Shines Thanks to StormCapture® Rainwater Detention System

Charlotte, North Carolina

DESIGN & CONSTRUCTION TEAM

General Contractor: Heard Ratzlaff Construction, Charlotte, North Carolina
Contractor: Siteworks LLC, Charlotte, North Carolina
Engineer: OEG
Developer: Wendy Field & T.H. Dorsett, Inc.
Site Designer: Osborn Engineering Group, Charlotte, North Carolina
Precastor: Oldcastle Infrastructure

The Cottages at Providence is a new luxury townhome development by Wendy Field Consulting. The site designer Orsborn Engineering Group of Charlotte, North Carolina, needed a combination stormwater detention and sand filter system to control and remove pollutants from post-construction runoff for this very dense urban development.

In order to accomplish this, the site required a 17,000 cubic foot stormwater detention and sand filter system.

PRECAST SOLUTION

Oldcastle Infrastructure supplied the stormwater detention and sand filter system at the new development by incorporating a StormCapture® modular precast concrete vault system.

Osborn incorporated the sand filter and detention chamber into a single stormwater management system using 27 StormCapture modules. The system, installed under the driveway between two rows of townhomes, includes 19 retention modules, six sand filter chambers and two pre-treatment sedimentation modules.

The pre-treatment chambers trap sediment and floatables, while the sand filter uses sand media to filter smaller particles and other pollutants. The detention chamber stores runoff while allowing sufficient time for treatment through the sand filter. Discharge from the system is controlled by an orifice plate at the outlet pipe. The system is designed to meet AASHTO HS-20-44 for traffic loads and has multiple manholes for future maintenance access.

The stormwater management system receives water from onsite storm drains and downspout collection pipes, as well as from a grate directly over the top of one of the pre-treatment modules. Runoff then passes through the StormCapture system and then out to the storm drains.

“The success of this job was due to the pre-construction meetings held by Scott Bovit (Owner) of Siteworks and his team. The owner and engineer were delighted to see the ease of the install and praised the quality of the material supplied”. Scott Polk, Oldcastle Infrastructure

PROJECT DETAILS

Infrastructure Detention and Sand Filter Infrastructure Management System

Oldcastle Infrastructure Product:

• 19 – 5’ tall StormCapture retention modules
• 6 – 9’ tall StormCapture sand filter chambers
• 2 – 9’ tall StormCapture sedimentation modules

DAY 1
The base sections of the sand filter, detention and pre-treatment modules were installed.
DAY 2
The modular nature of the StormCapture system provided the contractor with an opportunity to install all of the internal sand filter components (under drain piping, stone and sand media) very easily while the system was still open.
DAY 3
The tops of the modules were installed and backfilling operations were completed.

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on Benefits of Infrastructure Management

Redmond, WA

DESIGN & CONSTRUCTION TEAM

Architect: BLRB Architects, Tacoma, WA
Contractor: BNBuilders Construction, Seattle, WA
Precaster: Oldcastle Infrastructure, Auburn, WA
Engineer: AHBL Engineering, Seattle, WA

Protecting nature within our urban environment requires the proper movement and management of stormwater runoff. To do so, communities have a maze of drainage networks, and precast concrete often plays a critical role.

In Redmond, Washington, the Lake Washington School District is utilizing precast concrete panel components to construct two extra-large underground StormCapture PV detention vaults as part of the stormwater conveyance system at the new Redmond Elementary School. Working together, general contractor BNBuilders Construction, BLRB Architects and AHBL Engineering designed the massive underground stormwater vaults while also meeting the regulatory requirements of the Washington State Department of Ecology (WADOE). After review, they concluded that a precast concrete panel vault system would save approximately two-and-a-half months of installation time over a cast-in-place system. The precast solution would also detain stormwater to allow sediment to filter out in accordance with WADOE guidelines.

WADOE issues requirements for how stormwater runoff is treated before being discharged off jobsites. As a developed site with impervious surfaces, the school ensured its stormwater runoff would be as clean as from an undeveloped site. “The measures incorporated – to hold, filter, clean and discharge clean stormwater – were accomplished naturally by way of onsite biofiltration swales that allow the water to be channeled, filtering it naturally,” said the Lake Washington School District Support Services Team.

“Also, the system uses cartridges and mechanically filters the water. The engineering behind the stormwater system is pretty amazing in terms of the invert elevations and how the water level is going to build-up and be metered, then discharged from the site.”

Selected by BNBuilders Construction, Oldcastle Infrastructure of Auburn, Washington designed, engineered, manufactured and then delivered the precast concrete components of the underground detention vaults. Oldcastle Infrastructure Auburn Project Manager Rick Roof remarked, “Using precast provided a variety of benefits including strength, durability, flexibility of design, and it vastly improved the construction schedule, operational efficiencies and overall quality of the detention structures for this project.”

PRECAST SOLUTION

In total, the Auburn plant supplied 44 flat-base slabs, 54 wall panels, 44 top slabs as well as ladders, cast-iron covers and risers for the 44 foot-wide by 178-foot-long North detention vault. The South vault, scheduled to be installed in November, will require 48 flat-base slabs, 40 wall panels, 48 top slabs, plus ladders, cast-iron covers, and two H-20 rated five-foot by 10-foot grates and risers for the 44-foot-wide by 220-foot long vault. The segmented precast stormwater vaults hold approximately 900,000 gallons of rainwater while allowing sediment to settle before being discharged into the storm drain system. Each precast panel was sealed using hydrophobic sealer. As soon as water touches the sealer, it triggers the sealer to spread, harden and cure between the panels so there is no seepage. The construction of the North precast concrete panel vault took six days.

A paved parking lot will eventually cover the detention vaults, so stormwater will be piped into the underground structures. Oldcastle Infrastructure Area Technical Manager Deon Lourens remarked, “These are complicated systems, and it’s great to see what our capabilities are as a company. The benefits of precast include speed, quality and versatility, which saves time and money for onsite contractors.”

“The Oldcastle Infrastructure Auburn plant did an excellent job to make this happen. It is a great looking job! We have completed the North stormwater detention vault, and the South stormwater detention vault will be installed in November 2017,” he added.

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The city of Redmond, Washington needed a regional stormwater treatment facility capable of handling up to 20 CFS (cubic feet per second) or 9,000 gpm (gallons per minute). After contracting with IMCO Construction in Bellingham, Washington and Leidos Engineering in Auburn, Washington, the city settled on the revolutionary PerkFilter® media filtration system from Oldcastle® Infrastructure.

Media filtration products provide stormwater filtration to reduce pollutant loading in runoff from urban developments. Impervious surfaces and other urban and suburban landscapes generate a variety of contaminants that can enter stormwater, polluting downstream receiving waters. PerkFilter media filtration systems feature pre-treatment chambers and replaceable filter cartridges to capture and retain sediment, petroleum hydrocarbons, phosphorus, metals and other target constituents close to the source to reduce the total downstream discharge load.

DESIGN FLEXIBILITY

PerkFilter media filtration solutions are available in multiple configurations, including catch basins, vaults and manholes, allowing the engineer maximum design flexibility. The city of Redmond selected a continuous precast vault design, measuring 16’ high by 214’ long, and including 547 sets of stacked 12” and 18” replaceable PerkFilter cartridges.

Production of the precast concrete vault started in mid-October, 2014 at the Oldcastle plant in nearby Auburn, Washington. Both sizes of stackable PerkFilter cartridges were produced at the Oldcastle facility in Santa Rosa, California, then shipped north to Washington. Onsite assembly in Redmond quickly followed on December 8th and final installation was completed just three short days later on December 11th with the use of a crane to help expedite installation time.

Deon Lourens, Area Technical Manager with Oldcastle Infrastructure, explained that there are several advantages to the PerkFilter system. “Its cartridges have no moving parts and no cartridge hood, allowing for easier maintenance observation. In addition, its design allows for fewer cartridges than alternative models, and the bypass flow underneath the cartridge bay limits reentrainment of pollutants.”

He noted that cartridge lifecycle can range up to three years, depending on the pollutant load. “The cleaner the influent,” he said, “the longer the duration between maintenance cycles.”

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Redmond, Washington

DESIGN & CONSTRUCTION TEAM

Owner: Sound Transit
General Contractor: Kiewitt Hoffman East Link Constructors, Marshbank Construction, Inc.
Engineer: McMillen Jacobs Associates
Manufacturing Plant: Oldcastle Infrastructure, Auburn, WA

Protecting nature within our urban environment requires the proper management and treatment of stormwater runoff. To do so, most communities have a maze of drainage networks, and precast concrete typically plays a vital role.

In Redmond, the new Overlake Village park-and-ride is getting a 10’ wide by 36’ long by 18’ deep PerkFilter® stormwater treatment system with 65 30” tall cartridges with space for up to 84 additional cartridges.

The system also includes a 12’ diameter Downstream Defender® for trash and debris capture. As designed, the PerkFilter system has a design fl ow rate of 1,428 gpm (3.2 cfs), while the Downstream Defender has a treatment flow rate of 18 cfs.

Located adjacent to the Overlake Village park-and-ride on 152nd Avenue NE will be a new light rail station, with a targeted open date of 2023. The station’s entrance will be along 152nd Avenue NE, just south of SR520. Once completed, the new light rail line will link Overlake Village to Pioneer Square, with the ride taking about 30 minutes. Contemporary in design, the station was devised in accordance with the City of Redmond’s 152nd Avenue
Corridor Study and Overlake Village Neighborhood Plan.

PRECAST SOLUTION

Working together, general contractors Kiewit Hoffman and Marshbank Construction along with McMillen Jacobs Associates designed the deep underground PerkFilter vault while also meeting the regulatory requirements of the Washington State Department of Ecology (WADOE). After review, they concluded that a segmented precast concrete panel vault system would be easier to install with its reduced overall pick weight while also saving installation time over a cast- in-place system. The precast solution with the PerkFilter cartridges would also allow sediment and other pollutants to be removed in accordance with WADOE requirements.

WADOE issues guidelines for how stormwater runoff is treated before being discharged off jobsites. As a developed site with impervious surfaces, the park-and-ride facility ensured its stormwater runoff would be as clean as from an undeveloped site with its new stormwater treatment system.

Oldcastle Infrastructure of Auburn, Washington designed, engineered, manufactured and delivered the precast concrete components of the underground PerkFilter system. Oldcastle Infrastructure Auburn Project Manager Rick Roof remarked that “using precast provided a variety of benefits including strength, durability, flexibility of design, and it vastly improved the construction schedule, operational efficiencies and overall quality of the detention structures for this project.”

In total, Oldcastle Infrastructure supplied the flat-base slabs, wall panels, top slabs, ladders, cast-iron covers and risers for the underground stormwater treatment vault as well as the PerkFilter cartridges and associated installation hardware.

Once operational, the precast concrete PerkFilter vault can treat 1,428 gpm of rainwater before slowly releasing it into the downstream detention system. Each precast panel was sealed using hydrophobic sealer. As soon as water touches the sealer, it triggers the sealer to spread, harden and cure between the panels so there is no seepage.

A parking lot and pedestrian walkway will eventually cover the PerkFilter vault, so stormwater will be piped into the underground structure. According to Oldcastle Infrastructure Area Technical Manager Deon Lourens, “these are complicated systems, and it’s great to see what our capabilities are as a company. The benefits of precast include speed, quality and versatility, which saves time and money for onsite contractors.”

“The Oldcastle Infrastructure Auburn plant did an excellent job to make this project happen,” he added.

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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:

1. Remove rainwater from the hardscape and other impervious surfaces
2. Channel runoff so it does not erode the surrounding landscape
3. 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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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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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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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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