, the Adapter Plate, is secured into the Retention Socket on the day of the charger unit installation. The Adapter Plate corresponds with the unit manufacturer, in this case, BP Pulse.
Once the Adapter Plate is secured and the power cable is positioned in the Retention Socket the charger unit is lowered by a truck crane onto the plate. Locating pins screwed to the Adapter Plate assist in aligning the plate to the charger unit. These pins are then removed and 4 set screws secure the system in place, ready for electrical connection.
Reboundable X-Last bollards installed in composite sockets accompany the system to provide protection to the unit and can be demounted at any time if required.
_______________________________________________
| Featured Products
Shallow Foundation Retention Socket
Adapter Plate
Reboundable X-Last Bollards
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Four High Power Charger Foundations have been selected to install one high power EV charger and three rapid EV charger dispenser units, within an existing gas station situated in Worcester.
SOLUTION
Designed to accommodate all manufactured and custom high power dispenser units; the Modular Foundation System combines the STAKKAbox Modula Access Chamber with our Retention Socket. This design provides unrivaled flexibility, when accommodating the bend radius of large power cables.
Civils works were completed prior to the installation of EV dispensers, as the system allows for cables to be pulled through ducting and stored within the Retention Socket. If required, foundations can therefore be installed, and utilized when future demand dictates and, in this instance, eradicated any issues associated with conflicting time schedules.
Initially specified to improve the installation and cabling process, these systems are also future-proofed to allow for technological advancements and replacements. With inevitably increased demand, the High Power Charger Foundation will facilitate the upgrading of the rapid dispenser units without any further civils work.
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The Fast Charger Foundation has been selected and installed within a “Rapid Electronics” parking lot in Colchester. Working closely with Replenishh, an EV division within the Rapid Group, we supplied the foundation to install a Schneider fast charger dispenser.
SOLUTION
This universal system utilizes the Retention Socket, selected with a duckfoot bend option for this installation, to provide a positively ducted connection to an access chamber, located nearby. Dispensers can be installed directly within the Retention Socket, however, in this instance, the Schneider unit was secured to a spigotted adapter plate and then installed, to accommodate the manufacturer-specific design.
Facilitating civils and electrical cabling works completion prior to the delivery of dispenser units; the Fast Charger Foundation provided a simplified installation and guaranteed no conflict in time schedules between contractors, enabling adherence to strict time constraints. While not in use, the cables are stored in the Retention Socket, which is then sealed with a pedestrian plug to eradicate any trip hazards.
The system has provided improved access to all utility cables for ongoing maintenance purposes and will allow for future upgrades to accommodate inevitable advancements in technology.
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Baltimore MTA was developing a brand-new light rail system to alleviate vehicular traffic and move customers faster through the city. A key factor in the design involved a new solution to contain and protect the many cables that go into a modern transit system, including electrical, communication, signaling and fiberoptic cable. Traditionally, cables were buried in conduits, placed in a duct bank, laid into a cable trench or put up on catenary poles. These existing methods of cable management were costly, time-consuming and highly inefficient. Oldcastle Infrastructure introduced new products and technology that allowed us to provide an innovative solution to the Baltimore MTA that would save considerable time and money on installation. The newer method of cable management also makes maintenance easier following project completion.
CHALLENGE
The challenge in any Rail/ Transit/LRT project is determining which design methods are best suited to incorporate into the system based on the site conditions and limitations. Our goal as a major supplier to the market is to understand these conditions and how they relate to the overall conceptual design, and work with the customer to demonstrate the benefits behind those project plans. For the Baltimore MTA, Oldcastle Infrastructure provided an integrated cable management solution by leveraging application engineering expertise and products from across our global enterprise portfolio.
SOLUTION
Our first goal, as always, is to listen to the customer and understand their needs. After reviewing the existing design, we came back with a plan for a complete cable management system. Our deliveries included overall conceptual design, site conditions and long-term needs over the project lifecycle. We provided the technical information around the components and how they fit together into their design.
Key products featured in the overall cable solution include: Plastibeton for cable troughing and protecting vital cables from vehicular traffic, emergency vehicles and maintenance equipment. Multiduct cable protection ducting system replaces traditional concrete encased conduits while providing a faster installation, less space and overall material cost savings. STAKKAbox modular vault system built on-site with lightweight, easily connectable corner pieces and scalable sidewall lengths that configure to the unique project specifications and, depending on the size of the project, can be completely installed in just one day.
One of the advantages of this type of cable management solution is that it is component-based and does not require custom engineering along the way, or the time-consuming process of pouring and drying concrete. It can take 7-10 days for that traditional solution – versus 1-2 days for our innovative solution.
BENEFITS
Overall, our functional cable management solution offered a robust value proposition via a system that is:
Safer
Faster
Lower in cost
Easier to maintain
More efficient
Repeatable and scalable
All from a single supplier making it easier to manage
For the Baltimore MTA, this solution took cable from an underground, inaccessible conduit, to a place where the cable is more accessible and maintainable. No more burying cable underground and having to pull it out to gain access.
This idea of component building a cable management solution is now being used throughout our rail industry and to different degrees so owners like Amtrak and Metro North can benefit. Oldcastle Infrastructure’s engineering team is with them for support from day one – right through the entire life cycle of the project.
The Baltimore MTA project transcended geography, federal and local regulations, logistical and technical challenges and competitive pressures. It’s one more example of Oldcastle Infrastructure and CRH collaborating in action to get the job done. Rail projects like this one and others can have a 10-year life cycle. It’s good to know you can partner with a company like Oldcastle Infrastructure that has the innovative solutions and staying power to be there for you in the long run.
| Owner
Baltimore MT
| Consulting Engineer
Precision Approach Engineering, Inc.
| Featured Products
Plastibeton Cable Trench System
Multiduct Cable Protection Ducting System
STAKKAbox Ultima Connect Modular Vault System
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It may be early in the adoption curve for electric vehicles in the U.S., yet the timing is perfect for Oldcastle Infrastructure to be the first to market with scalable, sustainable solutions that set the infrastructure standards in the emerging eMobility industry.
By capitalizing on expertise, collaboration with a leading original equipment manufacturer (OEM), and trillions of dollars of infrastructure funding in the US, Oldcastle Infrastructure is creating a roadmap to be at the forefront of future-proofing the built world. Oldcastle Infrastructure teamed up with the OEM to assist with streamlining the installation process, allowing the OEM to save time and money, and standardize deployments across the U.S.
CHALLENGE
The OEM was using a cast-in-place design that was vulnerable to a series of inefficiencies. Cast-in-place is a cumbersome process that requires extensive prep work, field labor, challenging site constraints, and nearly perfect weather conditions. This combination of factors has slowed down the rollout of EV charging stations at a time when timing mattered.
SOLUTION
Oldcastle Infrastructure designed and tested multiple iterations of a precast mounting pad. Through our collaboration with the OEM, we discovered difficulties feeding wiring through the conduits. To solve this problem, our engineers created multiple blockouts in the pad. Additionally, the pad design was optimized for precast concrete manufacturing by making several adjustments including removing the customer-provided mounting plate.
The result is four standardized precast foundation designs that offer a turn-key solution across the U.S. eMobility space. The installation process was streamlined into a single-day installation, requiring the construction team to only drop a fully manufactured piece into the excavated area. This solution is being launched across the country and its success is driving the conversation toward a fully future-proofed solution.
Oldcastle Infrastructure continues to collaborate with the OEM in design enhancements that include a universal Retention Socket and adapter plate that can be used to prepare the foundation pad to accept the charging station and set the customer up for a faster installation and safe pedestrian walkways between installs. Oldcastle Infrastructure is leading the way with EV charging products that create easy-to-install, future-ready solutions and allow OEMs to standardize eMobility deployment across the U.S
BENEFITS
Speed up and simplify your installation with one foundation for all your EV charging infrastructure. The EVNext precast concrete pad arrives at the job site ready-to-go, with openings customized for your equipment and anchors inserted precisely where you need them. These durable foundations can be installed above or at grade and can accommodate EV chargers, cabinets, transformers, or switchgear components.
- Our engineering team works with you to create a customized solution that fits your specs
- Pads are designed for your equipment needs with openings precisely where you need them
- Precast foundations arrive on-site, ready for installation, and equipment connections
- A strong, durable foundation for EV chargers, cabinets, transformers, and switchgear components
- Inserts can be included for anchoring equipment
- Pads can be installed above grade or at grade, subject to engineering evaluation
- Conduits can be embedded upon request
- Precast concrete eliminates the wait time of cast-in-place options; equipment can be installed the same day
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Stormwater runoff poses increasing challenges to cities, straining sewers and water treatment plants while polluting nearby water bodies. The Indian River Lagoon, located on Florida’s coast southeast of Orlando, is no exception. The 2,284 square miles of this vital watershed generate billions of dollars annually and are key to the region’s economy.
Decades of stormwater runoff containing fertilizers, chemicals, and trash have wreaked havoc along the 156-mile-long Indian River Lagoon. This has resulted in a loss of sea grass, a proliferation of algae, and a threat to the habitat of fish, wildlife, and plant species.
CHALLENGE
The city of Melbourne, FL was in search of a solution to effectively mitigate and clean the stormwater runoff before entering the Indian River Lagoon. Specific challenges during this project included:
• High treatment and peak flows carrying large amounts of trash and pollutants harming the lagoon (Phosphorus, Nitrogen, TSS)
• Site constraints due to right-of-way and accessibility issues
• Aggressive installation schedule coupled with challenging installation conditions
• Designed with simple, accessible maintenance
in mind
SOLUTION
The Melbourne Engineering Department chose to partner with Oldcastle Infrastructure for a long-term solution that fits the parameters of this project.
The Nutrient Separating Baffle Box® (NSBB®) designed and manufactured by Oldcastle Infrastructure, removes trash, sediment, Total Suspended Solids (TSS), and nutrients. NSBB can handle extreme stormwater runoffs like the one on the Indian River Lagoon and offers a superior hydrodynamic separation system that treats the entire flow. The triple-chamber design removes high levels of TSS over a wide range of particle sizes. In addition, patented deflectors ensure no sediment scouring occurs during high flows, allowing for on-line installation without the need for separate diversion structures.
Unlike traditional stormwater treatment methods such as sedimentation ponds, the NSBB is smaller, more flexible and easier to install. Its shallow, small footprint is designed for easier and numerous placements around the lagoon. The engineered concrete product features a multi-stage treatment system with manholes and hinged screen doors. That makes it simple for Melbourne’s Engineering Department to access and maintain 15 baffle boxes, and counting, with one vacuum truck monthly.
“Our need to protect the Indian River Lagoon will only grow,” says Dani Straub, Melbourne Engineering Project Manager. “Our goal is to remove 90,000 pounds of total nitrogen per year and 27,000 pounds of total phosphorus per year. NSBB installations will help us meet that goal.”
BENEFITS
Designed for Easy Maintenance
The NSBB uses a patented screen system to capture and store debris in a dry state to minimize nutrient leaching and allow for efficient maintenance.
Made for a Variety of Application Sites
The NSBB’s innovative design allows for a shallow system in an optimized footprint, allowing it to be installed almost anywhere. The city has installed at least 15 baffle boxes to date and will continue to add more in the coming years.
Built to Capture Pollutants at High Flows
The NSBBs are designed to treat an average of five cubic feet of water
per second. That is more than three million gallons of treated stormwater each year.
Faster Installation Time
With a smaller footprint and a shallow profile, the NSBB is designed for easy installation. Quick installation times have allowed the city of Melbourne to meet its clean water goals within the desired time frame.
Removes Phosphorus and Nitrogen
Incorporating a filtration media in the NSBB allows it to remove more
Nitrogen and Phosphorus, two of the main pollutants that have been of concern to the city of Melbourne. Melbourne’s Engineering Department estimates the baffle boxes have removed more than 7,800 pounds of nitrogen and 1,550 pounds of phosphorus yearly.
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“Nutrient Separating Baffle Boxes have been a large part of the city’s efforts to clean the stormwater that enters the lagoon. Not only do the baffle boxes trap debris, trash, and pollutants that flow off of streets and into storm drains, they also remove nitrogen and phosphorus, two of the harmful pollutants draining into the Indian River Lagoon.”
Dani Straub
Melbourne Engineering
Project Manager
| Owner
City of Melbourne, FL
| Contractor
Melbourne Engineering Department
| Featured Products
15 – Nutrient Separating
Baffle Boxes (NSBB)
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The Washington State Department of Transportation (WSDOT) has been working to remove fish passage barriers throughout western Washington since 2013 as the result of a federal culvert injunction*. Ruling in favor of twenty-one northwest Washington Tribes, the U.S. District Court required the expansive culvert removal because of a treaty-based duty to preserve fish runs. The older legacy structures were built to allow water to flow through, but not fish. Acting as barriers, these box culverts impede salmon migration and prevent the fish from accessing their natural habitats.
Granite Construction, Inc. partnered with Oldcastle Infrastructure to manufacture a box culvert solution for the Pepin Creek install that will work towards providing a sustainable fish passage for the area.
CHALLENGE
The install at Pepin Creek with Granite Construction, Inc. required removal of the current box culvert structures that impede fish passage and a larger box culvert replacement as a solution that supports the native stream, imitating a natural creek bed.
Specific challenges that the Oldcastle Infrastructure team faced during this project includes:
• Customizing a larger box culvert solution for fish passage purposes that would imitate the natural creek bed using rocks and dirt.
• Ensuring design approvals were within the project timeline.
• Fitting the culverts together prior to shipping to assist with the tight three-day installation window.
• Overseeing the loading and delivery of 60 trucks leaving the manufacturing facility in timely intervals.
SOLUTION
This project showcases Oldcastle Infrastructure’s ability to provide comprehensive support from initial design and engineering services through timely delivery as a single source of supply for this split box culvert fish passage solution. With so many critical pieces to the project, thorough planning and departmental teamwork was required for success.
Three split box culverts with head walls and wing walls, were produced during a six-to-eight-month manufacturing period that ended with extensive quality checks, consistent with the specifications requiring the products to be dry fit and preassembled in the plant. These box culverts contributed to the overall coordinated effort of the removal and replacement of fish passage barriers.
BENEFITS
While the project met all time, budget, and specification parameters for the enlarged structure, the ultimate benefit is much bigger. This project is about restoring historic salmon and steelhead runs that have been interrupted for decades.
Sustainability
Restoring fish and wildlife habitats fits in naturally with Oldcastle Infrastructure’s overall commitment to sustainability and we are proud to have partnered with WSDOT to have completed over 100 fish passage culvert projects. These projects have helped to improve access to hundreds of miles of blocked salmon and steelhead habitat. The Department of Fish and Wildlife has found fish spawning upstream at over half of the completed WSDOT fish passage project sites*. The opportunity to recreate these natural migration patterns as part of a sustainable ecosystem is historically significant. Oldcastle is a full solutions provider for barrier corrections and fish habitat improvements providing a permanent sustainable solution like a natural stream.
Resilience
The strength of concrete contributes to the resiliency of these box culverts. They will deliver long-lasting, high-performance with a service life of over 100 years. Built for the long-term, precast box culverts are engineered to withstand external forces and maintain structural integrity throughout their entire lifecycle. The product’s long service life will prevent the need for replacement further contributing to its sustainability.
Installation Time
Precast concrete only requires onsite assembly, providing a quicker install compared to for allowing this project to be completed in 3 days.
Eliminating the need to pour concrete allowed this project to be completed in a tight timeline of 3 days and the roads were reopened in time for the Western Washington State Fair.
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https://wsdot.wa.gov/construction-planning/protecting-environment/fish-passage/federal-court-injunction-fish-passage
https://www.enr.com/articles/54660-wa-fish-passage-program-to-flood-contractors-with-work
“With a project of this complexity, on this challenging time frame, we needed the right partner, and we chose Oldcastle Infrastructure,” said Lance Chambers, Granite Construction. “They are a single-source company, meaning that the engineering team, the project leads, the plants, the capacity, and the experience – it’s all under one roof. One phone call (even in the middle of the night!) and we’re able to keep moving forward. The OIdcastle team was very responsive from the beginning and worked within a very short timeline to develop and submit the design needed. That dexterity and experience was one of the reasons we completed the project as projected.”
Lance Chambers
Granite Construction
| Owner
Washington Department of Transportation (WSDOT)
| Contractor
Granite Construction, Inc.
| Distribution Plant
Bellingham, WA
| Featured Products
Split Box Culvert with
Head Walls and Wing Walls
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While constructing a new e-commerce distribution center, our client turned to Oldcastle Infrastructure for a stormwater management solution and underground detention system. Utilizing our StormCapture detention system and supporting products, we provided a solution that was focused on efficiency both in function and installation.
CHALLENGE
Brent Scarbrough & Company, the operating contractor on this project, brought in Oldcastle Infrastructure in the face of several logistical challenges. The large amounts of rainfall customary to the area provided difficult working conditions, while additionally meaning that the stormwater system of choice needed to be stronger, more reliable and more effective than standard systems.
This installation provided a number of challenges along the way:
• A very tight working space for the installation caused the trucks to be in constant motion.
• The size of the system required staging of StormCapture units on site so that manufacturing could continue.
• Large amounts of rain provided a natural obstacle to the installation timeline.
SOLUTION
Oldcastle Infrastructure designed a completely custom stormwater detention system utilizing the StormCapture clamshell modules. Able to meet all the project requirements, work within site constraints and deliver a system that met application needs, our local manufacturing provided the most efficient and responsive installation process possible.
Due to the local production of the product, Oldcastle Infrastructure was able to deliver StormCapture units at an unmatchable pace, resulting in the complete installation in just 6 working days.
In addition, Oldcastle Infrastructure representatives were on site every single day during the installation. By providing attentive, ongoing support throughout the process, a deep understanding and high-functioning relationship was formed with the contractor.
BENEFITS
Build Quality
The quality of our StormCapture system was a difference maker, providing an easier and safer installation due to the interlocking modules. Additionally, every module was poured in the same plant, ensuring high and uniform quality across the board.
Easy Installation
Because of StormCapture’s unique design, installation was expedited through the interlocking nature of the product. This feature allows a faster setting process and resulted in 434 pieces being installed in just a few days.
Locally Manufactured
Oldcastle Infrastructure’s local manufacturing was a big advantage for this installation. Due to the tight timeline and working conditions, drivers were able to unload, and return to pick up the next round directly from the manufacturing facility, expediting the timeline and keeping installation moving.
“The quality and design of the StormCapture modules allowed for much faster set times. This kept our very tight schedule on track.”
Heath Head
Brent Scarbrough & Company
| Contractor
Brent Scarbrough & Company
| Consulting Engineer
Eberly & Associates
| Stormwater Volume
310,651 cubic feet of storage
| Featured Products
StormCapture®
Link Slabs
Grade Slabs
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