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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North Carolina
DESIGN & CONSTRUCTION TEAM
General Contractor: Commscope
Owner: MCNC
Precaster: Oldcastle Infrastructure
Manufacturing Facility: Oldcastle Infrastructure, Newnan, Georgia
New fiber build installation of approximately 2,000 miles of fiber optic cables throughout a 69 county area in the state of North Carolina. As part of the BroadbandUSA Initiative once complete the project will greatly increase the broadband capacity and stabilize bandwidth and Internet access costs for public school systems, community college campuses, libraries, universities, and other community anchor institutions.
Phase 1 required (2) two turnkey Co- Location Shelters to house the headend fiber network system.
Phase 2 required an additional (18) eighteen turnkey Co-Location shelter sites.
CONSTRUCTION CHALLENGE
In collaboration with MCNC, Commscope and the State of North Carolina Oldcastle Infrastructure provided a “turnkey” solution for (20) different sites. Oldcastle’s scope of work consisted of the manufacturing, outfitting and installation of (20) twenty RCS1020 shelters along with foundations, fencing, power service, dc installation, racking and generators.
PRECAST SOLUTION
The turnkey project involved the manufacturing and complete out-fitting of Oldcastle Infrastructure’s RCS1020 Precast Equipment Shelters with all specified equipment. In addition, the fully out-fitted shelters were shipped, installed and made fully functional at (20) twenty different locations in North Carolina. The RCS1020 shelters were manufactured at our Newnan, GA facility and foundations were installed in the field by our Oldcastle Services Group.
CONSTRUCTION SCHEDULE
Start Date: January 2012
Completion Date: Scheduled for September 1, 2012
SCOPE OF WORK
Precast Structure
A. STRUCTURE ENGINEERING
Drawings: Detailed engineering and drawings
B. PRECAST CONCRETE SHELL
Size: (1) RCS 1020 concrete shelter with waffled floor
Concrete: 5000 psi concrete
Outside Dimension: 20′-0″ Long x 10′-0″ W x 10′-1″ H
Finished Inside Dimension: 19′-0″ Long x 9′-0″ W x 9′-0″ H
Weight: Approximate finished weight: 48,432 pounds
Specifications: Floor load: 200 PSF
Roof Load: 60 PSF
Wind Load: 150 MPH, Exp “C”
Bullet Resistance: UL752 Level 4 equivalent
Fire Rating: 2 hour
Seismic Zone: Up to 50% gravity acceleration
C. FINISHES
Exterior Walls: Exposed aggregate finish with tan trim
Interior Walls & Ceiling: 1/8″ FRP mounted on 1/2″ board
Insulation: R-11 on walls and ceiling
Telco Board: (1) 4’x4′ telco termination board; white
Floor: Vinyl composition tile
Roofing: Dura-cool coating
D. DOORS AND OPENINGS
Doors: (2) 3’-0” x 7’-0” heavy duty steel door & frame
Locks: (2) Kaba – 5 key combination locksets
Door Hardware: NRP Stainless steel hinges, closer, pick plate, holder, weather stripping, door shoe & aluminum threshold.
Door Drip Caps: (2) Door drip caps – 2 ½” wide
Door Canopy: (2) Standard 3070 door canopies
E. POWER
Power Service: 200A, 1Ø, 120/240V
Main Distribution Panel: 200A, 1Ø, main breaker w/ 42 positions “SQ D”, breakers
Exterior Disconnect: 200A, 1Ø, exterior disconnect
Surge Suppression: (1) AC Data surge suppressor – AC2100NA
Convenience Outlets: (8) 120v/20A duplex outlets
Exterior GFI Outlets: (1) 120/20A outlet
Twistlock Receptacles: (4) 120v/20A twistlock receptacles
Automatic Transfer Switch: (1) Automatic Transfer Switch – Asco 300 Series
Fiber Termination Panel: (2) Fiber Termination Panels
Battery Plant: (2) 100A, Eltek Valere DC Battery Plants
Standard Racks: (2) Standard racks
Invertor: (1) 2000 Watt invertor
F. ENVIRONMENTAL SYSTEM
HVAC: (2) 3 ton, 1Ø – Marvair HVAC units with 5kw heater, no economizer
Controls: (1) Lead / Lag controller
G. ALARMS
Alarms: (1) 25 pair alarm terminal box with Intrusion, smoke, power failure, HVAC fail and high/low temperature
H. LIGHTING
Interior: (4) 4’, double tube fluorescent light fixtures with lexan covers
Exterior: (2) Exterior lights, 70 Watt HPS with photocell
Emergency: (1) Emergency fixture with dual flood lights
Switches: (2) 20 amp light switches
I. CABLE LADDER
Cable Ladder: 60 linear feet of 18” wide gold chromate cable ladder with supports and brackets
Cable Brackets: 22 each cable brackets – Central Steel Part #ACB2ZY
Also Offering Real Estate Services
- Identification/Evaluation
- Due diligence
- Contract negotiation
- Representation at closing
- Real Estate CommissionsFind out more about Oldcastle Precast Building Structures.
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The Pentagon Renovation Program (PENREN) was a long-term project by the U.S. Department of Defense to perform a complete top-to-bottom renovation of the immense facility in Arlington, Virginia. The renovation plans included building a Remote Delivery Facility (RDF), a new 250,000 square-foot shipping and receiving operation adjoining the Pentagon. The RDF would significantly improve the physical security of the Pentagon by providing a secure, consolidated location for receiving and screening the thousands of items shipped to the building each day.
CHALLENGE
All this new impervious hardscape created a stormwater management dilemma for the Pentagon. The new RDF facility with its surrounding roadways, loading docks and parking lots would generate a significant amount of stormwater runoff, so the Department of Defense contracted with Louis Berger Group, a full-service engineering firm based in Morristown, New Jersey to design a solution that could handle 5,700 cubic feet of stormwater storage in the 1,856 square-foot worksite.
SOLUTION
Needing an underground, traffic-rated stormwater detention system with a small footprint that could be installed quickly without heavy equipment, Louis Berger Group ultimately selected a CUDO® system from Oldcastle Infrastructure. In total, just 378 CUDO cubes were required to meet the Pentagon’s requirements, offering 5,731 cubic feet of stormwater storage with just a 1,512 square-foot footprint.
In addition, to mitigate the amount of trash, debris and sediment from entering the CUDO system, Louis Berger Group also specified a DVS-60, a five-foot diameter Dual-Vortex Separator, to be installed upstream of the structure. The standard DVS-60 offers 29 cubic feet of both sediment and floatables storage at a maximum treatment flow rate of 2.6 cfs, but the depth of the unit can be increased to add storage capacity.
BENEFITS
The CUDO modular stormwater storage system was able to provide a quick and easy installation without the need of heavy equipment and within a smaller footprint while the DVS pre-treatment provided particle separation from stormwater runoff. Settled particles and sediment are collected in the isolated bottom storage area, while floating trash, debris and petroleum hydrocarbons are retained in the cylinders and upper storage areas. This stormwater solution system provided by Oldcastle Infrastructure ensures that the system functions at peak storage volume, without reducing the design percolation rates or impeding flow in and out of the system during its service life.
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The Anna Mann House is a historic affordable housing development located in the Kerns neighborhood of Portland, Oregon.
In order to meet the City of Portland’s stromwater management regulations, (10) 30’ deep traditional drywells were originally specified for the project, which would require a large excavation area and a long construction timeline. To minimize the space needed, Oldcastle Infrastructure conducted performance modeling, leveraged the MaxWells smaller footprint and reduced the number of drywells needed from ten traditional drywells to six MaxWells.
The solution needed to address fast installation within a confined project site utilizing a reduced footprint and provide a cost savings over traditional drywells.
CHALLENGE
Site restrictions such as existing buildings, narrow streets surrounding the property and limited access to the site made traditional drywell installation difficult and expensive.
Using traditional stormwater management solutions to meet site parameters 10 Conventional 30’ deep drywells were required needing significant space for excavation.
Handle the water quality flow rate from 1.4 acres of impervious surface, or 1,300 gpm.
The City of Portland required onsite stormwater elimination which can be challenging when surface soil doesn’t infiltrate.
SOLUTION
A MaxWell drywell can be precision drilled and installed inside of an 8’ circular footprint compared to a large excavation area required to install a standard drywell. These deep drywell systems are easy to install by using one drill rig and onsite equipment.
Through a combination of primary settling chambers and 50’ deep MaxWell IV drywells the team provided a stormwater management solution that reduced the number of drywells needed by five which minimized installation time and footprint.
MaxWell drywells are a great solution in the Pacific Northwest when the surface soil doesn’t infiltrate and groundwater is fairly deep because we drill deeper gaining access to more permeable soils.
BENEFITS
MaxWell drywells are an industry-leading, sustainable deep infiltration solution for onsite stormwater management with more than 50-years experience setting the standard for drywell stormwater management.
MaxWell’s ability to drill to deeper soil levels which creates added head pressure creating better system performance within a smaller footprint than traditional drywell methods. Unlike traditional drywells, MaxWell systems are easy to maintain ensuring optimal performance. With a smaller footprint comes faster installation time and reduced costs due to less area impacted by excavation.
“The MaxWells allowed us to reduce the footprint of the stormwater system, and since Oldcastle handles the installation, we can feel confident that the work was done correctly. Oldcastle provided great design assistance and remained engaged from concept to construction.”
Alex Wesolovski
Principal
Vega Civil Engineering
| Owner
Anna Mann Limited
Partnership/Innovative
Housing, Inc.
| Contractor
Silco Commercial
| Engineer
Vega Civil Engineering
| Solution
2 – Primary Pretreatment
Settling Chambers
6 – 50’ deep
MaxWell IV Drywells
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The 3000 Powell affordable housing project is located in the Creston-Kenilworth neighborhood of Portland, OR and will provide a mix of studio and larger units, totaling 206.
Geotechnical testing concluded the site contains 50’ of undocumented fill and approximately 25’ of that fill is contaminated, which would make traditional 30’ drywells infeasible, but not MaxWell drywells. By using metal casings and slurry to seal off the contaminated fill, our drill rigs are able to drill into the native, sandy subsoil, which is ideal for infiltration. As a result, the native soil is protected from the contamination above and can be used to infiltrate on-site stormwater meeting City of Portland’s stormwater management requirements.
CHALLENGE
Twenty-five feet of contaminated fill made protecting the native soil from contamination and the ability to infiltrate on-site stormwater a top priority.
In order to address stormwater runoff and it’s impact on the surrounding area, the City of Portland requires stormwater runoff from the 1.4 acres of impervious surface be managed on-site.
Additional site footprint constraints limited the use of larger, shallow infiltration solutions.
SOLUTION
The team drilled 5’ past the contaminated soil line into native soil to install a metal casing and a bentonite slurry plug blocking further soil contamination and allowing for safe ground water recharge.
The MaxWell meets the City of Portland’s drywell requirements for on-site stormwater management.
A MaxWell drywell can be precision drilled and installed inside of an 8’ circular footprint compared to a large excavation trench required to install a standard drywell.
BENEFITS
The unique design of MaxWell and the ability to reach and infiltrate deeper into native soil not only reduced the footprint required to meet the needs of the project but also reduced installation time and costs.
The team delivered a solution that managed stormwater on-site and promoted safe groundwater recharge by working closely with the general contractor and consulting engineer to address site-specific needs to meet the City of Portland’s regulatory requirements.
“A traditional 30’ drywell was not going to work on this site. We needed a solution that would infiltrate below the 50’ undocumented fill line and control the contaminated soil to recharge the groundwater below. And MaxWell addressed those challenges.””
Josh Lighthipe
Sr. Project Manager
KPFF Consulting Engineers
| Owner
Home Forward
| Contractor
GC: Colas
Earthwork Contractor: M&M
Construction Services, Inc.
| Engineer
KPFF Consulting Engineers
| Engineer
1 – Primary Pretreatment
Settling Chamber
3 – 50’ deep
MaxWell IV Drywells
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During the development of a large commercial warehouse for Logistics Property Company (LPC), 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 to LPC 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, which would not fit a standard BioPod unit.
| 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 crew’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 unique design allows for seamless integration with other stormwater systems in the future.
“Through production, delivery and installation, our BioPod system surpassed client expectations at every turn. The developer was so pleased, that we immediately began moving to install a BioPod system at his next development.”
Oldcastle Infrastructure
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.
LOCALLLY 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.”
Brent Scarbrough & Company
Contractor: Brent Scarbrough & Company
Consulting Engineer: Eberly & Associates
Solution: StormCapture® | Link Slabs | Grade Slabs
Stormwater Volume: 310,651 cubic feet of storage
Download Full Case Study
As Auburn University continues to grow their phenomenal football program, a need developed to upgrade their football operations facility. This involved transforming campus tennis courts and track facilities into a new, state-of-the-art football operations building and practice facility. As part of the new development, an underground stormwater detention system was required.
THE CHALLENGE
Shortly after being awarded the project, the contractor reached out to partner with Oldcastle Infrastructure to bring the project to life. After previously working with Oldcastle Infrastructure in the Atlanta market, our team and the contractor had developed a mutually-respected working relationship.
Specific challenges the team faced during this project included:
| Introducing a new precast product to Auburn University engineered specifically for stormwater management.
| Reducing the lead times and installation window with a more efficient product.
| Ensuring the design engineer was in agreement that this product would be a better fit for this project than the box culvert.
THE SOLUTION
The Oldcastle Infrastructure team identified a unique opportunity to install two StormCapture systems in lieu of the specified box culvert, which would have required more pieces in addition to a longer delivery and set time.
This was the first time StormCapture units were delivered to the state of Alabama. The two StormCapture systems were successfully installed by ensuring all components were accounted for in advance, resulting in an expedited installation of one day per system.
The StormCapture footprint allowed the contractor to utilize a smaller number of modules.
BENEFITS
TIME-SAVINGS
With precision and nimbleness, Oldcastle Infrastructure was able to shave an entire week off of the installation timeline. Combining a perfectly-scheduled and executed delivery, with a system that required far less comparative laydown area, the project was delivered according to exact project specifications and a full week ahead of schedule.
DEDICATED SUPPORT
Oldcastle Infrastructure acted beyond the call of duty and scope as a complete supportive partner throughout the entire project. Oldcastle team members assisted with everything from crane setup, to rigging, to fitting, safety and more, impressing the general contractor and project owner.
“The support provided by the Oldcastle team during installation was unbelievable. I expect to see this system included as a solution for underground stormwater detention on many future Auburn University projects.”
VP of EVERGREN SITEWORKS
Owner: Auburn University
Contractor: Evergreen Siteworks
Consulting Engineer: LBYD
Solution: 44 6-foot StormCapture® units | Three Link Slabs
Stormwater Volume: 310,651 cubic feet of storage
Download Full Case Study
Oldcastle Infrastructure’s OneLift™ Pump Station offered a streamlined solution for the Sedona, Arizona, wastewater collection system by providing pump stations at two locations as part of the City’s infrastructure.
THE CHALLENGE
Because the City is situated at the bottom of a valley, most of its waste water goes through a series of pump stations to reach the treatment facility situated at higher elevation. The installation of the Mystic Station and Chapel Station units required excavation into rock to get the required depth in a short period of time.
This project raised a number of challenges along the way:
| The Mystic Station required a smaller footprint to build the masonry wall.
| The Chapel Station needed to be replaced in full.
| The contractor required rapid installation to avoid excessive bypass pumping costs.
THE SOLUTION
Oldcastle Infrastructure delivered and installed two OneLift Pump Stations at Mystic and Chapel stations as part of the City’s existing infrastructure.
| Installing OneLift at the Mystic Station allowed for a smaller excavation to avoid the long and costly process of a larger excavation required of a conventional station.
| OneLift served as a complete replacement at the Chapel station, allowing for extra capacity in the same footprint while staying out of an adjacent wash.
BENEFITS
The OneLift Pump Station was the perfect solution for this project. It met the customer’s needs for a quality solution with more capacity and a smaller footprint that could be installed quickly and efficiently.
TURKNEY SOLUTION
The OneLift Pump Stations from Oldcastle Infrastructure enhanced this project in a number of ways, including:
| A smaller footprint requiring less excavation on a challenging site
| Pre-assembly for the product allowed for rapid installation
| Seamless integration into pre-existing infrastructure
| Quick installation to save on excessive costs and time
“OneLift’s pre-packaged and pre-plumbed features made my job as project manager much easier. We were able to install the product in one day and it required only a minimal pipe and electrical work on-site, making it easily compatible with
project specifications.”
Kinney Construction Services, Inc.
During construction of the Intermodal Transportation Facility–West (ITF-West) at the Los Angeles International Airport (LAX), Oldcastle Infrastructure delivered superior stormwater management by installing multiple products including StormCapture. ITF-West will stand as a new parking structure as well as the face of LAX, housing approximately 4,300 stalls, drop-off and pick-up locations, and short- and long-term parking options for travelers. The StormCapture detention system and accompanying products provided an efficient on-site solution to facilitate stormwater drainage and treatment.
THE CHALLENGE
Swinerton contractors are playing a key role in transforming LAX through the Landside Access Modernization Program (LAMP) to provide more transportation options for travelers and allow for adjustments in the future. The ITF-West facility is the first component of future-proofing LAX, where Oldcastle joined forces with KPFF to install StormCapture for its large storage capacity under the new parking structure.
This installation provided a number of challenges along the way:
| Several site constraints and structural design parameters limited product options
| With moving parts to this overall project, StormCapture needed to be installed on a tight timeline
| The cistern’s location created size constraints for StormCapture
| The solution had to meet the City of Los Angeles Bureau of Sanitation and Department of Building and Safety approvals
THE SOLUTION
Oldcastle Infrastructure and KPFF worked together to design a custom stormwater management system and long-term storage solution that fit all parameters of the project with StormCapture, Dual-Vortex Separator and MaxWell drywells to be installed under the ITFWest’s building footprint. Where size constraints played a role, Oldcastle was able to showcase its ability to think outside the box by installing RCP pipe in place of vaults. From manufacturing to its fast installation process and minimal handling, the StormCapture installation added a valued solution that met the project’s tight scheduling deadlines. The design solution met the stringent permitting requirements of the City of Los Angeles Department of Building and Safety (LADBS).
Because of site constraints and structural design parameters, StormCapture was the ideal storage solution for this project.”
Associate with KPFF
BENEFITS
STRUCTURALLY SUPERIOR
| The ITF-West at LAX installation is a great example of StormCapture’s efficiency. With a large storage capacity that requires no concrete footing, StormCapture, integrated with other Oldcastle products, provides a reliable stormwater management system.
MODULAR DESIGN
| Focusing on the needs of the customer, the precast nature of StormCapture made it a customizable option for the ITF-West installation that could be used as part of a treatment train. It also came with the options to include Cisterns, space-efficient and sustainable modules, for harvesting rain and stormwater.
FUTURE-PROOF SOLUTIONS
| StormCapture is site-friendly with its easy-to-install design. Installed at a lifetime cost, this stormwater management product is made to maintain for a long-term quality solution.
Project: LAX ITF-WEST
Location: Los Angeles, CA
Distribution Plant: Fontana, CA
Product: STORMCAPTURE®
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In Rochester, Minnesota, changes were being made to a street section that included the installation of a new roundabout. Incidentally, a single manhole was positioned in the center of this new roundabout section and the existing infrastructure was failing.
THE CHALLENGE
As the roundabout was being built, it was discovered that the vault needed to be replaced as it was undersized and additional capacity was needed.
THE SOLUTION
The contractor, TD&I Cable Maintenance, decided to use Oldcastle Infrastructure’s precast, 3-piece, 612-7 vault. To solve the issue of the existing vault not having the needed capacity, it was decided that two new structures would get the job done. Each vault was positioned on opposite ends of the roundabout, eliminating the need for the single vault in the middle of the street.
This was the first install of this type of vault done by the contractor. In this case, the knockouts were removed, and this easily allowed for each section to be lowered directly into position. The pieces only needed to be moved horizontally a few inches to encase the existing duct bank. This allowed the contractor to position the bottom of the vault without having to over excavate the hole and without the risk of damaging live fiber cables.
THE PROCESS TOOK LESS THAN TWO HOURS FROM THE TIME THE CRANE SHOWED UP, UNTIL IT WAS BACK ON THE ROAD.
“We really liked the product manufactured by Oldcastle Infrastructure and fully endorse the use of their vaults.”
Spencer Pannhoff, Director of Business Development for TD&I Cable Maintenance
BENEFITS
Installing with Precast is Quick and Easy
The completion of this project is a great example of how easy precast is to use in comparison to pour in place. Because precast vaults are delivered in pieces that can slide into place, installation typically takes as little as one to two hours to be completed. This means there is no waiting for cure time and roads can be opened the same day, saving time, money, and energy. Additionally, minimizing disruptions in the community and increasing safety for all workers involved.
“Using precast vaults allows for a quicker install that saves both time and money”
Ben Gehrts, Sales Manager
Over-excavating Isn’t Necessary
Without having to over-excavate the existing hole, less work must be done. There is no need to spend time opening additional space on all sides and then closing a larger work space. This makes Oldcastle Infrastructure’s precast vaults very convenient to work with. Especially in tight locations where there are other utilities in the way.
NO Interruption of Service
Because assembly of the vaults is completed on site, the entire installation process can be performed without interruption to the surrounding area’s service. This lessens interference with local communities and reduces installation time as there is no need to have to turn electricity on or off.
Project: Rochester Vault Replacement
Location: Rochester, MN
Distribution Plant: Auburn, WA
Product: Precast, 3-piece, 612-7 Vault
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When faced with the significant design and construction challenge of building an electrified light rail line across Lake Washington, on an existing Interstate Highway floating bridge, the team at Oldcastle Infrastructure in Auburn, WA, showcased their ability to innovate a process to manufacture precast elements that were critical to the project.
THE CHALLENGE
The light rail line had to be constructed while keeping the bridge open to traffic. Sound Transit had a specific need to construct an electrified light rail line across Lake Washington on an existing Interstate Highway floating bridge. Significant challenges included minimizing the weight that would be added to the bridge and addressing the additional loads and stresses applied to the bridge during construction while the highway stayed open to traffic.
Oldcastle Infrastructure was instrumental in manufacturing 9,000 custom precast blocks to serve as rail ties. Careful control over the consistency of the concrete was needed, and that meant that the automation cycle times would limit the number of blocks that could be poured from each batch to 8-10 blocks. This would limit batch sizes to approximately 1/3 yard with batch-to-placement time limited to 30 minutes to achieve the required finish.
THE SOLUTION
Oldcastle Infrastructure developed a new mass production process for the manufacture of a highly specialized lightweight precast rail block. This, “Dual Block” railroad tie system provided the right solution for this unique situation. Kiewit/Hoffman partnered with Oldcastle Infrastructure for the production of the test blocks for full-scale proof of concept tests and production of the final blocks for permanent installation on the bridge.
The uniqueness of this task required development of a new construction method for installation.
A team of consultants and engineers, in collaboration with the University of Washington, developed and lab tested the product concept over several years in advance of the project.
Field testing for proof of concept was conducted using an initial production run of blocks produced by Oldcastle Infrastructure using the materials, methods and procedures that would be utilized for full-scale production.
To address the transition of the rail alignments on and off the bridge, pontoon freeboard elevations and cambers and the safety and maintenance of the rail lines, over 8,800 Dual Blocks of five types and 57 total variations were required.
The lightweight concrete minimized the weight of the installation and all conductive components for each block were grounded back to shore to prevent stray current penetration of the electrified rail system into the bridge.
THE MILE LONG FLOATING TRACK CONNECTS SEATTLE TO BELLEVUE WASHINGTON
BENEFITS
Superior Quality Control
A lightweight concrete mix with a hardened unit weight of 105 lb. PCF was required. The consistency of the lightweight concrete was carefully controlled in a “micro” batching environment.
An ACT WoCoMix WM750 batch plant, with fully automated computer control, provided the consistency required. Each of the final blocks was treated as a unique unit with registration, data acquisition and tracking of every block from the testing of the component materials prior to fabrication through delivery of each block, with all data provided at the time of delivery.
“Rail service from Seattle to Bellevue, Washington is slated to begin in 2023.”
Meeting Tight Tolerances
The tolerances required for block placement, to meet railcar rideability, requires the blocks to be hand positioned, suspended from the rails and leveled before attachment to the bridge
deck. The Dual Block system meets the very tight dimensional tolerance requirements of rail fasteners for fastening of the rails directly to the blocks.
Project: Sound Transit East Link (E130)
Location: Seattle, WA
Distribution Plant: Auburn, WA
Product: Precast Dual Blocks
Start Date: September 2017
Completion Date: Fall 2020
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The Oldcastle Infrastructure three-sided bridge offered a solution for the Utah Department of Transportation (UDOT) to create a large, open underpass crossing in a remote part of the state to allow elk to continue migrating safely past US-191.
THE CHALLENGE
Elk migration patterns created a need for a structure that was large enough to not disrupt their routine, and strong enough to withstand traditional highway traffic. Roads and other urban developments can often bisect wildlife habitats for a number of species, so providing connectivity between habitats can ensure greater survival for an entire ecosystem. This project raised a number of challenges along the way, including:
| The UDOT was looking for an economical, ecological solution to provide both road travellers and wildlife a way to coexist.
| Load rating the three-sided-bridge proved challenging as the required rating software and methods had not been used on a three- sided “clamshell” bridge.
| Drive-time restrictions due to the project’s remote location restricted the number of bridge sections that were able to be delivered each day.
THE SOLUTION
Oldcastle Infrastructure delivered 14, 26’x8’ three-sided- bridge units to be set in a “clamshell” configuration, creating a 26’ x16’ measuring 54 feet in length.
The installation process:
| First, a diversion around the highway was constructed to allow traffic to continue to travel and the contractor began excavation.
| Despite logistical limitations due to drive-time restrictions and travel distance, installation of the three-sided-bridges took just two days. The bottom seven units were set in one day, with the top units completed the next day.
| Lastly, the highway was reconstructed after the bridge was installed.
The Oldcastle Infrastructure engineering team was integral
in modeling the bridge in finite analysis software to calculate and incorporate the load rating into UDOT’s system. This project laid the foundation for the load-rating of three- sided-bridges and developed processes to streamline future projects utilizing this product.
Even with the remote location, we were able to supply enough bridges that our product was set in two days.”
Marketing Engineer
BENEFITS
The three-sided-bridge was the perfect product to design a system for such a project. It met the customer’s need for a highly constructible, precast solution and satisfied the Accelerated Bridge Construction (ABC) requirements. ABC is a bridge-construction that uses innovative planning, design, materials and construction methods in both a safe and cost- effective manner to reduce onsite construction time.
A HIGHLY CONSTRUCTIBLE PRECAST SOLUTION
Precast concrete advantages from the Oldcastle Infrastructure products enhanced this project in a number of ways, including:
| Improved site constructability
| Expedited total product delivery time
| Enhanced work-zone safety for the traveling public
| Reduced traffic impact
| Shorter onsite construction time
| Less weather-related time delays
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As part of a critical effort to deliver high-speed internet services and upgrade telecommunications infrastructure in remote areas of Wisconsin, Northwest Communications selected Oldcastle Infrastructure’s Duralite® 2436 handhole. The superior construction, lighter weight, and ease of installation provided Northwest Communications with an innovative, durable, and cost-effective solution.
THE CHALLENGE
Northwest Communications provides phone services, high speed internet and high-definition cable TV throughout its eight-community service area in Western Wisconsin. The second largest independent telecommunications firm in the state, Northwest Communications owns, manages, and maintains its own private cable and fiber infrastructure, including manholes, handholes, underground conduit, telephone poles, and antenna towers. Strategic positioning of this infrastructure ensures that the necessary facilities are ready and available to service customer needs.
The company is currently extending high-speed internet service to more remote areas of its coverage area under the FCC’s Alternative Connect America Cost Model. Northwest Communications is burying fiber optic cable to deliver these services to outlying areas and ultimately replace phone lines.
Selecting the right underground enclosure, cable vaults, and other infrastructure is crucial to sustain long service life, minimize maintenance, and reduce liability issues.
THE SOLUTION
Northwest Communications recently installed 80 Oldcastle Infrastructure Duralite 2436 composite handholes equipped with Tier 15 plastic lids for enclosure integrity as part of an expansion program around St. Croix Falls, Wisconsin. Able to withstand heavy loads, the lightweight 24” x 36” enclosure has been engineered and tested for maximum body, lip, and sidewall strength and durability.
Northwest Communications’ utility services contractor, Tjader & Highstrom, installed one box approximately every 1,500 feet. The resulting network of handholes now provides durable, accessible security to Northwest Communications’ growing service infrastructure.
Superior material selection was a big factor in selecting the Duralite units, according to Greg Cardinal, Northwest Communications’ Plant Manager. Cardinal oversees contractors for installs and day-to-day service, and is the purchasing decision-maker for underground enclosures. Duralite’s strategically engineered enclosure design and innovative material composite blend made it the right choice to deliver the reliable, high-quality performance that Northwest Communications and its clients depend on.
We really like the fact that you don’t have to use a backhoe to set the box, as you do for installing polymer units. At a box set every 1,500 feet, our contractor can install one-and-a-half to two miles per day.”
Greg Cardinal
Plant Manager, Northwest Communications
BENEFITS
The Duralite 2436 provides the strength of polymer concrete at half the weight, which translates into safer, easier, and significantly less costly installation.
THE LIGHTWEIGHT ADVANTAGE
Duralite’s significantly lower weight translates into convenience and flexibility because there is no need to coordinate transport by a flatbed truck. “We can use our pickup truck to deliver boxes to the site and work on our own schedule,” Cardinal said. “Also, the box’s lid is awesome. I can move it by myself, and it seems really sturdy.”
Only two crew members and a backhoe were necessary on site for the install of the Duralite enclosures. The backhoe was used only to dig the hole, drop pea gravel, backfill, and compact the soil; it wasn’t necessary for actually setting the box in place. Also, the crew did not require bracing when backfilling.
In addition, the box holds a substantial amount of additional fiber line. The contractor was able to store 60 feet of extra fiber in each box for each of three lines – 180 feet in all.
EASIER INSTALL EQUALS SIGNIFICANT COST SAVINGS
Beyond their reliable, high-quality performance, the Duralite 2436 boxes also delivered significant cost savings for Northwest Communications. Due to their lighter weight and the resulting streamlined set-up process, the company saved approximately 35 percent installing the Duralite 2436 boxes compared to standard polymer enclosures.
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The STAKKABOX Ultima Connect Chamber proved to be a natural fit for a telecommunications infrastructure replacement, owing to its ease of installation, flexibility to site conditions, and the ability to install the chamber without outages to in-place fiber cable.
THE CHALLENGE
Telecommunications providers use pull boxes to splice fiber optic cables and store additional cable slack. Over time, plastic pull boxes deteriorate and need replacing both to protect components and to allow more room for cable
storage and additional fiber lines to meet ever-increasing demand.
In this replacement project for a telecommunications provider in Ottawa, Canada, existing fiber optic lines and conduit were running through three sides of a pull/splice box. Typically, to replace such a box without a break in service, a large “mouse-hole” must be cut into the new box on any side where it is being placed over existing cable. Adding these large holes usually compromises the integrity of the box and causes it to fail prematurely.
In addition, such projects frequently come with a degree of uncertainty, since it often is not known exactly how deep the replacement box will need to be – creating the need for guesswork.
THE SOLUTION
For this effort, Oldcastle Infrastructure provided one 36″ x 60″ x 54″ STAKKABOX Ultima Connect Chamber unit with composite covers. The unit was delivered flat-packed (unassembled) and then constructed in the field.
Installation was extremely straightforward:
| An excavator was used to dig the hole and remove the existing box.
| The ground was leveled for placement of the new chamber assembly.
| The chamber was built from the ground up, using components and connecting pegs, one layer at a time.
| As the rising walls of the chamber approached conduit or fiber optic lines, the chamber components were easily cut with a saw to allow for building around the obstructions.
| The layers were built to the required final grade.
| The frame was placed and screws were used to secure the composite covers to it.
The total time for installation was approximately four hours (one half-day).
“We foresee substantial time and cost savings when replacing or upgrading pull/splice boxes— quickly and with minimal impact.”
Chris Schultz | Product Manager
BENEFITS
CUSTOMIZED DEPTH
The STAKKABOX Ultima Connect Chamber system gave the provider the flexibility to dig the hole and place the box as deep as necessary without concern for the box’s ultimate height. During the building process, the number of layers could be easily adjusted to bring the box’s final height to grade level- a huge advantage over the typical installation.
NO INTERRUPTION IN SERVICE
Because the STAKKABOX is constructed around the existing infrastructure, it minimizes outages when upgrading/replacing a current pull box. Workers simply drill or cut holes in the Ultimate Connect layers where necessary as the box is built. This process allows existing fiber optic cable and conduit to pass through the sides without affecting any lines currently in service.
This feature is especially important in confined urban environments that often have both deteriorating equipment/ infrastructure and high demand due to the population density.
NO IMPACT ON BOX INTEGRITY
The layered system for integrating existing cable does not impact the integrity of the box, unlike the large holes that must be cut in typical replacement boxes. The Stakkabox can be customized to meet the unique site requirements while ensuring a load resistance well above the ANSI/SCTE Tier 22 standard.
SPEEDY & COST-EFFECTIVE INSTALLATION
The STAKKABOX Ultima Connect Chamber provides huge advantages in installation time, ease, and labor effort. In as little as four hours, the chamber can be built and installed in the field with lightweight components following a straightforward assembly process.
The telecommunications provider was extremely impressed with the innovation of the Stakkabox. They foresee substantial time and cost savings when replacing or upgrading pull/splice boxes—quickly and with minimal impact.
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A national railroad passenger authority put the STAKKABOX Ultima Connect Chamber to the test, and found it to be an extremely durable, customizable and easy-to-install solution for protecting railway wiring components.
THE CHALLENGE
Transit signal and communications functions are key to the effectiveness and safety of mass transportation systems, particularly commuter rail. The reliability of the infrastructure that protects these critical components is therefore of utmost importance.
The national railroad passenger authority conducted a test of an innovative STAKKABOX Ultima Connect Chamber wiring box for application to a commuter rail line. Typically, heavy polymer concrete boxes are used along with cable trench and conduit to provide a protective system to coordinate transit signal and communication wiring. These polymer concrete boxes have traditionally been difficult to modify without compromising their strength. In addition, the covers are heavy to remove, and the concrete is susceptible to cracking.
THE SOLUTION
For the test, Oldcastle Infrastructure provided a 4′ x 4′ x 4’ Stakkabox Ultima unit with composite covers. The opening was designed to allow easy interface with the Plastibeton Cable Trench System.
Installation was simple and straightforward:
| An excavator was used to dig a hole in the ground for installation.
| The excavator then lifted and set the completely assembled chamber into the hole. (Note: Due to the layered design of the Stakkabox Ultima, the chamber could also be assembled directly in the hole, if necessary.)
| The area around the chamber was backfilled.
| The frame was placed and screws were used to secure composite covers to the frame.
The total time for the installation was approximately three hours.
“The national railroad passenger authority was extremely impressed with the strength and durability of the chamber, along with how simple it is to install.”
Chris Schultz | Product Manager
BENEFITS
THE STAKKABOX PROVED TO BE A DURABLE AND EASY-TO-CONFIGURE SOLUTION DUE TO THE FOLLOWING OUTSTANDING CHARACTERISTICS:
| The components and covers are lightweight, which assists with installation and provides easy access to cables in the future.
| Openings for cable trench or conduit can be provided in advance or even cut onsite, without compromising strength and performance.
| The layered design of STAKKABOX means that rings can be added or removed to reach a customized final depth as required.
| The Glass Reinforced Polyester Resin (GRP) components will not crack when placed close to vibrating rails.
GOLD STANDARD DURABILITY: THE “TRACK TEST”
To assess its reliability, the STAKKABOX Ultima Connect Chamber was subjected to the “track test.” The maintenance crew made their best attempt to destroy the box, to ensure that it would perform under extreme encounters during normal use.
The evaluation included the following rigorous measures:
| Driving a fully loaded excavator over the chamber.
| Placing the excavator stabilizer directly on the chamber and moving the arm up and down so the entire excavator was “bouncing” on the chamber.
| Igniting CADWeld directly on the cover and chamber sides, producing temperatures that exceeded 2500º F.
| Lifting and dropping an 850 lb concrete rail tie directly on the chamber from approximately 10 feet high.
After testing was complete, the chamber still met all form and function requirements and was left in a main maintenance way next to the rail.
The national railroad passenger authority was extremely impressed with the strength and durability of the chamber, which was even more notable given the simplicity of its installation.
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THE CHALLENGE
The Water and Sewer Department in Arlington, Virginia had a specific problem area behind
a commercial plaza. The difficult location of a loading dock was causing trucks to damage the area’s 3-meter pits. Drivers had to make tight turns when coming and going, harming the curb where the meters were located and affecting the local commercial plaza and businesses.
Arlington identified an opportunity to combine the 3-meter pits into 1 larger enclosure as part of the solution to this problem. The enclosure would need to be housed completely in between the sidewalk and the curb, and it would need to have the ability to protect the meters. Choosing to partner with Oldcastle Infrastructure, the city was able to pilot the STAKKAbox Ultima Connect chamber system.
THE SOLUTION
A variety of features were noted by Arlington when choosing the STAKKAbox Ultima Connect chamber system. The high strength of the product was key considering the location of the installation. However, the most important factor was the ability to build around existing services without interruption. The modularity of the design gave them the opportunity to put in place a strong system capable
of withstanding truck loading, while having the ability to fit within the physical constraints given the job site. This system’s strength would have the ability keep the sidewalk, curb and road intact, and installation would cause little disruption to the surrounding businesses and residences. Because the system is comprised of sidewall and corner pieces that are easy to handle and easy to modify, it was a good fit for the construction site.
During the initial stages of the construction process, challenges began to arise. As excavation and the removal of the old system began, it was discovered that there were in fact, 5-meter services as opposed to 3 and a conduit that had some electrical service was also present. Additionally, a pad was originally poured for a foundation, but it was poured at a different height than was desired. The team was able to overcome these issues with some field modifications that could easily be made thanks to the flexibility of this system.
“The STAKKAbox chamber’s flexibility allowed us to fit a heavy truck rated chamber in a small footprint, install it with a small crew and no heavy equipment, and overcome challenges when unmarked existing infrastructure was discovered during excavation.”
Micah Denton
PE of Arlington County DES
BENEFITS
The overall installation took approximately 1.5 hours. Senior Product Manager, Ian Marten, and Regional Sales Manager, Rick Miller, performed the bulk of the installation with assistance from two Arlington employees. The easy-to-handle lightweight components made it possible to install the chamber with a minimal crew. No additional machinery was needed to lift the system into place. The project finished in June
of 2019.
The STAKKAbox Ultima Connect chamber system was the right choice for this project. The product’s flexibility in design allowed a solution to be developed that fit within the limitations of the jobsite, with the strength required to protect the water meters from future damage. Micah Denton, PE of Arlington County DES, said, “The flexibility of the STAKKAbox chamber is unmatched. With tens of thousands of water meters throughout a dense county, there are bound to be some unusual and challenging installations. The STAKKAbox chamber’s flexibility allowed us to fit a heavy truck rated chamber in a small footprint, install it with a small crew and no heavy equipment, and overcome challenges when unmarked existing infrastructure was discovered during excavation that would have delayed any conventional chamber installation. That flexibility adds a new tool to the toolbox that simply wasn’t available to us before.”
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As part of a system-wide water meter update for the City of North Las Vegas, Oldcastle was awarded the contract to develop and manufacture new meter box lids for the municipality. This retrofit project showcases Oldcastle’s ability to develop an advanced and efficient customized solution that saves the client effort, time and money. Oldcastle’s FL03 lid allowed the City to adapt and improve select elements of their existing meter infrastructure and reap the benefits of the latest meter technologies.
CHALLENGE
The residential water meter system in North Las Vegas, Nevada, was approaching the end of its useful life. As a result of this outdated system,
the City of Nevada was spending money on labor and battery replacement every year. Updating and replacing the 88,000 residential meter units was
necessary to reduce maintenance costs, improve the accuracy of revenue collections and identify waste and leaks in the system.
Oldcastle was part of a team selected for the contract to complete the update. The project required not only changing out the meters inside the existing boxes with more current technology, but also replacing the meter box cover with one that could accommodate a new antenna configuration to permit remote readings.
Complicating the project was the fact that the municipality uses a wide range of meter boxes, of different sizes and materials (concrete, polymer, plastic) from a number of manufacturers. To meet project deadlines, it was necessary to design a new cover, source the tooling and tool build and produce the initial product in a greatly compressed time frame.
SOLUTION
The City selected Oldcastle’s Fibrelyte line of covers to be installed system-wide, citing a number of important factors:
- High strength/weight ratio
- Ability to accommodate the proposed new antenna configuration
- High coefficient of friction, to prevent slippage in pedestrian footpath areas
- Availability in a variety of sizes to fit the assorted meter boxes used in the system
Oldcastle’s rapid prototyping capabilities helped ensure the custom-designed FL03 samples were delivered to the customer quickly, while the unique Product Stage Gate process allowed for quick completion of the mold. Through the collaboration and disciplined workflow of the Oldcastle
teams, production design and tool build was completed in
under five months.
Within a week of the first purchase order, Oldcastle delivered every product needed for the first phase, totaling thousands of lids.
For the installation phase, the project team is deploying three crews of three members each, to install 250–300 meter update kits per day, including the new covers. Installation should be complete by October 2020.
BENEFITS
RETROFIT: A SMART MONEY-SAVING STRATEGY
The North Las Vegas update is an excellent example of the best practice of retrofitting. While meter boxes stand up well over the years, lids tend to wear down over time through exposure to the elements and human error (such as cars running over them).
Through retrofitting, the City can keep the original enclosure and replace only the lids, saving both time and money. And the new Fibrelyte lids can leverage the latest technologies. In this case, the new antenna probe hole saves considerable labor time and expense over the life of the product, because it will no be longer necessary to lift the lid to scan the meter. Instead, a utility
representative can simply wave the wand/scanner over the probe hole to get the meter reading.
A TAILORED SOLUTION ON A TIGHT TIMELINE
This effort demonstrates Oldcastle’s ability to customize products by first focusing on the needs of the customer, rather than forcing them into a cookie-cutter solution. This is a key differentiator in this industry. Through the efficient and unified efforts of Oldcastle’s sales, project management,
engineering and manufacturing teams, the City of Nevada received a custom solution that addressed every critical requirement related to the project.
Just as important, the project was accomplished on a very tight timeline. The design, build and approval process were completed in less than five months (from July to November), so that installation could begin the following March and the City could immediately begin receiving the benefits of the improved design.
SUPERIOR QUALITY AND ENDURANCE
The FL03 is not only a replacement of but an improvement over the original equipment. For example, because of its load-rating strength and durability, the lid can survive a car driving over it, unlike traditional concrete. In making the selection, the City noted that the Fibrelyte cover:
- Was much lighter than others being considered
- Was non-floating
- Did not chip
- Did not swell in extreme heat, which typically causes seizing in meter boxes
- Had a superior slip rating (based on the City’s own internal testing)
- Had an aesthetically pleasing appearance
The FL03 is another example of Oldcastle’s ideal combination of industry-leading innovation, responsiveness to customer requirements, speed of implementation and superior quality.
“Completing a product design/ tool built/ process buyoff in approximately
19 weeks is a monumental accomplishment, said” Ian Marten, Senior Product Manager.
Designed approximately 8 x 14 inches to accept antenna and fit into “03” size
meter box widely used throughout the municipality. Additional FL covers
(FL9X, FL12, FL30, FL1527 and FL36) are being used as well.
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Project Overview
Surf’s up and clean in Southern California thanks to Oldcastle and the Santa Monica “Clean Beaches” stormwater cistern. Located at the base of the world-famous Santa Monica Pier, the Deauville basin will be used to harvest up to 1.6 million gallons of stormwater runoff from the pier’s downtown drainage basin.
The harvested runoff will then be diverted for treatment at the Santa Monica Urban Runoff Recycling Facility and distributed for non-potable uses. Overflows from the tank will be discharged into the sanitary sewer system.
The project was scoped in May 2017 and originally designed as a standard modular StormCapture® system. After evaluation of the project’s unique design and specification requirements, Oldcastle proposed the use of a StormCapture PV precast panel vault system in lieu of the conventional modular StormCapture system as a value-engineered solution.
The challenge was to design a system 262-feet long by 78-feet wide by 12-feet tall (inside depth), or “very close to the size of a football field,” said Selim Eren, project engineer with the city of Santa Monica. Plus, the system was going to be erected on sandy soil, with a water-table at grade, and able to withstand 15-feet of compacted backfilled soil while supporting a surface parking lot over the entire basin. The system also needed to be water-tight when filled with 1.6 million gallons of stormwater while passing a mandatory 24-hour leak-test.
To complete the test, groundwater was pumped into the tank, then measurements were taken two days later to document any water loss. “With this type of structure some water loss is expected,” Eren said. However, the tank met the acceptable limit of losing no more than 0.01% of water. “That would amount to half an inch from the whole 1.6 million-gallon tank,” he explained. After the structure passed the leak test, the water was later used during the construction phase, such as preparing the backfill for compaction.
To reduce the project’s energy footprint, rather than installing pumps that require both ongoing maintenance and power, the project relies on gravity to transfer water from the pier outfall to the 1.6 million-gallon cistern. However, that meant placing the cistern well below grade.
“In our case, we were going extremely deep; there would not only be traffic loading from the top but heavy soil pressure, as well as water table pressure and buoyancy from the shallow water table that is kind of acting against it. We really needed to have a specially designed system,” Eren said. “During design, we were deciding whether the structure should be precast or cast in place. The ground level is at the beach level, and the water table is very shallow. It varies seasonally, changing between 5 and 10 feet and depending on the tides as well. Also, the footprint of the site is very small, so there is no way to cut and slope the edges of the excavation that would be needed to get approximately 30 feet below the surface.”
Complicating matters, Eren said the Santa Monica Pier “is actually busy all year, with some of the busiest days right around Christmas time. We needed to stay outside of the summer season as much as possible.” Therefore, building a form and then casting the structure in place would have added an unacceptable duration to the construction schedule. “We decided to use the StormCapture PV panel vault system from Oldcastle,” Eren said.
To fully comply with leak-test requirements, the basin was designed to withstand hydrostatic (water pressure) loads and the hydrodynamic (seismic) loads during the test, without any external support or backfill. Oldcastle’s ability to recognize the need for pursuing an alternative solution that was both practical and economical was key in securing the project.
The successful design-build project was the result of an early and ongoing collaborative effort between Kube Engineering, Corrpro Companies, ACME Construction, and Oldcastle’s sales and engineering teams in Southern California and Auburn, Washington. Relying on the Auburn team’s vast experience with the design and manufacturing of panel vault systems was invaluable in developing the solution.
Eren said the goal of the “Clean Beaches” initiative was simple and direct, “to prevent any of the polluted stormwater from the city from contributing to degrading the quality of the water on Santa Monica beaches.” And the only way to achieve that goal for the Santa Monica Pier watershed was “to eliminate most of the runoff and stormwater from reaching the ocean.”
Overall, the project consisted of 191 precast wall panels and roof slabs. Production at the Oldcastle plant in Fontana, California began on January 30th, 2018 and was completed on March 26th, 2018. On-site installation of the system started on March 13th, 2018 with the last roof panel installed on April 3rd, 2018. In addition to the precast basin supplied by the Oldcastle plant in Fontana, the general contractor also chose to use a proprietary OneLift® pump station supplied by the Oldcastle plant in Chandler, Arizona.
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HIGHLIGHTS
Project Location: Richmond, Virginia
Owner: Richmond Raceway
General Contractor: Barton Malow
Site Contractor: Alpine Construction Corporation
Civil Engineer: Richmond-based HG Design Studio
Precast Manufacturer: Oldcastle Infrastructure – Fredricksburg, VA
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 DESIGN
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.”
THE SOLUTION
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 culverts 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.
Oldcastle Product(s)
49 Precast Concrete Box Culverts
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