NEW ESTHER SIMPLOT WATER PARK

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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AMERICAN TOWER CORP.

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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SEMINOLE ELECTRIC COOPERATIVE

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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SUNY ADIRONDACK STUDENT HOUSING

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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TWIN CITIES METRO TRANSIT

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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FIRESTONE BOULEVARD BRIDGE

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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GAS INSULATED SWITCH STATION (GIS) AND CONTROL BUILDING PROJECTS

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.

Find out more about Oldcastle Infrastructure Gas  Insulated Switch Stations.

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CACHE WATER

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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RIGHT-OF-WAY (ROW)

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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October 4, 2018

OMNI POLE FOUNDATIONS FOR SITE LIGHTING IN A NEW VINEYARD

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.

Find out more about Oldcastle Infrastructure Omni Pole Base Products. 

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AT&T ANTENNAS FOUNDATION

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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I-10 TEX WASH BRIDGE EMERGENCY REPLACEMENT PROJECT

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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October 3, 2018

CELL BLOCKS®

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.

Find out more about Oldcastle Precast Concrete CELL BLOCKS. 

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AT&T CELL BLOCKS® MONOPOLE CELL TOWER FOUNDATION

Near I-9 and Pulaski Skyway Corridor

Kearny, NJ

DESIGN & CONSTRUCTION TEAM

Owner: AT&T Telecommunications
General Contractor: Multi Tech Electric Corp.
Design Engineer: Maser Consulting
Oldcastle Infrastructure Product(s): Precast Concrete CELL BLOCKS®
Foundation (25 CELL BLOCKS foundation)
Precast Concrete Manufacturer: Easton, Pennsylvania

The precast concrete post tensioned foundation satisfied the design criteria and was installed in one day. In 2015, AT&T required a 150-foot cell tower and a 28-foot-long shelter close to the Pulaski Skyway corridor (also known as US Rt. 1/9), near the NJ Turnpike connector. It was essential for the height of the antenna, at 150-feet, to be above the bridge. Oldcastle Infrastructure, engineering firm Maser Consulting and general contractor Multi Tech Electric Corp. partnered to complete the AT&T Communications cell tower project.

The purpose of using a CELL BLOCKS foundation was to prevent any ground disturbance and to complete the project as quickly as possible. The monopole accommodates services for the lead carrier AT&T and for a future carriers.

THE DESIGN

Designed by engineering firm Maser Consulting, using Oldcastle Infrastructure CELL BLOCKS, the foundation was designed to extend above the 100 Year FEMA flood elevation.

To achieve the necessary elevation for the top of the precast foundation, a structural wood retaining wall surrounds a compacted granular material to a depth of approximately one foot. The wall also protects the long term integrity of the compacted material supporting the CELL BLOCKS foundation.

Once the compacted material was precisely leveled and the alignment strings were set, the setting of the precast 15,000 pound precast concrete blocks proceeded. The pole block containing the anchor rods is located at the center of the 25 block layout. The anchor rods, hex nuts and templates were provided by Sabre Towers and Poles Inc. to the precast concrete manufacturing facility in Easton, Pennsylvania. Using 6000 psi concrete, the anchor rods were cast into the pole block with special steel rebar details and independently inspected. Post tension Grade 150 galvanized steel bars were inserted. Heavy steel plates and hex nuts were mounted on each end of the steel rods and hydraulic tensioning of the rods proceeded.

INNOVATION

Using post tensioned precast concrete CELL BLOCKS for this wireless facility demonstrated that the use of a precast concrete block foundation was extremely dependable, provided minimal interruption to the nearby business, provided no disturbance to existing ground 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.

Find out more about Oldcastle Infrastructure Precast Concrete CELL BLOCKS.

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ONELIFT RC509 PUMP STATION

Used to Maximize Holding Capacity at University of Arizona $100M Cancer Center

Phoenix, AZ

DESIGN & CONSTRUCTION TEAM

Owner: University of Arizona
Distributor: James Cook & Hobson (JCH), Phoenix, AZ
Design Engineer: Dibble Engineering, Phoenix, Ariz.

University of Arizona $100 million Cancer Center at Dignity Health St. Joseph’s Hospital and Medical Center clinic. As a National Cancer Institute – designated comprehensive cancer center, the six-story, 230,000 sf building provides chemotherapy, infusion, radiation oncology, and diagnostic imaging. St. Joseph’s Hospital and Dignity Health will operate the facility as well as leasing space in it.

THE CHALLENGE

Late placement of electrical utilities prevented the building from using a gravity drain. The shape of the basin was of particular interest because of the extra per foot storage volume. Also, there was very little room to fit the station.

The OneLift pump station was the contractor’s product of choice due to the speed in product delivery and installation, plus it was specified in the bid.

Oldcastle Infrastructure’s OneLift pump station is installed between the building and sidewalk on a very busy street in downtown Phoenix.

The OneLift submersible pump station with integral valve vault was pre-assembled as a complete package, prior to delivery, to ensure the proper fit for concrete and all components. Oldcastle Infrastructure incorporated and pre-installed all equipment in their factory, minimizing re-assembly time and potential problems in the field.

The installation took about 2-1/2 hours and every one was very pleased with the results of this new system. The contractor also mentioned that they saved time and money with the OneLift in lieu of building from scratch.

PRECAST STRUCTURE

OneLift Model RC509x1410-0-H20-4P1-0B pump station package with Integral valve vault, interior fillet and exterior anti-floatation collar: Overall exterior height: 15’-6”

OLDCASTLE INFRASTRUCTURE PRODUCTS USED

OneLift Model RC509x1410-0-H20-4P1-0B pump station package. Integral valve vault, interior fillet and exterior anti-floatation collar: Overall exterior height: 15’-6”. Cored opening and MH boot for 4” incoming air vent/emergency overflow. Oldcastle Infrastructure’s OneLift continues to provide customers with beneficial solutions, high quality construction, and rapid supply at an overall cost savings.

STANDARD EQUIPMENT INCLUDED

• Installation of (2) submersible sewage pump base elbows
• 4” Interior SCH80 PVC discharge piping, fittings and SS hardware for flange packs as required to common pump station discharge (ending plain-end approx. 12” outside of station).
• (2) Flanged check valves (L&W), epoxy coated
• (2) Flanged plug valves w/lever operator, epoxy coated
• (2) Galvanized foor pipe stands in valve vault
• (1) Valve vault drain w/trap & back water valves to pump station
• (1) Wall-mounted aluminum ladder in valve vault
• (1) Manhole boots as required for discharge piping Manhole boot(s) as required for inlet(s)
• (1) 30” x 36” aluminum valve vault access hatch
• (1) 1 ½” SCH 40 PVC hatch drain from valve vault hatch to pump station
• (1) 30” x 48” aluminum pump access hatch with safety grating,
• (2) Sets 304 Stainless steel pump removal guide rails, SCH40 (upper/intermediate guide brackets supplied with base elbows)
• 4-Gang electrical coupling access for incoming conduit from control panel
• (1) 4” glue-fitting access for PVC passive vent intake piping run underground to intake area. UG vent-run

INNOVATION

Single Structure design
The factory built OneLift pump station offers a monolithically cast valve vault, in what is typically an unused portion of the pump station. This results in a significantly smaller footprint – up to 50% smaller than conventional 2 structure pump stations – allowing it to fit tight sites. The innovative shape and structural design provides ample space for the interior valve vault, while increasing workable system volumes and decreasing the depth of the excavation. The single structure of the OneLift pump station eliminates any potential differential settlement issues, allows for a quick and easy installation by eliminating the typical two-tier excavation of conventional stations, and is proven to be a cost effective method of providing a high quality pump station solution with rapid and reliable delivery. With the OneLift pump station you get fast turnaround time on submittals; which include standard structural and mechanical components.

Find out more about the Oldcastle Infrastructure OneLift Pump Station. 

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SEATTLE’S NEW ELLIOTT BAY SEAWALL

Precast Concrete “Z” Superstructures and Wall Panels Used to Construct

Seattle Washington Waterfront, Seattle, WA

DESIGN & CONSTRUCTION TEAM

General Contractor: J E Dunn Construction
Project Manager: Kyle Quigley
Owner: City of Seattle, Wash.
General Contractor: Joint Venture team of Mortenson-Manson, general contractor/construction manager (GC/CM).

The Elliott Bay Seawall project, part of Seattle’s Water-front Program, is a joint effort between the City of Seattle Department of Transportation {SDOT), and the U.S. Army Corps of Engineers {USACE) to replace the 100 year old seawall. Built between 1916 and 1936, the failing wall has suffered significant timber decay and deterioration of the structure from continued exposure to storm waves and tides, including damage from the magnitude 6.8 Nisqually Earthquake. Oldcastle Infrastructure, Auburn, WA was selected by the Joint Venture team of Mortenson-Manson, general contractor/ construction manager {GC/CM), to supply precast concrete Z-shaped superstructure segments and 20-foot tall seawall face panels for the reconstruction of the new $330 million Elliott Bay Seawall at the waterfront in downtown Seattle, Wash.

THE CHALLENGE

Acting as a barrier between Elliott Bay and the waterfront, the new seawall structure consists of a cast-in-place support slab with custom precast concrete face panels, precast concrete zee shaped superstructure segments, and precast sidewalk panels. The precast elements were designed to be connected to the support slab by closure walls and a shear block. Once the “Z” superstructure segments were in place, concrete was poured to form a closure wall and edge beam, which connects the zee panels to each other on the land side and the waterside, respectively. This innovative solution resulted in expedited construction and minimized the impact on adjacent piers, which are valuable sources of tourism for the city.

To successfully construct the new seawall, Oldcastle Infrastructure worked closely with Mortenson-Manson and Paron’s to complete the design and engineering of the fascia panels and specialty “Z” superstructure segments essential to the seawall’s stability. The “Z” superstructures were a critical step in building the seawall and acts as the concrete backbone of the new seawall’s cantilevered sidewalk. These large, zee-shaped concrete segments provide a counter-balance and support structure for the new overhanging sidewalk.

In all, 400 precast concrete “Z” superstructure segments, 8-foot wide by 9-foot tall, that extend 13-feet and 400 precast concrete fascia panels, with various architectural finishes, measuring 8-ft-wide by 20-ft-tall with a thickness of 15 inches were manufactured and shipped by Oldcastle Infrastructure.

OLDCASTLE INFRASTRUCTURE PRODUCTS USED

• (400) “Z” Superstructure Segments: 8-foot wide by 9-foot tall, and extend 13-feet over the waterfront.
• (400) Fascia Wall Panels, with various architectural finishes, measuring 8-foot wide by 20-foot tall with a thickness of 15 inches. There are three different wall face designs throughout the project area, including tide lines, cobblestone and marine life textures.

USE OF PRODUCTS

Construction of a Seawall

WHY SELECTED

Precast concrete products reduced environmental impact, provided rapid construction, improved constructability, increased quality, and lowered life-cycle costs. Constructing Elliott Bay’s Sea Wall in this manner provided the most efficient and durable solution for the City of Seattle.

INNOVATION

Seawalls protect homes and businesses by withstanding some of the most violent conditions any marine product must endure.

The design and engineering of the fascia panels and specialty “Z” superstructure segments were essential to the seawall’s stability. The “Z” superstructures were a critical step in building the seawall and act as the concrete backbone of the new seawall’s cantilevered sidewalk and provide a counterbalance and support structure for the new overhanging sidewalk.

Providing a high quality, durable precast concrete approach to an interesting construction challenge – limitations of working in constrained area, tight construction schedule, and production within exacting tolerances of large precast components for field assembly – shows an excellent use of how precast concrete construction can accelerate a construction schedule and easily overcome demanding challenges of a project that other methods could not have achieved.

The state-of-the-art precast concrete seawall system reduced environmental impact, minimized the impact on adjacent piers, provided rapid construction, improved constructability, increased quality, and lowered life-cycle costs.

Find out more about Oldcastle Infrastructure Precast Concrete Seawall Systems. 

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