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.

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.

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.

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.

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

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.”

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.

Oldcastle Infrastructure delivered and installed two OneLift Pump Stations at Mystic and Chapel stations as part of the City’s existing infrastructure.

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

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 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.

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.

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.

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.