Salisbury, MD
DESIGN & CONSTRUCTION TEAM
Client: City of Salisbury, MD
Project Coordinator:
Bill Sterling
Dept. of Public Works.
Utility Contractor:
Drainage Protection Systems
(DPS), a Division of Oldcastle
OLDCASTLE STORMWATER PRODUCTS INSTALLED
24” & 36” Nettech Devices, plus 30 Flogard Plus Catch Basin Insert Filters
The City of Salisbury, located in southeastern Maryland, is the county seat of Wicomico County and is also the largest city in Maryland’s Eastern Shore region. It is the commercial hub of the Delmarva Peninsula and is sometimes called “the Crossroads of Delmarva”. One of the focal points of the downtown area is a riverwalk along the Wicomico River which the city maintains.
When the City of Salisbury decided to make an effort to clean-up the trash and debris flowing into the Wicomico River from the adjacent contributing watershed, they chose Oldcastle Infrastructure’s NetTech™ gross pollutant traps (GPT) and FloGard Plus catch basin insert filters using a community development block grant. In February 2011, Drainage Protection Systems (DPS), a division of Oldcastle, installed a 24” circular GPT, attaching it to an existing 24” stormwater outfall pipe beneath the Division Street Bridge which is adjacent to the city’s riverwalk. Then in September 2011, a 36” circular GPT was installed on a nearby outfall pipe. The NetTech device will capture trash and debris from the outfall and contain the contents until the city’s maintenance crews pickup and dispose of the debris.
Once emptied, the netting device is reattached and the process begins anew. The NetTech, an end-of-pipe treatment device, was selected by the city due to the conspicuous location of the outfalls. Not only is the location highly visible by local residents and adjacent property owners, thereby providing an immediate showcase of the captured debris, it also allows appropriate maintenance accessibility for debris collection and disposal.
One of the most significant, yet unrecognized types of water pollution is stormwater runoff. When it rains, stormwater collects everything in its path, including trash, debris and other pollutants. Eventually, the water reaches streams or rivers, either over land or via storm drains. But unlike sanitary sewers that divert water to treatment plants, storm drains ultimately empty directly into surrounding lakes and rivers without any type of treatment. All of the debris and pollutants that were picked up by the stormwater eventually end up in our nation’s waterways.
The Baltimore shipyard is the U.S. Coast Guard’s active maintenance and repair facility for the Atlantic Fleet. This historic facility has served as regional headquarters, shipyard and depot since 1899. Currently, the shipyard employs over 1,500 personnel to overhaul and recondition ships, from propellers to defensive systems.
INSTALLATION ISSUES
The timing of the tidal-influenced Wicomico River had to be accounted for during installation due to the outfall pipe being partially submerged during high tide. Additionally, the upstream storm sewer system maintained a constant runoff through the pipe network, which had to be temporarily dewatered during the installation sequence.
DPS accomplished this through the use of sandbags and a sump pump in the adjacent upstream manhole, thereby providing for a relatively dry installation environment. Furthermore, access for the installation had to be considered due to the river’s proximity to the outfall. The city provided a boat to assist with the installation along the riverwalk, which was needed in conjunction with DPS’s boom-lift vehicle. Traffic was controlled along the Division Street Bridge during installation by the city, while DPS provided power access through a mobile generator which was necessary for properly securing each NetTech device to the outfall pipe. Total installation time took about four hours per unit.
RESULTS
The two NetTech units had an immediate impact by drastically reducing the amount of trash and debris deposited into the Wicomico River, thereby providing an enhancement to the city’s river beautification project. These installations were the first two completed portions of the city’s overall stormwater master plan. In May 2012, the city contracted with DPS to install 30 FloGard Plus catch basin insert filters within the watershed as well.
Though these are the first NetTech devices to be utilized in the Maryland Eastern Shore region, neighboring communities outside of Salisbury, including Talbot County and the City of Easton, have recently installed several NetTech units as well.
It is of the utmost importance to keep trash and debris out of our nation’s waterways, keeping our water as clean as possible for current and future generations, and Oldcastle Infrastructure is helping city and county agencies accomplish this task, one step at a time.
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Environmentally Friendly TerraMod® Planters
Baltimore, Maryland
DESIGN & CONSTRUCTION TEAM
Client: United States Coast Guard
Contractors: Skookum Contract Services, Inc.
Manufacturing Plant: Oldcastle Infrastructure, Fredericksburg, VA & Edgewood, MD
On April 21, 2017, Oldcastle Infrastructure co-sponsored an Earth Day educational fair at the U.S. Coast Guard’s shipyard in Baltimore, Maryland. This marked the 47th Earth Day celebration of its kind since 1970.
The Coast Guard hosted the Earth Day fair to help educate the community and reduce pollution in the Chesapeake Bay from stormwater runoff. As part of the festivities, the Coast Guard purchased three “green” Low-Impact Development (LID) stormwater filtration planters for their campus, thereby protecting the local environment, its members and the community they serve. Planning for the planters began in January 2017, when the Coast Guard approached Oldcastle Infrastructure for ideas on how to treat stormwater runoff on such a tightly packed campus with many acres of impervious hardscape.
After discussions and in support of the Coast Guard’s Earth Day celebration, Oldcastle Infrastructure manufactured and supplied three TerraMod® precast concrete stormwater retention and filtration units. The TerraMod planters allow for the treatment of a larger volume of stormwater runoff in a smaller footprint than traditional rain gardens. These environmentally friendly units remove pollutants via filtration while assisting in the Coast Guard’s compliance with the nt (MDE) to mitigate rainwater pollutants.
Oldcastle Infrastructure’s Edgewood, Maryland and Fredericksburg, Virginia facilities provided two at-grade precast concrete bioretention planters and one above-grade planter designed to capture, retain and filter stormwater runoff. One 4-foot by 24-foot by 6-foot bioretention planter was installed near Parking Lot #20 to collect runoff from nearby streets and parking areas. The runoff was diverted to the retention system by means of a culvert designed by the site contractor.
A second planter measuring 4-foot by 25-foot by 6-foot was placed adjacent to Building #40 for retaining and filtering stormwater from the roof. This process is called “rooftop disconnection” where the stormwater does not actually runoff, but instead is intercepted, thereby decreasing the amount of rainwater pollutants.
Finally, a third above-grade planter measuring 4-foot by 10-foot by 6-foot was installed beside Building #42 in order to handle rooftop runoff which is piped directly to the retention planter. Harvest RGI engineered the planter’s filtration media and volume (stone and soil depths) in accordance with the State of Maryland’s stormwater management specifications. “Harvest RGI is the largest supplier of bioretention soils in Maryland, and is very excited to be involved in this dynamic TerraMod system developed by Oldcastle Infrastructure,” said David Lundberg, Director of Business Development at Harvest RGI. “The bioretention media used on this project is from the MDE Infrastructure Design Manual. While an extremelyrigid specification issued by MDE, Harvest is able to manufacture to meet the needs to better manage stormwater on this project as well as 100’s of thousands of cubic yards of this material used for other projects statewide.”
The shipyard’s Earth Day fair was a remarkable success. The Coast Guard’s environmental industry partner companies and organizations set-up booths and focused on pollution prevention and environmental education. Various volunteers from partner organizations as well as students from Monarch Academy, a local charter school, helped install the TerraMod planters and attended the environmental education presentations on the parade field near the Earth Day cookout.
Chris Gorman, Oldcastle Infrastructure Territory Manager for the Chesapeake Region, gave an informative presentation to the students, volunteers and Coast Guard staff regarding the science and engineering behind the TerraMod units. The students also toured the shipyard, planted shrubs and learned valuable lessons about environmental stewardship.
“Earth Day is a very good opportunity to do something great for the environment. Partnering with the U.S. Coast Guard’s Earth Day Education Fair, providing the TerraMod planters and volunteering was a small gesture towards creating a healthy environment for the future,” said Doug Bruhns, Oldcastle Infrastructure Regional General Manager for the Chesapeake Region. “It’s definitely a group effort. Environmentalists facilitate a lot of things, but we need the participation of others. We need everyone to get involved to make it work, protecting our future and the environment. I would personally like to thank each Oldcastle Infrastructure volnteer and our precast plants for their hard work and dedication to the environment.”
One of the most significant, yet unrecognized types of water pollution is stormwater runoff. When it rains, stormwater collects everything in its path, including trash, debris and other pollutants. Eventually, the water reaches streams or rivers, either over land or via storm drains. But unlike sanitary sewers that divert water to treatment plants, storm drains ultimately empty directly into surrounding lakes and rivers without any type of treatment. All of the debris and pollutants that were picked up by the stormwater eventually end up in our nation’s waterways.
The Baltimore shipyard is the U.S. Coast Guard’s active maintenance and repair facility for the Atlantic Fleet. This historic facility has served as regional headquarters, shipyard and depot since 1899. Currently, the shipyard employs over 1,500 personnel to overhaul and recondition ships, from propellers to defensive systems.
Find out more about Oldcastle Infrastructure TerraMod and Stormwater Management Systems.
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Scores Big with TerraMod® System
San Francisco, CA
DESIGN & CONSTRUCTION TEAM
Engineer: GHD Engineering, San Francisco, CA
Contractors: Ghilotti Construction (1st Phase), Turner-Devcon (2nd Phase), Santa Rosa, CA
System Manufacturer: Oldcastle Infrastructure
PROJECT FACTS
Hardscape area drained: 5+/- acres
Total lineal feet of bioretention cells: 2,500 ft
Total bioretention surface area: 15,000 sf
Scheduled completion: August 2014
A large construction project such as a major league sports stadium can include significant expanses of runoff- generating hardscape. A venue capable of seating nearly 70,000 people requires large grounds and parking areas. If rain can turn a football field into a mud pit, it can also turn a parking lot into a floodplain. Draining that area effectively and treating the runoff is a basic function that should be provided from the very beginning of the project, but it can present challenges.
The new San Francisco 49ers Stadium in Santa Clara, California is a case in point. The new stadium moves the team out of Candlestick Park in San Francisco, into a location with about double the stadium square footage, better freeway access, and more than twice the parking spaces. Parking lot runoff always carries with it petrochemical pollutants that drip or leak from vehicles, as well as litter and other debris. The new stadium sits adjacent to San Tomas Aquino Creek, which flows directly into the Guadalupe Slough and San Francisco Bay, sensitive ecologies less than six miles away. The site is on land with a high water table, and existing storm-drain lines are not very far below the surface. An infiltration system would not work.
To handle stormwater in the parking lots, access roads, and other hardscape surrounding the stadium, project engineers GHD Engineering, San Francisco (formerly Winzler & Kelly) selected the TerraMod biofiltration system, a stormwater collection and natural treatment system made by industry leader Oldcastle Infrastructure. The stadium site will have six biofiltration systems, in parking lots and in the grounds immediately adjoining the stadium itself installed at the very outset of the project, even before the contract for stadium construction had been awarded, which added to the overall challenge.
THE TerraMod METHOD
Water is one of nature’s most powerful forces. Hardscaping can turn that force destructive, both in terms of erosion and pollution. A stormwater collection system has three mandatory functions:
- Remove rainwater from the hardscape and other impervious surfaces
- Channel runoff so it does not erode the surrounding landscape
- Treat runoff so it does not pollute the landscape or downstream waters
Biofiltration is one of the simplest, most natural, and cost-effective ways to collect runoff and treat it onsite, and it is considered a best practice under U.S. Environmental Protection Agency (EPA) guidelines for Low-Impact Development (LID).
TerraMod is a modular system of precast concrete biofiltration units. The fully deployed system looks to the casual observer like nothing but a flower bed or tree-planter, with the earth-level somewhat lower than the surrounding pavement. Beneath the surface, it is a series of concrete cells filled with layers of mulch, biofiltration media and drainage rock, with pipe in the bottom to carry treated water out of the system.
The surface-level of soil in one of these biofiltration modules is about 6-inches below pavement-level, to provide ponding depth. In storm conditions, water runs into the modules, ponds, and percolates into the media, where it is naturally filtered along the way. The filtered water is collected in a perforated pipe that runs through the bottom of the biofiltration system and carries water into a storm drain system.
Filtered pollutants are naturally broken down by microbes and provide nutrients for the plantings in the module. Plants and trees are irrigated by the rainwater. In locations where rainfall may not be frequent or consistent enough to sustain them – such as the 49ers stadium – integral drip-lines that are built into the modules can deliver supplemental irrigation water.
TerraMod module types include basic units (used with small ornamental plantings), tree modules, pre-filtration units, light pole modules, and custom modules for special situations. Pre-filtration modules have an upper chamber designed to collect litter and other solid debris, and detain it so it does not interfere with drainage. Pre-filtration units must be periodically cleaned to dispose of collected debris.
Overflow drains are built into selected modules to handle extremely heavy rains. During unusually high flows, when the ponding depth is filled and cannot be drained fast enough through the filtration media to keep up with rainfall, the parking lot must still be protected from flooding. Excess water then goes into the overflow drains and directly into the stormwater system. The stadium system was designed to handle a 10-year rain event. Having an integrated overflow bypass built into the biofiltration system eliminates the need to design and install a separate peak conveyance system, as is often necessary with other biofiltration setups.
The biofiltration system prevents hazardous conditions and collects water so it does not erode the surrounding landscape. Simultaneously, it is treated so it can be safely reintroduced into the landscape or drained into the creek, the natural drainage basin of the area. Pollutants are kept out of the bay, but no chemicals are used, there are no moving parts to maintain, no energy is consumed to do it, and maintenance is minimized.
SPECIAL CONDITIONS
The high water table of the site was a primary challenge. Even though TerraMod closed-bottom modules would be able to filter runoff without interference from existing groundwater, the runoff system would have to tie into the existing, shallow storm-drain lines, dictating that the drain system could not go very deep into the ground. Modules for the 49ers stadium had to be custom designs that are slightly shallower than standard TerraMods.
The reduced filtration depth available had to be compensated for in the overall design of the drainage system by increasing bioretention surface area. The first system installed includes special units for that purpose. These sections are more than twice as wide as standard TerraMods, and are laid out perpendicular to the main system, with a large rounded end for aesthetic purposes and to allow for easier entry to neighboring parking stalls. The shape has been described as resembling a hockey-stick.
The architect designed the side walkway of one parking lot with a shallow S-shaped jog in its otherwise straight path. The biofiltration system runs along the edge of this walkway, and follows the jog. This required custom modules. None of the custom pieces caused any production delays or presented any problem to fit into the modular system.
CONSTRUCTING THE SYSTEM
The kickoff to construction at the stadium site was to create the parking lot on the east side, next to the training field. It will serve the parking needs of construction activities, plus those of the 49ers’ team offices. It was started in January 2012, months before the official ground-breaking for the stadium.
The lot has two biofiltration systems. The one on the north side, featuring the wide, rounded special modules, was manufactured and installed first. The main run is 2.5-feet wide and just over 600-feet long, mostly basic curb-cut units without pre-filtration. The hockey-stick modules that lie perpendicular to the main run are 7-feet wide. They divide the parking lot into six drainage management (DMAs) areas, each comprising about 100-feet of the main run, and each draining 7,500-10,000 square feet of parking and walkways.
Installation of the TerraMod units was relatively simple. The excavation was cut to the proper depth and leveled, and the units set in place. Sections weighed 10-13 tons. Joints between sections were sealed with a specialized tape and adhesive. The tops of the sections include holes for dowels to attach to adjacent pavements. At the ends of the U-shaped sections, a small amount of fresh concrete was required to fill around curves. Perforated pipe was laid into the bottom and connected to the overflow drains, and the system was ready to be filled with drainage rock and filtration media.
The drainage rate is determined by the surface area of the bioretention system and by the composition of the filtration media. The system does not require proprietary biofiltration media. For the 49ers stadium, engineers accordance with the Contra Costa County requirements. Other growing media blends are capable of drainage as high as 100 in/hr, where required. Computed against the size of the lot and the predictable rainfall, the size of the required bioretention system can be calculated. However, the media must be selected not only for drainage characteristics, but also for compatibility with the intended plantings.
The greatest challenge of the first phase proved to be timing. The underground contractor had a mere 70 days to install the system and tie it into an existing stormdrain, or pay liquidated damages of $25,000/day for every day the project ran over. Use of the TerraMod system helped him meet this deadline. The modules for the first system were manufactured and delivered in under six weeks. The second system was installed later, with a mere two weeks production time for 55 modules. The two systems will be fully installed, filled, and planted by early June 2012.
The contractor noted there was a learning curve, but it was a fast one. They installed 120-feet of the system on the first day. By the fourth day, they set 480-feet in a day with a single crew.
The second, main phase of the project includes four more bioretention systems: two in a large parking lot south of the stadium, and two lining the walkway area surrounding the main entrance to the stadium. Onsite parking for the public will include about 10,000 parking spaces. A total of over 2,500 lineal feet of TerraMod cells, approximately 14,000 square feet of bioretention area, will drain the overall stadium site.
While the standard bioretention modules used in most of the 49ers project are 3-feet wide, two systems in the second phase feature tapered plans: one is 3-feet wide at one end and 14-feet at the other, an irregular wedge over 300-feet long. The other is 230-feet long and rectangular over most of its length, with a subtle taper at the south end. The main entrance to the stadium runs between the two systems, and the area they drain is immediately outside the luxury boxes. The unusual shapes were designed by the architect with specific visual goals, helping to define the focus of a key space in the stadium’s grounds.
THE LONG TERM
One of the great advantages of a biofiltration system is that it is easy to maintain and essentially self sustaining. It harnesses the method by which nature breaks down petrochemical pollutants, a process that needs little help from us. Debris must be occasionally removed from the system, and plants must be maintained like any other landscaping, but little more is necessary. The San Francisco 49ers biofiltration system will largely maintain itself, keeping the grounds looking good and safe from flooding, and protecting the San Francisco Bay and sensitive areas surrounding it from contamination.
Find out more about the Oldcastle Infrastructure TerraMod System.
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Imperial Valley Substation Screen Wall
Ocotillo, CA
Precast concrete screen walls protect power supply from public view , deterring attempts to vandalize transformers.
DESIGN & CONSTRUCTION TEAM
Owner: San Diego Gas & Electric
General Contractor: Suffolk Construction and Liberty West
Design Engineer: AARK Engineering, El Cajan, CA
Oldcastle Infrastructure Product(s): Precast Concrete Screen Wall, 1,026 Panels and 155 Foundations
In September of 2014 the design stage of the Imperial Valley Substation Screen Wall project was initiated with Oldcastle, SDG&E, and AARK Engineering in San Diego. The purpose of these walls is to protect the power supply from public view to avoid any attempt/s to vandalize these power units.
“After several discussions …they decided on a hybrid precast and cast-in-place option.”
THE DESIGN
There was several different designs considered by the owner, including alternate products such as high density plastic and polymer concrete. The design team vacillated between a complete (one piece) concrete T-wall system and a more modular design. After several discussions on the most appropriate approach they decided on a hybrid Cast-In-Place application), galvanized steel I-beam columns that Oldcastle Infrastructure panels would slide down into.
For the interior of the facility; the owner decided on precast foundations with the same I-beam and precast panels. This option on the interior allows these screen walls to be taken apart and re-located as needed.
The Request for Proposal (RFP) was issued in early July 2015 and was awarded to Oldcastle Infrastructure, Inc. in early August. The project consisted originally of 1026 precast panels (9’-9” x 7’-5” x 0’-6”) and 155 foundations (some 8’ x 5’ x 2’ and 11’-6” x 5’ x 2’). More panels and foundations are being added as needed. The project started shipping in early October 2015 and is anticipated to complete shipping in early March 2016. This was a very fast paced project due to the ease of installation of these components. Once the appropriate amount of material was stocked at our facility, we were able to run multiple loads per day to the jobsite in Imperial Valley.
INNOVATION
This project has garnered a tremendous amount of attention from several state and federal organizations, including the Department of Homeland Security who has visited the project job site several times.
San Diego Gas and Electric has several other facilities planned for this design in the coming years. We are looking forward to a bright future with this product line and design in Southern California.
Find out more about Oldcastle Infrastructure Precast Concrete Screen Walls.
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Features Special Precast Components
Boise, Idaho
The uniquely crafted, precast concrete, decorative park signage and bridge components add striking features to the park. An additional 326-feet of precast box culvert was supplied for a drainage structure.
DESIGN & CONSTRUCTION TEAM
Owner: Boise Parks and Recreation Department
Design Build Firm: McMillen Jacobs Associates
Oldcastle Infrastructure Plant: Oldcastle Infrastructure, Nampa, Idaho
Oldcastle Infrastructure Product(s): Precast Concrete Signage, Bridge Fascia Components, 326-feet of Precast Box Culvert
THE CHALLENGE
Funded privately by the J.R. Simplot Foundation, Esther Simplot Park is the newest addition to the “Ribbon of Jewels”, the string of riverside parks named for prominent women in this community. Located north of the Boise River between Fairview Avenue and Veteran’s Parkway, Esther Simplot Park is the largest of the city parks, encompassing 23 acres of ponds, wetlands and other water- ways for fishing, wading, and swimming, covering more than 40 percent of the park’s 55 acres. Amenities include bridges, docks, trails, restrooms, boardwalks, natural and paved pathways, shelters, grassy open areas, a playground, and wildlife habitat. The Esther Simplot Park, bordered by Whitewater Park Blvd. and the Boise River, is designed to reduce flood risk and manage storm- water, as well as provide valuable recreational opportunities.
THE SOLUTION
For main contractor, McMillen-Jacobs, Oldcastle Infrastructure – Nampa, Idaho supplied six precast concrete, arched bridge fascia panels, twelve bridge column pier caps, nine park signs, various catch basins and manholes for stormwater drainage, box culverts for water conveyance, and numerous parking bumpers.
Creating a very distinguishing look for the park’s new vehicular bridge, Oldcastle Infrastructure cast the arched bridge fascia panels with wood grain finish which were installed three on each side of the bridge, with the column pier caps mounted on top of the bridge columns.
The uniquely crafted, precast concrete, decorative park entrance and directional signage, specifically designed for Esther Simplot Park, is a striking feature of the park. To achieve the complex and highly sculp- tured form of the signage’s external facade, Oldcastle Infrastructure cast four-inch deep, intricately detailed, block out shapes, for the inset of the stonework. In all, nine decorative signs were produced, seven small signs, 9-foot-tall by 4-foot-long and two large signs, 12-foot-tall by 17-foot-long.
Additionally, Oldcastle Infrastructure provided 326-linear-feet of box culvert, multiple 30’ wide x 10’ high precast segments, to create the new diversion structure which includes an improved intake/trash rack and flow control gates at the downstream end of the culvert. The ground surface in the vicinity of the diversion was lowered approximately 3 feet to provide additional flood conveyance through this area.
The 326-foot box culvert bridge lies underground, directly after the water intake structure, for park water conveyance and redirection to the river, whereas the precast catch basins, manholes and sediment box tanks provided controlled park stormwater drainage.
“Working closely with McMillen-Jacobs, the Oldcastle Infrastructure Nampa, Idaho team delivered the precast concrete park elements on budget and on time to keep the project flowing smoothly,” said Mike Blackham, P.E., Idaho Engineering Manager. “The team worked tirelessly to ensure the high standard of the products, both at the factory and after installation.”
For Oldcastle Infrastructure, the project proved a stimulating challenge and the company was delighted with the result. Challenges to the project included a tight schedule. The fast-track project was carried out with high predictability, reducing dependency on skilled trades while maintaining safety standards. This ensured a high quality solution providing a benchmark for future schemes of a similar nature.
Find out more about Oldcastle Infrastructure Box Culvert, and Concrete Bridge Solutions.
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Berks County, PA
DESIGN & CONSTRUCTION TEAM
General Contractor: J D Eckman
Owner: PA DOT
PA DOT Contract Amount: $968,000
Precaster: Oldcastle Infrastructure
Manufacturing Facility: Oldcastle Infrastructure Telford; Folsom & Croydon, PA
The PA Department of Transportation project entailed the Mohnton Boro Bridge Replacement of the existing two span steel pipe culverts conveying a tributary of Wyomissing Creek with a single barrel 90” pipe culvert for STATE ROUTE 3020, SECTION 01B, in MOHNTON BORO, BERKS COUNTY, PA. Roadway over culvert will have two 11 foot lanes and 4 foot shoulders. Structure length is 122 feet, for a total of approximate length of 475 feet (.090 miles).
CONSTRUCTION CHALLENGE
Oldcastle Infrastructure had extensive experience with manufacturing the 66” & 90 “ RCP Culvert but needed to create a new joint for the 90” RCP Culvert. In collaboration with CCJM Engineers they designed and engineered a new 90” baffle for the 90” RCP culvert.
PRECAST SOLUTION
Oldcastle Infrastructure designed, engineered and shipped 120 Linear feet of RCP Culvert which was comprised of : 90” RCP culvert ; 66” RCP culvert and 90” baffles to replace the steel pipe culverts that were deteriorated.
SCOPE OF WORK
Precast Structure
A. STRUCTURAL ENGINEERING
Detailed engineering:
Drawings: Detailed drawings
B. Precast Concrete Product
Size: 66” * & 90“ RCP & Baffles
Concrete: 5000 psi concrete
40.00 FT 20663481 66” O-RING
A/S 25’-1.5’
351.30 14,052.00
5.00 Ea 24302018 66” O-Ring Gasket
72.00 Ft 20903382 90” O-Ring Type A/S
25’-1.5’ Fill **Oring Joint**
5.00 Ea 4000180 90” Baffles O/Ring for
The 90” Pipe for 25’-1.5’
Fill***Item 9000-0002**
Aprox Weight is 22 Tons
Baffels to Join the Pipe
The Dimensions Are Aprox 14’ L X 13’ W By 2’ Thick**
9.00 Ea 24000027 Mastic Joint
Sealant**For The 90” Baffels**
9.00 Ea 24302022 90” O-Ring Gasket
10.00 Ea 24000023 Gasket Lube 3.5
Gallon Pail
Find out more about Oldcastle Infrastructure RCP Culvert Products.
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NASCAR Distributed Antenna System (DAS) Building Projects
Daytona Speedway, Daytona, FL
Chicagoland International Speedway, Joliet, IL
Phoenix International Speedway, Phoenix, AZ
DESIGN & CONSTRUCTION TEAM
General Contractor: American Tower Corporation (ATC)
Owner: ISC, NASCAR
Contract Amount: $249,345
Precaster: Oldcastle Infrastructure
Manufacturing Facility: Oldcastle Infrastructure, Newnan, GA
American Tower Corporation (ATC) signed an agreement to design and install DAS and other wireless infrastructure solutions at all 12 of International Speedway Corporation’s (ISC) NASCAR motorsports facilities to enhance wireless signal strength and distribute radio capacity for customer use and general track operations during events. ISC selected American Tower due to its experience and proven solutions to help ISC overcome these challenges and enhance the fan experience at ISC facilities. American Tower was selected for its customized wireless infrastructure solutions that support wireless coverage and capacity. Oldcastle Infrastructure was contracted by ATC to supply a portion of the customized wireless infrastructure solution. Oldcastle Infrastructure supplied the turnkey wireless equipment shelters known as Distributed Antenna System (DAS) Network Buildings for these projects.
“This significant award, to provide turnkey shelter solutions, once again validates Oldcastle Infrastructure as a significant market leader in the shelter industry, offering a combination of innovative technology, manufacturing skill and comprehensive turnkey services, while above all improving the customer experience for clients who choose to partner with Oldcastle Infrastructure” John Albert, Oldcastle Infrastructure Director of Sales for Shelter Solutions.
PRECAST SOLUTION
Contracted to manufacture and provide comprehensive turnkey services for the speedway (DAS) Network Buildings, Oldcastle Infrastructure provided a 12’ x 28’ DAS Equipment shelter for the Daytona Speedway; a two piece, 42’ x 24’ DAS Equipment Shelter for the Phoenix International Speedway and three (3) DAS Equipment Shelters for the Chicagoland International Speedway – (1) 12’ x 28’ DAS Equipment Shelter and (2) two 12’ x 20’ DAS Equipment Shelters. Oldcastle Oldcastle Infrastructure’s total turnkey services offered the client single vendor responsibility for the DAS Equipment Shelters from installation of all electrical, environmental systems, alarms, lighting, on-site delivery and site construction, zoning, permitting and foundations, in addition to on-site architectural enhancements.
DAYTONA SPEEDWAY
Daytona, FL
SCOPE OF WORK
Precast Structure
A. Structure Engineering
Detailed engineering:
Drawings: Detailed drawings
B. Oldcastle Model RCS11828 precast shelter building
C. Design and Permitting
D. Project Management and Site Supervision: Manage the design, budget, schedule and quality on the shelter project
E. On-Site Supervision: Manage field activities, coordination of Oldcastle provided trades and quality assurance of Oldcastle provided trades
F. Testing: Field Testing of Oldcastle provided Services. Oldcastle start-up and function tested the shelter electrical and HVAC
Precast Building
Exterior Finish (wall): Washed Exposed Aggregate Sealed w/ two coats Thorosheen
Exterior Finish (roof): Sealed with two coats of Dura Cool
Insulation (walls): R-11, Rigid board type with foil facing
Insulation (ceiling): R-22, Rigid board type with foil facing
Interior Finish (walls & ceiling): ½” Tk. moisture board finished
Interior finish (floor): VCT Tile, 12”x12” Square
Interior finish (base): 4” Rubber base / Color: Gray
Door: 4’0” x 7’0”, 16ga. Heavy Duty steel galvanized primed & painted
Door Frame: 4’0” x 7’0” 14ga. Heavy Duty steel galvanized primed & painted
Door Closer: Hydraulic closer with hold open feature on the arm. Pick plate / Lock Guard
Door Key Box: Heavy Duty cast box for key storage with combo lock
Entry Panels: (4) 24” x 24” Blank plates covering wall openings (primed & painted)
Power and Electrical
Disconnect: 200A, 1Ø, 120/240V, Exterior Mounted, Fused Disconnect Switch
Transfer Switch: 200A, 1Ø, 120/240V, Exterior Mounted Manual Transfer Switch
Generator Receptacle: 200A, 1Ø, 120/240V, Appleton Generator Receptacle
Main Distribution Panel: 200A, 1Ø, 120/240V, 42 Space Panel
Surge Suppression: AC Data B82XXR
Receptacles: (6) 20A, 1Ø, 125V, Interior Wall Mounted Convenience
Receptacles: (1) 20A, 1Ø 125V, Exterior Wall Mounted GFIC
HVAC Unit: (2) 5 Ton, 60,00btu, Wall mounted units with 5kW Heat strip
HVAC Grille: (2) Wall mounted adjustable supply grilles
HVAC Grille: (2) Wall mounted adjustable return grilles
Alarm Box: 12” x 10” x 6” Deep hinge cover box with back plate, Power Fail Alarm; HVAC Fail Alarms; High Temp Alarm;
Low Temp Alarm; Smoke Alarm
Fluorescent light fixtures (8) with acrylic lens cover; Incandescent Exterior light fixture mounted on back box, photo-cell/motion sensor control
Emergency: Exit fixture w/illuminated sign
90 LF Cable Ladder: 12” Wide
Fire Extinguisher: 5 lb. CO2 Wall Mounted
Oldcastle Infrastructure provided turnkey deployment of a 12’ x 28’ DAS Equipment shelter. The 12’ x 28’ RCS Design shelter was engineered and manufactured by Oldcastle Infrastructure for seismic zone: 50% G. The outside dimension is 28’ Long x 11’8” Wide x 10-4’ High and the finished inside dimension is 27’ Long x 10’8” Wide x 9’” high. The project included total outfitting of the shelter from installation of all electrical, environmental systems, alarms, lighting and on-site delivery and site construction, in addition to on-site architectural enhancements.
CHICAGOLAND INTERNATIONAL SPEEDWAY
Joliet, IL
SCOPE OF WORK
Precast Structure
A. Structural Engineering: Detailed engineering & Detailed drawings
B. Oldcastle Model RCS11828 and (2) RCS11520 precast shelter buildings
C. Design and Permitting
D. Project Management and Site Supervision: Manage the design, budget, schedule and quality on the shelter project
E. On-Site Supervision: Manage field activities, coordination of Oldcastle provided trades and quality assurance of Oldcastle provided trades.
F. Testing: Field Testing of Oldcastle provided Services. Oldcastle start-up and function tested the shelter electrical and HVAC.
Precast Buildings
Exterior Finish (wall): Washed Exposed Aggregate Sealed w/two coats Thorosheen
Exterior Finish (roof): Sealed with two coats of Dura Cool
Insulation (walls): R-11, Rigid board type with foil facing
Insulation (ceiling): R-22, Rigid board type with foil facing
Interior Finish (walls & ceiling): ½” Tk. moisture board finished
Interior finish (floor): VCT Tile, 12”x12” Square
Interior finish (base): 4” Rubber base / Color: Gray
Door: 4’0” x 7’0”, 16ga. Heavy Duty steel galvanized primed & painted
Door Frame: 4’0” x 7’0” 14ga. Heavy Duty steel galvanized primed & painted
Door Closer: Hydraulic closer with hold open feature on the arm. Pick plate / Lock Guard
Door Key Box: Heavy Duty cast box for key storage with combo lock
Entry Panels: (4) 24” x 24” Blank plates covering wall openings (primed & painted)
Power and Electrical
Disconnect: 200A, 1Ø, 120/240V, Exterior Mounted Fused Disconnect Switch
Transfer Switch: 200A, 1Ø, 120/240V, Exterior Mounted Manual Transfer Switch
Generator Receptacle: 200A, 1Ø, 120/240V, Appleton Generator Receptacle
Main Distribution Panel: 200A, 1Ø, 120/240V, 42 Space Panel
Surge Suppression: AC Data B82XXR
Receptacles: 20A, 1Ø, 125V, Interior Wall Mounted Convenience
Receptacles: 20A, 1Ø 125V, Exterior Wall Mounted GFIC
HVAC Unit: 5 Ton, 60,00btu, Wall mounted units with 5kW Heat strip
HVAC Grille: Wall mounted adjustable supply grilles
HVAC Grille: Wall mounted adjustable return grilles
Alarm Box: 12” x 10” x 6” Deep hinge cover box with back plate, Power Fail Alarm; HVAC Fail Alarms; High Temp Alarm;
Low Temp Alarm; Smoke Alarm
Fluorescent light fixtures with acrylic lens cover ncandescent Exterior light fixture mounted on back box, photo-cell/motion sensor control
Emergency: Exit fixture w/illuminated sign
70 LF Cable Ladder: 12” Wide
Fire Extinguisher: 5 lb. CO2 Wall Mounted
Oldcastle Infrastructure Provided Turnkey Deployment of (3) Three Shelters.
One is a 12’ x 28’ DAS Equipment shelter. The 12’ x 28’ RCS Design shelter was engineered and manufactured by Odcastle Infrastructure for seismic zone: 50% G. The outside dimension is 28’ Long x 11’8” Wide x 10-4’ High and the finished inside dimension is 27’ Long x 10’8” Wide x 9’” high. The other two are 12’ x 20’ DAS Equipment shelters. The 12’ x 20’ RCS Design shelters were engineered and manufactured by Odcastle Infrastructure for seismic zone: 50% G. The outside dimension is 20’0” Long x 11’6” Wide x 10’4” High and the finished inside dimension is 19’0” Long x 10’6” Wide x 9’0” high. The project included total outfitting of the shelter from installation of all electrical, environmental systems, alarms, lighting and on-site delivery and site construction, in addition to on-site architectural enhancements.
PHOENIX INTERNATIONAL SPEEDWAY
Phoenix, AZ
SCOPE OF WORK
Precast Structure
A. Structural Engineering: Detailed engineering: Detailed drawings
B. Oldcastle Model RCS2442DW Two Piece Precast Reinforced Concrete Building
C. Design and Permitting
D. Project Management / Site Supervision: Manage the design, budget, schedule and quality on the shelter project
E. On-Site Supervision: Manage field activities, coordination of Oldcastle provided trades and quality assurance of Oldcastle provided trades.
F. Testing: Field Testing of Oldcastle provided Services. Oldcastle start-up and function tested the shelter electrical and HVAC
G. Building Foundation: 2’ wide strip footing, up to 1’ above grade and as required below grade for frost. Includes necessary back fill. 174-LF
H. Stoop(s): 5’ x 8’ Concrete Pad (Precast or Poured In Place) 2/EA
I. Compound Stone: 4” of stone cover within 5’ perimeter of building 10-CuYd
J. Fabric: Landscape fabric/weed barrier under compound stone 800-SF
K. Pipe Bollards: 8” Dia. Sch 40 Steel Pipe Bollard Filled With Concrete, Bollards placed ~ 2’ into the ground encased in concrete and painted – 9/EA
Exterior Architectural Enhancements (Installation of Rubber Roof Membrane) Electrical (exterior): Exterior Ground Halo: Perimeter loop ( ~ 200-LF) with #2 Thinned Copper Wire / ( ~ 6) 10’ Copper Cladded Rods / (1) Inspection port / ( ~ 10 ) Grounding Tails From Exterior Ground Loop To Building and Related Building Equipment. Includes conduit to interior ground bar.
Oldcastle Infrastructure provided turnkey deployment of a 42’ x 24’ DAS Equipment shelter. The 42’ x 24’, two piece, DAS Equipment shelter was engineered and manufactured by Oldcastle Infrastructure for seismic zone: 50% G. The outside dimension is 42’0” Long x 23’8” Wide x 11’2” High and the finished inside dimension is 41’0” Long x 22’10” Wide x 9’0” High.
The turnkey project included total outfitting of the DAS Equipment shelter from installation of all electrical, environmental systems, alarms, lighting, on-site delivery and site construction, zoning, permitting and foundations, in addition to on-site architectural enhancements.
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Control Enclosure
Palatka, FL
DESIGN & CONSTRUCTION TEAM
General Contractor: WorleyParsons, TCI Sales
Owner: Seminole Electric Cooperative
Precaster: Oldcastle Infrastructure, Shelter Solutions
Manufacturing Facility: Oldcastle Infrastructure (Newnan, GA), Oldcastle Infrastructure Enclosure Solutions (Cable Trench System)
The intent of the SECI Riverview Substation project, located at the intersection of County Landfill Rd. and Cow Bay Rd. in Palatka, FL, was to design, engineer, fabricate, deliver and secure to Owner-supplied foundation, a substation Control Enclosure in preparation for a future project that will relocate existing DC batteries, communication equipment and protection and control facilities from within the existing Control Enclosure. In addition, Oldcastle Infrastructure provided the cable trench system.
CONSTRUCTION CHALLENGE
Oldcastle Infrastructure was contracted to provide a – 23’ long x 15’ Wide x 11.6’ High- precast concrete Control Enclosure with complete and functioning equipment and systems capable of safe and reliable operation including electrical, lighting, building and equipment grounding, lightning protection and HVAC.
The cable trench system consisted of 30ft. Oldcastle Plastibeton High Density Polymer Concrete 2016 Drive-On Cable Trench complete with covers and
76ft. Oldcastle DUO Molded 2016 Pedestrian Trench complete with covers.
PRECAST & TRENCH SOLUTION
The turnkey project involved the manufacturing and complete out-fitting of a bullet resistant, precast concrete OPIRCS1523 Precast Shelter having 4 inch thick exterior walls with an exposed aggregate concrete finish. In addition, all equipment and systems were installed at the factory before shipping. (See Scope of Work). The RCS1523 Precast Shelter was manufactured and equipped at our Oldcastle Infrastructure – Newnan,GA facility and installed in the field by our Oldcastle Infrastructure Shelter Solutions Group.
The Oldcastle Cable Trench System was tied into an existing concrete trench system with a transition piece attaching Oldcastle Infrastructure’s new cable trench system together with the existing concrete trench system.
CONSTRUCTION SCHEDULE
Start Date: May 2012
SCOPE OF WORK
Precast Structure
A. STRUCTURAL ENGINEERING
Engineering: Provided complete product engineering services.
Drawings: Provided detailed engineering drawings.
Supervision: Provided an on site managing supervisor.
B. PRECAST CONCRETE SHELL
Size: (1) RCS 1523 Precast Concrete Shelter
Outside Dimension – 23’ long x 15’ Wide x 11.6’ High
Finished Inside Dimension – 21’ 9” Long x 13’ 9” Wide x 10’ High
Weight: Approximate finished weight: ~76,000 pounds
Specifications: Floor load: 200 PSF
Roof load: 85 PSF
Wind load: 150 MPH, Exp “C”
Bullet Resistance: UL752 Level 4 Equivalent (.30-06 at 15 Ft.)
Fire rating: Two Hour Equivalent
Seismic Zone: Up to 50% Gravity acceleration per IBC2006.
C. FINISHES
Exterior Walls: Solid Precast Concrete, 4” Thick, exposed aggregate with grey sealer and trim
Interior Wall & Ceiling: Nudo white 1/2 “ FRP board
Insulation: R-19 in the walls and R-30 in the ceiling
Floor: Grey slip resistant Thorocoat coating (floor insulation in foundation)
Roofing: White Elastomeric coating
D. DOORS AND OPENINGS
Doors: (1) 6’-0” x 8’-6” heavy duty steel double door and frame, R-3.8 (Doors / frame galvanized, primed and enamel painted)
Locks: Cylindrical lockset with changeable core and interior panic bar
Other Door Hardware: (1) NRP Stainless steel hinges, anti pick plate; door holder, hydraulic door closer, weather strip, aluminum threshold, door sweeps, and surface bolts
Door Hood: (1) Door drip cap – 2 ½” wide and full width canopy
Openings: Floor and wall block-outs determined by customer,
Telco Cable Entry: (1) 4 port Microflect waveguide entry panel
E. POWER
Power Service: 200A 10 120/240V supplied by others
Main Distribution Panel: (1) SqD 200A 10 120/240V panel, 40 space, 22kAIC with main breaker
Surge Suppression: (1) SqD SDSA1175 integrated into MDP Convenience
Receptacles: (4) 20A, 120V
Exterior GFI Receptacle: (2) 20A, 120V
F. ENVIRONMENTAL SYSTEM
HVAC: (1) Bard 2 Ton 10 HVAC Unit with 5kw heater, no economizer
Controls: (1) Automatic thermostat
Exhaust Fan: (1) Centrifugal fan, Grainger 4HZ34 with timer control and hood
Intake Louver: (1) 24” X 24” fixed aluminum intake louver with hood
G. ALARMS
Alarms: (2) Door intrusion alarm switches, Honeywell S&C, DTE6-2RN2
H. LIGHTING
Interior: (8) 4ft.- 2 Lamp (32W each) fluorescent light fixtures with acrylic lens covers
Exterior: (1) 70W HPS Exterior light with photocell, Grainger 2RGW8
Emergency: (1) Emergency fixture with dual 1.5 watt lamps, EXIT sign, 3 hour battery (Larger lamps not available with 3 hour battery)
Switches: (1) 20A light switch
K. ADDITIONAL ITEMS
Smoke Detector, GE 350CX; (1) Fire extinguisher, Grainger 4XP83; Tie down kit with anchors; (1) eye wash station, Grainger 1KW77; Interior and exterior cable ladder system per specification and drawing; (1) Trenwa # CR2212-120 enclosure
TRENCH SOLUTION
Scope
Oldcastle Infrastructure Enclosures Solutions provided the Cable Trench System for Seminole Electric’s Riverview Substation Expansion project. The Oldcastle Cable Trench System was tied into an existing concrete trench system with a transition piece attaching Oldcastle Infrastructure’s new cable trench system together with the existing concrete trench system. The cable trench system consisted of 30ft. Oldcastle Plastibeton High Density Polymer Concrete 2016 Drive-On Cable Trench complete with covers and 76ft. Oldcastle DUO Molded 2016 Pedestrian Trench complete with covers. The Oldcastle trench system was installed by a construction crew hired by Seminole Electric and installed in between the existing substation cable trench system and attached into the new Oldcastle Infrastructure Control Building.
Manufacturing
The Oldcastle Enclosure Solutions Cable Trench System was manufactured and shipped from its Candiac, QB, Canada Manufacturing Facility.
The Plastibeton Cable Trench System is designed and tested to support 40,000 lbs over a 10X10 square area and is manufactured utilizing a patented High Density Polymer Concrete material. With a combination of 6% resin and 94% stone, this 20,000 psi composite material does not absorb water, is not affected by acids, salts, chemicals with exceptional resistance to freeze/thaw cycles and is a dielectric material with no grounding required.
The Duo Pedestrian Cable Trench System is manufactured utilizing two composite materials and a patented manufacturing process. The Duo trench is the lightest most durable pedestrian trench system available today and is designed to withstand the lateral loads of passing vehicles without deflection and light enough to hand install.
Find out more about Oldcastle Infrastructure Cable Trench Systems and Precast Concrete Building Structures.
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28 College Drive
Queensbury, NY
DESIGN & CONSTRUCTION TEAM
General Contractor: Bette & Cring Construction Group, LLC
Architect/Engineer: Cannon Design Architects/Engineers
Owner: Adirondack Housing Authority LLC
Engineered Panelized Metal Stud: NCI Steel Panels NY
Precaster: Oldcastle Infrastructure, Building Systems
Manufacturing Facility: Oldcastle Infrastructure, Selkirk, NY
The SUNY Adirondack $25.5 million, student housing complex, owned by Adirondack Housing Authority LLC, is a design-build, 148,00 square foot, two building complex that features 400 beds. The residence hall facility has suite style rooms accommodating four (4) students per suite. Each suite has a living room and kitchenette, two bedrooms and two bathrooms. Their first-ever, sustainable student housing complex creates a flexible open space for the students as well as a quiet and safe environment.
CONSTRUCTION CHALLENGE
The project schedule was critical. SUNY wanted to open the student housing on time and enroll the students in Fall 2013. Oldcastle Infrastructure was contracted to manufacture and install the 8” hollowcore plank allowing for a fast-track, lighter building solution in addition to delivering a very cost-effective, best value building system that was not limited to weather conditions for construction. Ground Breaking took place in April of 2012 and Oldcastle Infrastructure completed installation of the hollowcore plank on October 24, 2012.
PRECAST SOLUTION
Oldcastle Infrastructure was contracted to provide and install 116,500 square feet of 8” hollowcore plank for the two, 4-story main building floors 2nd, 3rd, 4th and roof level and 1,350 pieces of 8” thick, 4’-0” wide hollowcore plank for the design-build project. A unique feature is that the precast-prestressed
8” hollowcore plank bears on load bearing pre-assembled panelized, heavy gauge, metal stud walls. “Precast prestressed hollowcore planks on the modular load bearing panelized metal stud walls went super fast putting us in front of our construction schedule”, said Bryan Lamansky, project manager for Bette & Cring’s who is the general contractor for this project.
CONSTRUCTION SCHEDULE
Start Date: April 2012
Completion Date: July, 2013
“The system was so cost effective and gave the best value when we valuated among the other construction systems” Bryan Lamansky, Project Manager, Bette & Cring
PROJECT DETAILS
Project Size: 2 Buildings – connected with a connector. Each building has 4 floors and roof. This is the first on-campus housing at the college.
Square Footage: 148,000 square feet
Levels: 4 levels
Precast Structural
Elements: 116,500 sf 8” thick, 4’-0” wide hollowcore plank at the main building floors 2nd, 3rd, 4th and roof level. Totaled 1,350 pieces 8” thick, 4’-0” wide hollowcore plank.
Special Features:
- Hollowcore Plank on load bearing modular heavy gage metal stud. Design-build project. Hollowcore plank + load bearing metal stud (panelized -modular) was chosen for:
- Fast track project
- Sound – students have quiet atmosphere
- Fire- 2 hour fire rating
- Light structure, less foundation
- No affect from weather conditions
- 4’-0” wide concrete planks are used. Smaller crane. Very efficient installation. The structural part of the project was constructed very fast.
- Modular load bearing metal studs were installed in one wing while hollowcore plank was being installed on the other. Continuous fast installation.
- Each floor/wing was approx 14,500 sq.ft. – 160 pieces
- 8” hollowcore plank: It took 2 days to erect & 2 days to grout.
- Plank span from outside bearing wall to inside corridor and corridor to the outside bearing wall creating open flexible space with only 8” thick shallow depth.
- 8” thick hollowcore plank, with 2 spans at the width of the building, creates an open and flexible area. From outside of the building wall to the corridor and to other end of the building.
“The system is lighter than most of the other systems which saved us design and money on the foundation. I will definitely use this system moving forward”. Bryan Lamansky, Project Manager, Bette & Cring
Find out more about Oldcastle Infrastructure Hollowcore Plank solutions, and Precast Concrete Building Structures.
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Hiawatha Light Rail Line
Minneapolis, MN
DESIGN & CONSTRUCTION TEAM
General Contractor: Railworks
Owner: Twin Cities Metro Transit
Precaster: Oldcastle Infrastructure
Manufacturing Facility: Oldcastle Infrastructure, Ramsey, MN
The new Minneapolis-Hiawatha Light Rail Line extends 11.4 miles from downtown Minneapolis through Minneapolis – St. Paul International Airport to the Mall of America in nearby Bloomington, MN. The track work portion of Railworks Corporation’s contract included embedded, ballasted, direct-fixation track and special track work; the electrical portion; site improvements; traction power system; catenary; signaling, and Oldcastle Infrastructure’s StarTrack grade crossing modules.
CONSTRUCTION CHALLENGE
Oldcastle Infrastructure had extensive experience with manufacturing the StarTrack 17’6” modules allowing fast-track manufacturing and construction. The use of StarTrack on this project allowed Railworks to install crossings quickly which allowed the crossings to open to vehicle traffic before pulling the rail at several of the locations.
PRECAST SOLUTION
Oldcastle Infrastructure designed, engineered, manufactured, shipped, and installed approximately 5,000 linear track feet of their patented Standard StarTrack 17’6” modules for the railroad grade crossings at the Twin Cities Metro Transit – Hiawatha Light Rail Line.
TIME LINE
Design work began in fall, with construction following in late 2001, continuing through 2004.
SCOPE OF WORK
Precast Structure
A. STRUCTURE ENGINEERING
Detailed Engineering
Engineering Calculations
Drawings: Detailed drawings
B. Precast Concrete Product – StarTrack Grade Crossings
Size: 17’-6” x 8’-0” Section
Concrete: 6000 psi concrete
Quantity: 285 pieces – Totaling 5,000 track feet
Find out more about the Oldcastle Infrastructure StarTrack Rail Solutions.
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Precast Concrete Hollow Core Plank; Wall Panels & Storm Capture® Storm Water Harvesting System
Bronx, New York
DESIGN & CONSTRUCTION TEAM
General Contractor: Blue Sea Construction Co., LLC
Owner: Blue Sea Development Company
Architect: ABS Architects, Danois Architects P.C.
Engineer: Ty Lin International
Precaster: Oldcastle Infrastructure; Selkirk, New York and Edgewood,
Maryland, Colorado
As part of Mayor Bloomberg’s $7.5 billion New Housing Marketplace Plan to provide affordable housing for 500,000 New Yorkers, the new Forest House development is designed as a “green” and energy savings precast concrete building, containing 124 affordable units available to households making 60% of the AMI or less. The 109,000 square foot building also contains a landscaped open space, 43 underground parking spaces, under the first level, and features a unique rooftop, commercial greenhouse that will yield 80,000 to 100,000 pounds of fresh produce a year to be distributed to residents and local markets in the Bronx.
CONSTRUCTION OVERVIEW
Oldcastle Infrastructure, using their expertise in precast concrete structures, manufactured 136,162 square feet of precast concrete hollowcore plank for the floors and roof, which was specifically designed to handle the unique load of a roof top greenhouse and 70,000 square feet of precast concrete wall panels to construct an energy efficient building envelope for the eight-story Forest House Development building. The exterior precast walls were cast with GlenGery thin-brick and sandblast type finish (via form liner) with colored concrete to provide a comprehensive exterior finish.
Oldcastle Infrastructure worked closely with Blue Sea and ABS Architects, the project architect, during the design phase to develop a cost effective solution that met all of the project requirements.
SPECIAL STORM WATER HARVESTING SYSTEM CONSTRUCTED
In addition to the housing structure, Oldcastle Infrastructure Solutions manufactured and installed their Storm Capture® Storm Water Harvesting System. The Storm Capture Harvesting System included special Storm Capture retention modules that handle approximately 16,000 gallons of captured water and an equipment package that treats the captured water making it available for irrigation to the roof mounted hydroponic greenhouse, providing another unique feature to this environmentally friendly project.
Oldcastle Infrastructure Building Systems supplied locally produced precast concrete building components to allow the structure to be built quickly,
and with minimal disturbance to surrounding areas. The site is located in a high density area with little space for construction activity. Precast elements will also create a superior energy-efficient building envelope.
SCOPE OF WORK
Precast Building Structure
A.STRUCTURAL ENGINEERING
Detailed engineering:
Drawings: Detailed drawings
- Multi-Family
- 8 story building
- 136,162 SF of precast concrete hollow core plank for foors and roof
- 70,000 SF of precast concrete walls
Break down of Precast Concrete components
- 110,000 sq ft of 8” Elematic Hollowcore planks in building
- 24,500 sq ft of 12” planks at rear courtyard and roof
- 190 pcs of 8” thk exterior bearing walls with thin brick
- 180 pcs of 8” thk interior bearing walls
- 34 pcs of precast parapets
- 49 precast lintel beams
- 37 precast stairs and landings
- Exterior precast walls have Glen-Gery thin brick cast into them
- 3,000 sq ft of solar panels
OLDCASTLE STORMWATER SOLUTIONS FOREST HOUSE STORMWATER HARVESTING SYSTEM
The project has a commercial hydroponics greenhouse built on the roof and incorporates Oldcastle Infrastructure Solutions’ Storm Capture Storm Water Harvesting System for rainwater harvesting. The Oldcastle storm water system captures and reclaims water to be used to help grow the greenhouse produce. *Solar panels supplied by Oldcastle, on the roof, will supply renewable energy for the greenhouse power needs.
Challenge
The system was sized to maximize water savings, but there was no room to excavate a cistern outside of the building. Water quality needed to be high so that there would no harm to the plants in the greenhouse. And because the building was to be LEED certified, the system needed to gather, store and report data on the rainwater, and make-up water used.
Solution
Oldcastle Infrastructure Solutions designed a concrete vault for the system to be integrated into the basement of the modular concrete structure – both of which were supplied by Oldcastle. It was determined that 16,000 gallons was the most efficient cistern size to maximize savings using minimum building space. Wahaso designed and supplied the processing equipment to treat and pressurize needed for most rain events. Water in the cistern was transferred to a processing also served as the location for municipal make-up water to be added when the cistern is empty
Wahaso’s series 100 custom control system manages all system functions and records tank water levels, rainwater harvested and applied, and the amount of municipal water required during droughts.
Results
The rainwater system should save approximately 60% of the total water demand for the greenhouse each year – representing about 380,000 gallons per year. The UV system ensures that the harvested non-potable water should be safe for exposure to greenhouse workers. In addition to the rainwater harvesting system, the greenhouse will use left-over heat from the residential portion of the building. The farm will be used to provide fresh, perishable vegetables to a local non-profit food cooperative. The rooftop farm will be able to supply enough produce to meet the annual fresh vegetable needs of up to 4,500 people.
“Oldcastle’s unique thin brick inlay saved labor and reduced the construction cycle time for exterior walls”. Barbara Skarbinski, ABS Architects
Find out more about Oldcastle Building Structure Solutions and StormCapture Products.
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Over San Gabriel River Replacement Project
Norwalk, California
HIGHLIGHTS
Project: Reyes Construction Inc., Pomona, California
Prime Consultant and Structural Engineer: Biggs Cardosa Associates (BCA)
Owner: The City of Norwalk, California
Precaster: Oldcastle Infrastructure
Manufacturing Facility: Oldcastle Infrastructure, Perris, California
The Firestone Blvd. Bridge Replacement Project involves the replacement of the existing, structurally deficient Firestone Boulevard Bridge at the San Gabriel River in its entirety with a new bridge to meet current standards with wider sidewalks, center median, and shoulders. The same number of travel lanes (six) will be provided on the new 239 foot bridge. The new bridge will improve existing approach widths, thus eliminating bottlenecks and improve efficiency while accommodating future vehicle capacities in both directions. The bridge replacement project is being constructed in three stages. Stage One will remove the existing north half of the bridge and construct a new north half.
Stage Two will remove the existing south half of the bridge and construct a new south half. Stage Three will include the closure pour (where concrete is poured to seal the two halves of the bridge together) and completion of the center median.
PRECAST SOLUTION
The general contractor for the project, Reyes Construction Inc., contracted Oldcastle Infrastructure – Perris, California to produce a total of thirty-nine prestressed concrete, 4 foot high, wide fange bridge girders, ranging in length from 71 feet to 95 feet, for the new $9.5 million bridge replace project. The wide fange bridge girders, similar to an I-beam, support the bridge decking.
For the first stage, the new north half of the bridge, Oldcastle Infrastructure provided a total of twenty-one wide fange girders, fourteen girders at 71 length, weighing approximately 35 tons (70,000 lbs) and seven girders at 95 feet in length, weighing approximately 47 tons (94,000 lbs), were erected in three days, August 4th, 5th, and 6th of 2014.
During the second stage, the new south half of the bridge, Oldcastle Infrastructure will provide a total of eighteen wide fange girders, twelve girders at 71 feet in length and six girders at 95 feet in length. Since the second phase is not scheduled until late October 2014, Oldcastle Infrastructure girders at their facility.
When complete, Oldcastle Infrastructure – Perris will have supplied and erected a total of thirty nine wide fange girders. The girders have a form finish on the sides and soffit and the ends are square. The girders were manufactured per PCI Tolerance Manual MNL-116, Concrete fci: 4600 psi and fc: 6000 psi were factored in.
PROJECT COMPLETION
2015
PROJECT DETAILS
Total Project Cost: $9.5 million for Firestone Bridge Replacement
Funding: Federal Highway Bridge Program (HBP) and state Regional Surface Transportation Improvements funds
Oldcastle Infrastructure Product: Furnish PC/PS Concrete Girder (70 ft- 80 ft)
Stage 1: Qty 14 and Stage 2: Qty 12
Furnish PC/PS Concrete Girder (90 ft- 100 ft)
Stage 1: Qty 7 and Stage 2: Qty 6
Bearing pads: 2 EA per Girder
Erection: Erect 39 Precast Prestressed Girders
Special: “Buy America” Applies
Find out more about Oldcastle Infrastructure Bridge Components.
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Oldcastle Infrastructure has extensive experience in the design, fabrication, outfitting and erection of complete weather tight GIS buildings. The GIS building is composed of insulated – architectural – thin-brick design exterior walls (if specified) and interior load bearing precast concrete walls and any other interior walls required. Oldcastle Infrastructure offers turnkey project services with complete installation of all MEP.
These GIS projects have given us the opportunity to showcase our attention to detail and performance to successfully complete essential structures to exacting specifications within a critical, highly demanding schedule.
Our project experience provides us with intimate knowledge of all aspects of the design, submittal, production/ procurement, and installation phases for GIS buildings, along with sustaining positive working relationships with designers and management staff. Oldcastle is a proven resource when performance matters.
EXAMPLE OF SCOPE OF WORK
Generic Example – Precast Structure – design, off-site fabrication, delivery, erection and fit-out
of an 85’ x 47.5’ GIS Building
A. GENERAL CONSTRUCTION:
- Manage the design, costs, schedule, deliverables and quality of the project
- Manage GIS building field construction activities, coordination of trades/vendors, and quality assurance.
- Structural Engineering and piece detailing for structural precast concrete and steel construction of insulated precast wall panels cast with structural grey cement.
- Start-up testing of HVAC system installed by Oldcastle.
- Erection of precast and steel, including shims and grout.
- All panel connections to be exposed welded or bolted connections.
- Precaster reserves the right to adjust panel joints to maximize structural proper ties and manufacturing efficiencies.
- One (1) mobilization of erection crew, one (1) move on and one (1) move off the project site for building erection. 50’ Access around perimeter of building footprint to be provided by others for our exclusive use during erection and exterior work. Must be level, compact and free of impediments including any foundations or excavations.
B. PRECAST CONCRETE BUILDING ELEMENTS
- Precast Wall Panel -12” sandwich type precast concrete panels cast with 4” structural interior wythe, 4” rigid insulation, and 4” architectural exterior wythe.
- Structural Precast or CIP Floor System (2nd Floor)
- 12” Hollow core plank with 2” topping in field. Under side of hollow core cast with form finish.
- Topside of slabs cast with standard machine screed finish
- Erection of Hollow Core plank including bearing strips.
- Standard Grout for grouting of keyways after erection of hollow core plank.
- Inserts / embeds required for precast construction
- Any and all electrical conduit. (unable to cast into plank).
- Grout filling of butt ends and sides of slabs.
C. PRECAST STAIR TOWER
- Precast concrete stairs with landings.- Stair treads cast with steel form finish.
- Underside of stairs cast with standard foat finish.- Embeds cast into stairs for precast to precast connections.
D. STANDING SEAM METAL ROOF SYSTEM
Steel roof framing (bar joist & decking); Exterior cage ladders for roof access (1 Unit); “Griffolyn” type vapor barrier over roof deck; Polyisocyanurate insulation at GIS roof; 4.5” JCAS type acoustical roof decking over GIS building; White .060 reinforced fully adhered EPDM single ply roofing system; 050 metal coping ;Scupper and leaders.; 20 year Warranty on roof; Roof protective walkway mats at Oldcastle installed access ladder.
E. BRIDGE CRANE
Steel crane runway (prime painted) supported by precast columns integral to precast wall panels; bridge crane with catwalk and inverter controlled bridge and trolley travel motion with two speed low headroom CXT heavy duty wire hoist with upper/lower limit switches and bridge travel slow down limits;40# runway rail with hook bolt fasteners and bolted splice bar; (4) runs of runway conductor bar system complete with weld on brackets, snap hangers, power feeds and double sliding collectors for 208V 3 phase with dedicated ground;Hand held radio control with pendant control on quick plug
as back-up; Start-up and testing including performing load test using Crane factory personnel; Crane access platform with cage ladder.
F. FIRE DETECTION / ALARM SYSTEM
Smoke & Fire detection system at GIS AND Manual pull stations at exterior egress Interior and exterior horn / strobe lights per drawings AND HVAC shutdown system Main Distribution Panel (MDP). One unit total AND CO2 and dry type chemical fire extinguishers.
MECHANICAL CONSTRUCTION
Engineering for HVAC system; GIS room Exhaust fan with motorized dampers, storm louvers, bird screen, ductwork and fan rack; GIS room Intake Assembly with motorized dampers, storm louvers, bird screen, ductwork and filter rack; Equipment disconnect and/or motor starter for all Oldcastle supplied equipment Electric heater units w/ remote thermostats, GIS area.
ELECTRICAL CONSTRUCTION
Electrical design with drawings stamped in USA; Switchboard, panel boards, and transformers for items supplied by Oldcastle Infrastructure; all pack fixtures at each exterior door; GIS room lighting including 400w metal halide fixtures mounted above bridge crane switched at entrance doors; Exit signs with battery backup at each entrance; Receptacles surface mounted; Exterior GFI receptacles; Grounding of roof framing to Burndy lug cast into precast panels; Perimeter lightning protection system consisting of all copper cable adhered to roof; lightning arrestors adhered to roof Ground conductors and Power Wiring for Oldcastle supplied equipment; Supply and installation of branch circuits for lighting, receptacles, and mechanical equipment; Power and control wiring to overhead door; 208V 3-phase power connection to bridge crane; All conduit to be EMT; Grounding of door frames & caged ladders.
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Restoration Project
Cache County, Utah
DESIGN & CONSTRUCTION TEAM
General Contractor: Whitaker Construction Co.
Owner: Cache County, NRCS
Precaster: Oldcastle Infrastructure
Manufacturing Facility: Oldcastle Infrastructure, Ogden, UT
Special precast box culverts were used for one of the most significant segments of the $25.8 million emergency water restoration project, designated by the NRCS, known as the Cache Water Restoration Project (CWRP). The CWRP project involved the re-construction and improvement of approximately six miles of mostly open, unlined channels that make up the Logan and Northern, as well as the Hyde Park and Smithfield canals. The project incorporated new precast concrete pipe and box culverts, a section of pressurized pipe, metering systems, turn-outs, head gates, and improved maintenance access. The revamped Cache Valley canal system came in under budget and ahead of schedule.
CONSTRUCTION CHALLENGE
One of the key components of the project was designing the piping for the open channel section of Logan Canyon. There was uncertainty about fitting a precast, reinforced concrete box culvert into the existing canal section. This section of the canal, constructed over 100 years ago,
was basically carved into the cliffs along the canyon. At its widest, the open canal was approximately 14 feet wide with steep cliffs rising above the canal and sharp drop-offs to the state highway below. After considerable investigation, the project designers decided on concrete box culvert to solve part of the problem.
PRECAST SOLUTION
Oldcastle Infrastructure was contracted to supply approximately 10,000 linear feet of specially designed, precast concrete box culvert and precast pipe that was used in the upper portions of the canal project. Of this nearly 4,300 feet of precast box culvert was used (some 5’ x 5’ and some 6’ x 5’ to match the hydraulics of the canal) for the Logan Canyon section.
Designing a box culvert that would fit within the channel without impacting the steep slopes on either side was the challenge. To accomplish this, designers had to bevel the majority of the concrete box culvert segments so that the culvert could “snake” along the alignment, without elbows, transition vaults or closure pours.
SCOPE OF WORK
Precast Structure
- Structural Engineering
- Detailed Engineering drawings
- 5000 psi concrete
- Precast Concrete Box Culverts
Amount & Size: 4,300 feet – some 5’ x 5’ and some 6’ x 5’ to match the hydraulics of the canal
To manufacture bevels, Oldcastle Infrastructure designed and purchased new “headers” that could bevel (or angle one side of the box culvert so that a series of bevels would form a curve) up to an eight inch drop in length when measuring opposing sides of the box culvert. The joint at the end of each bevel was the same as straight box culvert sections, so that there were no extra requirements at the joints.
To fit the numerous curves in the canal alignment, beveled precast box culverts were designed in ½ inch increments with bevels ranging from ½ inch to 8 inches. The bevels had to be specifically designed as “curve to the left” or “curve to the right” and each piece of box culvert had to be numbered and installed in a series so that the box culvert did not deviate from the alignment. After emerging from Logan Canyon, the water is transferred from the box culvert to a 66 inch concrete pipeline that heads north.
Whitaker Construction installed each section so that the inner joint gap measured 1/2”. Once the alignment was established, the installation progressed rapidly with the contractor averaging over 15 sections per day. This was a record rate of installation when considering winter conditions and that only one access to the upper section of the project existed, so the box culvert and its bedding materials had to be transported 3,000 feet along the canal at the start of the section.
The box culvert was backfilled with 6 inches of road base to provide for a maintenance access road and a recreational trail. The top of the box culvert is now gated at both ends and can be used for maintenance as well as access by the U.S. Forest Service. “The canal operators used to have to drive a truck in the channel to do maintenance like removing rocks. The box culvert eliminates that problem. We’ve built an access road on top of the box culvert with openings for access,” said Zan Murray, from the Logan office of project manager J-U-B Engineering, in the June Issue article of Utah Construction & Design.
While the project requirements were difficult enough, the construction schedule started in October of 2012 with the irrigation facilities required to be operational by May of 2013. When operators opened the new facilities in 2013 they were amazed by how much water savings had been achieved with the addition of concrete box culvert and pipe. Early reports indicated that flow metering showed almost no water loss over two miles of concrete culvert and concrete pipe. While 2013 was a difficult water year, with many areas of Utah on water restriction, the Cache Valley irrigators were able to have water throughout the growing season
The revamped Cache Valley canal system came in under budget and ahead of schedule.
Find out more about Oldcastle Infrastructure Concrete Culvert Products.
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Communication Shelter Sites
Turnkey Communication Shelters located at Railroad Right-of-Ways. Site preparation; excavation and foundation construction; setting of a new precast modular building which includes interior and exterior finishes, mechanical units, electrical distribution and devices, lighting, controls and security systems, doors and hardware; electrical service entrance; site fencing; site utility connections; and other work as described in the Documents.
Each of the turnkey ROW projects consisted of the production and installation of a new RCS 1236, 12 foot by 36 foot, fully-outfitted Communication Shelter, added to a line of shelters.
Upgrades to the commercial power system, installation of a new generator, and reworking the fence.
- CL – Alexandria, VA
- CL – Baxter Springs, KS
- CL – Bentonville, AR
- CL – Corsicana, TX
- CL – Dayton, TX
- CL – Fontana, KS
- CL – Front Royal, VA
- CL – Ft. Worth, TX
- CL – Kosse, TX
- CL – Mocksville, NC
- CL – North Little Rock, AR
- CL – Savannah, GA
- CL – Sharpsburg, MD – Shelter Only
- CL – Shippensburg, PA – Shelter Only
- CL – Stroud, OK
- CL – West Memphis, AR
Owner
CenturyLink
CenturyLink is the third largest telecommunications company in the United States and is recognized as a leader in the network services market by technology industry analyst firms. The Company is a global leader in cloud infrastructure and hosted IT solutions for enterprise customers. CenturyLink provides data, voice and managed services in local, national and select international markets through its high-quality advanced fiber optic network and multiple data centers for businesses and consumers. CenturyLink is an S&P 500 company and is included among the Fortune 500 list of America’s largest corporations.
SCOPE OF WORK
Precast Structure
- Structural Engineering
- Detailed Engineering drawings
- 5000 psi concrete
- Precast Concrete Box Culverts
Amount & Size: 4,300 feet – some 5’ x 5’ and some 6’ x 5’ to match the hydraulics of the canal
OLDCASTLE INFRASTRUCTURE PRODUCTS USED
RCS 1236 and RCS 11836 Pre-engineered precast concrete building to shelter fiber optic communication equipment.
BUILDING SPECIFICATIONS
Oldcastle Model: RCS1236 or RCS 11836
Building Description: Concrete Precast Building
RCS1236 Dim (Exterior): 36’0” Long x 12’0” Wide x 12’6” High
RCS1236 Dim (Interior): 35’0” Long x 11’0” Wide x 11’2” High
RCS 11836 Dim (Exterior): 36’0” Long x 11’8” Wide x 10’2” High
RCS 11836 Dim (Interior): 35’0” Long x 10’6” Wide x 9’-0”High
Weight: 95,000-LBS Total
Floor Loading: 300-LBS./PSF/Battery area – 800 PSF
Roof Dead Load: 43.1 LBS / PSF
Roof Live Load: 60 LBS / PSF
Wind Speed: 110 MPH (When secured to proper foundation)
Floor Thickness: 6”
Roof Thickness: 5-6”
Wall Thickness: 4”
Concrete Specification: 5000 PSI Light Weight
Fire Rating: Two Hour Equivalent
Seismic Acceleration: Standard Design 50% g (IBC and ASCE7)
Bullet Resistance: UL752, Level 4 (.30-06 at 15 Ft.); Doors Level 3
Find out more about Oldcastle Infrastructure Precast Concrete Shelter Solutions.
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New Fiber Optic Building for New FTTH Network
Opelika, AL
The City of Opelika is developing a new fiber to the home (FTTH) network to provide both broadband services as well as the ability to monitor and manage their own energy consumption. The FTTH new fiber optic network and new smart grid technology for the network will give residents and businesses access to new high quality broadband voice, data and video services, including lightning-fast Internet access, IPTV and video-on-demand services. Opelika will be the first city in the State of Alabama to build an all fiber optic network and will leverage that infrastructure to enhance economic development and attract new businesses to the community.
CONSTRUCTION CHALLENGE
The $2.6 million project included the complete “Full Turn Key” construction of a 60 foot by 96 foot building that would house the new head-in building and data center building. The scope of work consisted of manufacturing, out-fitting and installation of the building, fencing, power service, dc installation, racking and generators.
PRECAST SOLUTION
The turnkey project involved the manufacturing and complete out-fitting of (2) two Oldcastle Infrastructure # 3096 Precast Concrete Maxi-Mod components to create the required 60 ft x 96 foot building with all specified equipment.
In addition, the fully out-fitted building modules were shipped, installed and made fully functional for the City of Opelika. The # 3096 Precast Concrete Maxi-Mod components were manufactured at our Newnan, GA facility and foundations were installed in the field by our Oldcastle Shelter Solutions Group.
CONSTRUCTION SCHEDULE
Start Date: May 2012
Completion Date: Scheduled for August 1, 2012
SCOPE OF WORK
Precast Structure
A. STRUCTURAL ENGINEERING
Engineering: Provided complete product engineering services.
Drawings: Provided detailed engineering drawings.
Supervision: Provided an onsite managing supervisor.
B. PRECAST CONCRETE SHELL
Size (2) Model 3096 maxi-mod concrete building.
Each outside dimension: ~ 97’-4” Long x 31’-4” Wide x 10’-1” High.
Each finished inside dimension: ~ 96’-0” Long x 30’-0” W x 10’-0” H.
Weight: Approximate weight: 59,000 pounds per
concrete section.
Specifications: Floor load: 150 PSF Roof load: 60 PSF.
Wind load: 130 MPH, Exp “C”.
Seismic Zone: Zone 4.
C. FINISHES
Exterior Finish: Smooth chamfered surface w/ textured finished.
Interior Finish: Interior walls & ceiling finished w/FRP laminated board.
Insulation: Outside walls & ceiling insulated.
Floor: VCT anti-static tile with rubber base molding.
Interior Walls: Steel Stud 2×4 framing, insulation, drywall,
and FRP (2hr rated);
(2) Video Head-End Offices-# 1 & #2;
(1) Set-Up Office/Lab;
(1) Electrical/Battery Room; (1) Storage/Receiving Area;
(1) Server Room.
Roofing: 60 mil Duro Last Roof with a 20 year warranty
D. DOORS AND OPENINGS
Doors: (3) 4’-0” x 7’-0” heavy duty steel doors and frames.
Doors: (9) 6’-0” x 7’-0” heavy duty steel doors and frames.
Locks: (12) Locksets w/ changeable core; (6) Mortise; (5)
Passage; (4) Panic Bars Doors; frames have
electric strike & card reader
Door Hardware: NRP Stainless steel hinges, door closer, door pick
plate, door holder, weather strip, aluminum threshold,
2.5”drip cap.
E. POWER
Power Service: 1200A, 3Ø, 480V
Disconnect Switch: (1) 2000A @ 480VAC 3 PHASE main switch gear.
Surge Suppression: (2) 100K Peak Amp Surge Suppressor.
Generator: Included in section 11.
ATS -A: ASCO 7000 series service entrance rated with isolation
1200A/4P ATS – NEMA1.
ATS -B: ASCO 7000 series with isolation bypass switch –
1200A/4P ATS – NEMA1.
Main Distribution Panel: (1) 1200A (DSSB) support phase one loads.
HVAC Panel: (1) 600A HVAC (HM) Panel.
DC/UPS Panel: (1) 800A (HC) Panel.
LA Panel: (1) 225A (LA) Housekeeping Panel.
HA Panel: (1) 100A Lighting Panel.
Transformer: (1) 75kVa 480VAC to120VAC step transformer
for non-critical housekeeping loads.
Convenience Outlets: (61) 20A, 120V Duplex outlets
(as needed throughout bldg.).
Exterior GFI Outlets: (11) 20A, 120V outlets.
Power Conditioning: (2) APC Symmetra PX 100 kW UPS with 50 kVA
modules, PDU & cables with connectors to the “A”
power strips in Rows 1 & 2 (3) APC Symmetra
PX 40 kW UPS with 10 kVA modules, including
batteries, PDU & cables with connectors to the
“A” power strips in Rows 1 & 2 complete.
DC Plant/Batteries: Lineage DC Plant and Batteries.
F. ENVIRONMENTAL SYSTEM
HVAC: (2) Bard W60A1C06MP 2. 5 Ton 3Ø HVAC Units
with dehumidification, 9kw heat, “E” controls
(low ambient control).
(17) Bard W60A1D06MP 5 Ton 3Ø HVAC Units
with dehumidification, 9kw heat, “E” controls
(low ambient control).
Controls: (10) Bard MC4000B Lead Lag Controller with
enhanced alarm board.
HFans: (5) Broan 331H wall exhaust fans.
Grills: Return air, and exhaust grills.
G. ALARMS
Security Management: Security Management System per E2.06 and the
Security Management System specification.
H. LIGHTING
Interior (Mod A): (96) 4’ fluorescent light fixtures with 20% up light.
Interior (Mod B): (20) 4’ fluorescent light fixtures with wire guards.
Exterior: (13) 100 HPS Exterior fixtures with photo cell.
Emergency: (11) Emergency fixture with exit sign and dual flood lights.
Exit: (8) Exit sign/lights.
Switches: (12) 20 amp light switches.
I. CABLE LADDER:
Cable Ladder: (750) LF of 12” gray cable ladder mounted above rack
spaces: Ladder mounting hardware, Two layers of
cable ladder mounted above DC rows, One lay of cable
ladder mounted above AC rows.
Fiber tray: (321) LF of fiber tray as shown on drawing T2.01.
J. GROUNDING WILL MEET REQUIREMENTS ON T2.03 & T2.04.
Halo: No.2 AWG Bare, Stranded copper wire around inside
perimeter of building.
Bonding: No. 6 insulated copper wire from metallic items such
as conduit, electrical boxes and equipment to perimeter ground bus. #2 stranded green jacketed
communication equipment ground bus secured to
Newton #2106C brackets mounted to the cable ladder.
Ground Bar: (2) 24” x 4” x ¼” Cooper ground bars, insulators,
connecting rods & exterior; Copper straps (4”)
to earth ring; One bar interior, one exterior.
K. ON-SITE MECHANICAL AND ELECTRICAL
Electrical (exterior):
Exterior ground halo : Perimeter loop with copper cable, 10’ copper cladded
rods, inspections ports,conduit entry into building with
all connections cadwelded.
Lightning protection: Lightning protection system adhered to roof; lightning
arrestors adhered to roof with each down leg cadweld
to 10’ copper cladded rod connected to the main
ground loop.
Generator work: Included as part of Section 11.
Power Conditioning: Included as part of Section 7.
Electrical (interior): Included as part of section seven.
Plumbing: Water lines and condensate lines. Lines outside 5 feet
from the building are excluded.
Fire Protection: System engineering per NFPA protocol; tanks, piping
and FE-25 agent to 9% concentration; smoke detectors
and relays; abort buttons, pull stations and strobes;
required testing, start-up and instructions.
HVAC: Included as part of section seven.
Controls and automation: Included as part of section seven.
L. EQUIPMENT
Generator: CAT Model C27 – 750 KW (480V) diesel generator with
standard weather enclosure with critical grade
silencer; main line circuit breaker; 24 hour belly fuel tank
(1,600 gallon); analog / digital control panel;
start-up and training.
Generator work: Receive, set and anchor; up to 20 lf of conduits (line
voltage, blocker heater and controls) and matching
number of conductors for 750KW generator.
UG conduits to be encased in concrete.
Load Bank Test: Complete a 4 hour load bank test of the generator per
specifications and plans.
ATS -A: Included as a part of Section 7.
ATS -B: Included as a part of Section 7.
Power Conditioning: Included as a part of Section 7.
M. ELECTRONIC EQUIPMENT INTEGRATION
Cable ladder: Included in section seven.
Find out more about Oldcastle Infrastructure Precast Concrete Maxi Mod Building Components.
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Northern California
DESIGN & CONSTRUCTION TEAM
General Contractor: Weckworth Electrical
Challenge: Tight schedule installation of light pole bases
Solution: 15-Omni Pole Bases-In Stock, Installed in 1-Day
Oldcastle Infrastructure Product(s): Precast Concrete OMNI Foundations 15 Light Pole Foundations
Weckworth Electric approached Oldcastle Infrastructure, Pleasanton in need of pole bases for a time sensitive project in which fifteen pole bases were required to complete site lighting in a new vineyard at a winery in Northern California. Following the 2016 wine crush, Weckworth Electric was given a tight schedule to order and complete the installation of the lighting for the new vineyard. Omni Pole Base foundations were chosen as the ideal solution to expedite construction. Oldcastle Infrastructure delivered and set all fifteen pole bases in one day, meeting the construction schedule.
THE DESIGN
Omni Pole Bases feature a unique design in which the bolts can be adjusted within a plate to fit a variety of pole base sizes. Omni is stocked in inventory in a variety of Oldcastle Infrastructure plants throughout the country meaning we have a ready-to-go solution for your last-minute pole base job.
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Pittsburgh Zoo
Pittsburgh, PA.
DESIGN & CONSTRUCTION TEAM
Owner: AT&T
Construction Manager: Black and Veatch
Design Engineer: Mountain State, Community Wireless
Oldcastle Infrastructure – Precast Manufacturer: Telford, PA
Oldcastle Infrastructure Product(s): Precast Concrete CELL BLOCKS® Foundation (5 CELL BLOCKS foundation)
The Pittsburgh Zoo had an existing wooden pole supporting AT&T’s antennas for cellular service to the visitors and employees of the Pittsburgh Zoo located in Pittsburgh, PA. The existing service was located behind the education building opposite the parking lot. At the back of the education building, the ground sloped up a hill. Access to build a traditional foundation for a new steel monopole was formidable. Working with Black and Veatch, various options using the CELL BLOCKS precast foundation system were reviewed. An additional challenge was keeping the existing antennas on the wood pole until the new mono-pole was in place.
THE DESIGN
The plan view layout (shown on page 2) placed the CELL BLOCKS foundation in front of the existing wood pole. Using the design reactions of the proposed monopole and antenna loading, the precast foundation was indicated on the zoning drawings as 7-foot x 14-foot in plan view consisting of five blocks.
THE SOLUTION
Due to limited access with lifting equipment, the CELL BLOCKS system was modified to make the blocks one third the size of the typical 7’ x 7’ block. The blocks were cast as 2’-4” wide by 7’ long, therefore reducing the weight from 15,000 pounds to 5,000 pounds. The weight was similar to the handling weight of the new monopole.
The contractor installed the grounding system and prepared the level granular base foundation. In the afternoon prior to setting the foundation blocks, the crane set up in the parking lot and unloaded the pole and the blocks from the delivery truck.
Since the parking lot had to be vacated by 9 AM, the setting of the blocks commenced at 5 AM and were placed and post tensioned in less than 90 minutes.
Taking into account the completed foundations are immediately full strength, the poles and cabinets were set immediately after the foundations were installed. Using patented post tensioned precast concrete CELL BLOCKS for the Pittsburgh Zoo foundation made the installation extremely fast and it fit perfectly into the limited space available.
The steel monopole, antennas and other heavy lifting was complete by 8 AM and the crane was removed from the parking lot at 9 AM.
Using CELL BLOCKS provided for minor disturbance of the existing ground conditions, minimized the safety concerns about unknown underground hazards and was predictable. As an added bonus, the business interruption was minimal and improved connectivity for the visitors at the Pittsburgh Zoo is assured.
Find out more about Oldcastle Infrastructure Precast Concrete CELL BLOCKS.
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Riverside County, California
DESIGN & CONSTRUCTION TEAM
Owner: California Dept. of Transportation
General Contractor: Granite Construction Company, Indio, CA
Design Engineer: CALTRANS, Diamond Bar, CA.
Oldcastle Infrastructure Product(s): Precast Concrete Bridge Components; (2) Precast Abutments, (4) Wing Walls, (10) Prestressed Box Girders
Precaster: Oldcastle Infrastructure – Perris, CA.
On July 19, 2015, the Tex Wash Bridge on Interstate 10 (I10) in Riverside County, CA, collapsed during an intense rainstorm event, causing havoc on a crucial link between California and Arizona. But thanks to precast concrete and an accelerated bridge construction (ABC) strategy, engineers were able to replace the bridge and get it fully operational in just a matter of weeks.
Following the collapse, the California Department of Transportation (Caltrans) quickly agreed that an ABC design was the best way to replace the collapsed bridge with a 105-ft, single-spand structure as quickly as possible. The new bridge accommodates two lanes of traffic with an additional 5ft-wide shoulder and standard barrier rails.
The $5 million, Interstate 10 Emergency Bridge Replacement-Tex Wash Bridge project required the complete demolition of the existing eastbound bridge, replacement of rock slope protection in the channel below, and rebuilding the bridge in an accelerated fashion.
“They’ve worked at lightning speed out there because they wanted it open as soon as possible,” said Tyeisha Prunty, public information officer for Caltrans District 8 in San Bernardino. “We’re very proud of the work, which was done to specification.”
THE DESIGN
Caltrans designed the bridge superstructure as a modular precast concrete system using precast concrete bridge superstructure elements, making it possible to install the prefabricated bridge units over two weekends.
For the bridge replacement, Granite Construction contracted Oldcastle Infrastructure to manufacture two precast concrete bridge abutments, cast in four segments, measuring 6-foot by 6-foot by 20-foot long, four precast concrete wing walls measuring 18.5-foot by 1-foot by 9-foot tall and ten prestressed box girders measuring 4-foot by 3.5-foot by 105-foot long at the precast firm’s Perris, Calif. plant. As a team, Caltrans, Granite Construction, and Oldcastle Infrastructure worked around the clock to ensure the emergency bridge replacement stayed on schedule. The result, Caltrans rebuilt the bridge under budget and earlier than their required deadline. The rebuilt eastbound Tex Wash Bridge on Interstate 10 fully reopened to traffic just over two months after beginning construction.
PRECAST SOLUTION
Speed was of the essence for this emergency project, and designers took advantage of the many benefits of precast concrete to meet the rapid delivery goals. Using precast concrete girders eliminated the need for temporary false-work, which accelerated girder placement and limited the environmental impact on the channel area. Precast concrete segmental abutment and wingwall elements were used to accommodate a staggered construction schedule. In addition, an adjacent precast concrete girder arrangement meant the project did not require deck forms, which further shortened the timeline.
During construction, precast concrete girder, abutment, and wingwall elements were fabricated concurrently in a precast plant while cast in piles were placed at the bridge site. After the site was prepared, precast concrete elements were transported to the site from the plant 130 miles away.
The close collaborative working environment on the project, and relentless focus on accelerated delivery, enabled the team to reopen the bridge for traffic just 67 days after the original bridge collapsed.
Find out more about Oldcastle Infrastructure Precast Concrete Bridge Products.
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Used For Major Telecommunications Carrier at Rural Ridge Top
Idaho
DESIGN & CONSTRUCTION TEAM
Owner: Major Telecommunications Carrier
General Contractor: Strata, Inc.
Oldcastle Infrastructure Product(s): Precast Concrete CELL BLOCKS® Foundation (9 PRECAST CELL BLOCKS )
The precast concrete post tensioned foundation satisfied the design criteria and was installed in one day. As a result of a lease not being renewed on an existing tower, a major telecommunications carrier needed a temporary solution to continue to provide cell services in a rural area of Idaho. The carrier desired a definitive solution, a small footprint, no digging and an easy removal solution. The site was also identified as having Indian artifacts. Furthermore, the site was on top of a ridge reachable only by a dirt lane. Cell Blocks® provided a foundation that minimized disruption to the existing ground and allowed for future site removal with very little impact on the land.
THE DESIGN
Structural drawings and calculations were provided to the carrier and the on-site contractor Strata, Inc.
The blocks were prefabricated at a precast manufacturing facility near Reno, NV. Anchor bolts and templates were provided to the precast facility by the monopole supplier and cast in. The post tension GR 150 galvanized steel bars, hex nuts and plates were ordered from DSI America, Inc.
THE SOLUTION
After the (9) Cell Blocks were prefabricated they were transferred up the mountain by a straight bed truck carrying two blocks each trip.
The Strata Inc. work crew transferred and placed the nine Cell Blocks in one day atop the pre-prepared granular base material. The minimum allowable soil bearing requirement was 1500 psf.
The post tension bars, hex nuts and plates were immediately inserted to begin the hydraulic post tensioning process. The post tensioning sequence was completed the next morning. Cell Blocks provided a certified hydraulic pump and 100 ton jack to post tension the steel bars to the specified tension force of over 132,000 pounds each.
After the Cell Blocks foundation is post tensioned it is immediately at full load strength and ready for installation of the monopole. The tower was set immediately after the blocks were post tensioned using the same crane that set the blocks.
The structural advantage of the Cell Block foundation was that, once post tensioned, the foundation was instantly full strength. Cell Blocks Inc. provided an experienced representative, on-site, for the duration of the block installation and post tensioning process. The representative was able to ensure proper construction and assure the quality of the completed foundation.
Using post tensioned precast concrete CELL BLOCKS for this wireless facility facilitated the installation to be extremely dependable, preserved the safety of the Indian artifacts, and is removable in the future.
No cast in place concrete was needed for this cell tower installation. We are looking forward to a bright future with this product line and design in the United States.
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