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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RENO COUNTY CORRECTIONAL FACILITY

Manufacture and Installation of 120 Precast Concrete Prison Cells

Hutchinson, Kansas

DESIGN & CONSTRUCTION TEAM

General Contractor: J E Dunn Construction
Project Manager: Kyle Quigley
Owner: Reno County, Kansas
Architect: Treanor Architects (HQ-Lawrence, KS)
Project Architect: Jeff Lane
Precast Manufacturing Plant: Oldcastle Infrastructure (Topeka, Kan.),
Oldcastle Infrastructure Modular (Precast Concrete Cell / building components contract award and Project Management)

This project entailed the construction of a new 75,000 square foot single story correctional facility for the County of Reno located in Hutchinson, Kansas. The $21,000,000 new correctional facility has a capacity for 250 inmates ranging from minimum to maximum security and includes special needs units, a kitchen, and medical area which contains two negative pressure isolation cells to prevent the spread of airborne diseases, and a work release area.

The new jail is designed so that guards can have a direct line of sight into cells surrounding a secure control station from which the officers can electronically lock and unlock doors. A maintenance corridor along the outer perimeter of the cell block will allow maintenance workers to repair plumbing and other systems without entering the cells. The design also allows for the easy addition of another 40-bed cellblock when it is needed in the future.

THE CHALLENGE

J E Dunn Construction, the general contractor, and RENO County chose precast modular technology as the desired method of construction for the housing units and awarded the precast concrete cell contract to Oldcastle Infrastructure Modular. The prefabricated concrete cell modules, equaling 120 rear chase jail cells, were manufactured at the Oldcastle Infrastructure -Topeka, KS plant and shipped to the job site. “Once the precast cells are dropped into place, they are done,” said Shawn McClay, the new Reno County Jail Captain, in an August 8, 2014 Hutchinson news article.

Oldcastle Infrastructure Modular and Oldcastle Infrastructure -Topeka manufactured, outfitted, and shipped the prefabricated cells. The quantity of precast cells was comprised of 64 Modules (56 double mods, 8 singles), 120 Cells, (80 double occupancy, 40 single occupancy), 200 beds.

The 12 foot 9 inch by 7 foot, two-man rear chase precast cells were stacked two high. The interiors of the cells were painted and outfitted with fixtures: two beds (for two-man cells), a table, sink, toilet, and four (combo) shelves with breakaway hooks for clothing and towels. Additionally, the plumbing and electricity are already connected to the individual cells.

Oldcastle Infrastructure Modular completed the erection of all 64 cell modules in only four days. The lower level cells have a monolithically cast balcony acting as the walkway for the cells stacked above. The rear chase allows for a corridor along the outer perimeter of the cellblock for maintenance workers.

OLDCASTLE PRECAST PRODUCT USED

• (40) General/Female Population Cell
• (10) Handicap Accessible, General/Female Population Cell
• (50) General/Female Population Cell w/integral ceiling slab.
• (8) Maximum/Special Management Population Cell
• (2) Handicap Accessible, Maximum/Special Management Population Cell
• (10) Maximum/Special Management Population Cell

Each Rear Chase precast cell has integral ceiling/mezzanine floor slab and 5’ wide mezzanine balcony at full width of cell.

PRODUCTION DURATION

5/8/14 through 8/13/14 which was the last pour.

CELLS WERE ERECTED

8/20/2014 thru 8/25/2014 (four working days, W-F and Monday)
Use of Products: Construction of 29,000 square feet of inmate housing units

WHY SELECTED

Fully Out-fitted precast concrete prison cells reduced environmental impact, provided rapid construction, improved constructability, increased quality, and lowered life-cycle costs. Constructing the facility in this manner provided the most efficient and durable solution for Reno County.

Find out more about Oldcastle Infrastructure Precast Concrete Correctional Facility Solutions. 

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SPOOKY NOOK SPORTS COMPLEX HOTEL AND RESTAURANT EXPANSION

Onelift RC509 Pump Station used to Maximize Holding Capacity

Manheim, PA

DESIGN & CONSTRUCTION TEAM

General Contractor: Ashlin Woods
Owner: Spooky Nook Sports Complex
Precast Manufacturing Plant: Oldcastle Infrastructure, Spokane, Wash.

Utilizing the vacant 14-acre Armstrong building in Manheim, PA, along with its 65 surrounding acres; Owner Sam Beiler has created a facility to host 20-plus sporting programs, including the Women’s USA Field Hockey Team. The sporting complex opened last year, and this year a complementary Hotel and Restaurant expansion is being completed at the East Hempfield Twp., Lancaster County, PA facility.

Beiler is adding a new 130-room Warehouse Hotel and 260-seat restaurant to support the sporting complex, with new construction scheduled to be completed in the spring of 2015. Spooky Nook Sports is currently the largest sports complex in the country, and claims that it is not aware of any larger indoor sporting venue in the world.

THE CHALLENGE

Oldcastle Infrastructure was contracted to supply an additional turnkey submersible wastewater pump station to handle the additional wastewater capacity required for Spooky Nook Sports’ new 130-room hotel and 260-seat restaurant in East Hempfield Twp., Lancaster County, PA.

Oldcastle Infrastructure provided their OneLift RC611 pump station, with a 25 foot depth and storage capacity of 468 gallons per vertical foot, to accommodate the hotel expansion requirements of needing to maximize holding capacity within a very small area of land located adjacent to the hotel portion of the complex. The small footprint provided by Oldcastle Infrastructure’s OneLift pump station and the capa- bility to provide the required working volume and emergency storage was just the solution in the small space available.

The OneLift Pump Station is designed with an integral valve vault built into the unused top portion of the wet well, yielding a single-structure product, solving the problems of differential settlement found with the conventional 2-structure systems. In addition; the single-structure design, pre-assembled and ready for installation, significantly reduces the product footprint for sites such as Spooky Nook Sports with tight area restrictions. The manufacturing schedule of the OneLift was also a benefit to Ashlin Woods, the general contractor. The standard design and stock castings allowed Oldcastle Infrastructure to deliver the pump station just 6-weeks after release for production.

As this was the second station provided to this project by Oldcastle Infrastructure in as many years, the owner felt comfortable with the product. The owner wanted consistency at the sports complex and liked the quality and benefits of the One- Lift pump station. The first was installed during the initial construction of the sports complex in 2013 to service the needs of sewage transfer for a portion of the indoor complex and the outside soccer and field hockey rest rooms.

OLDCASTLE INFRASTRUCTURE PRODUCTS USED

• Qty (1) – RC611 OneLift pump station
• 25-foot-10-inch deep
• 468 gallon per vertical foot

USE OF PRODUCT

Sewage pump station to serve hotel facility with 135 rooms, bar & restaurant.

WHY SELECTED

The owner already had a OneLift station on site servicing another part of the facility. They wanted to maintain consistency. Also, the limited space for the sewage pump station made it an ideal fit for a OneLift pump station.

DATE OF INSTALLATION

March 4, 2015

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 in- creasing 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 Pumpstation. 

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MONTANA DEPARTMENT OF TRANSPORTATION

Deep Creek Canyon Weekend Bridge Replacement

Broadwater County, Montana

DESIGN & CONSTRUCTION TEAM

General Contractor: Dick Anderson Construction, Great Falls, Mont.
Owner: State of Montana
Precast Manufacturing Plant: Oldcastle Infrastructure, Spokane, Wash.

The Montana Department of Transportation’s $2.75 million, Deep Creek Canyon Weekend Bridge Replacement project required reconstruction of three of eight deteriorating timber bridges built in the 1930s. The new Deep Creek bridges are located in Deep Creek Canyon between Townsend and White Sulphur Springs, MT.

To replace the three bridges, MDT and Morrison-Maierle Engineers selected Accelerated Bridge Construction {ABC) techniques to significantly accelerate the bridge reconstruction process. ABC entails prefabricating as many bridge components as possible to minimize road closures and traffic disruptions, promote traffic and worker safety, and improve the overall quality and durability of the bridges.

Morrison-Maierle and its partners designed the bridge foundation and the superstructure system as a complete, modular concrete system. The ABC system, consisted of precast concrete bridge superstructure and substructure elements, ensuring the bridges could be built during the weekend closures.

Built over three weekends, the new single-span, 54-foot- long, 31-foot 8-in. wide modular bridges were constructed in less than 60 hours per bridge. As a result, the MDT bridge construction project came in under budget, opened ahead of schedule, and did not interrupt the public’s traffic patterns.

PRODUCTS SUPPLIED

• (15) 53-ft-6.5-in.-long by 2-ft-3-in.-deep by 6-ft-4-in.-wide prestressed concrete tri-deck beams with the curbs and end diaphragms cast on.
• (6) 40-ft-3-in.-long by 3-ft-wide by 4-ft-tall, precast concrete grade beam abutments
• (12) 4-ft-4-in.-long by 2-ft-7-in.-tall by 1-ft-8-in.-thick precast concrete wingwalls

USE OF PRODUCTS

Construction of three single-span, 54-ft-long, 31-ft 8-in.-wide, modular bridges. Oldcastle Infrastructure assembling precast concrete elements for one of the bridges, at the precasting plant, and checking for precise precast component fit, prior to shipment.

INNOVATION

Complete, modular precast concrete bridge system. Superstructure and substructure elements consisting of three stem units with integral deck {tri-deck), grade beam abutments, and wingwalls were chosen to overcome the site and time problems at the bridge locations.

The top flange of the tri-deck concrete beams were designed to be the riding surface of the bridge deck.

This selection provided a high quality, durable precast concrete approach to an interesting construction challenge — limitations of working on a congested site, 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.

AWARDS

Regional award in the 2015 America’s Transportation Awards, “Best Use of Innovation, WASHTO Region; 2015 Project of the Year by the Rocky Mountain Chapter of the American Public Works Association; 2015 Engineering Excellence Award, Structural Systems Category, by the American Council of Engineering Companies of Montana.

Find out more about Oldcastle Infrastructure Precast Concrete Bridge Solutions. 

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CHATHAM COUNTY’S DETENTION CENTER EXPANSION

Using Unique Rear-Chase Precast Concrete Modules Communication Shelter Sites

Savannah, Georgia

DESIGN & CONSTRUCTION TEAM

General Contractor: Hunt/Mills, a Joint Venture (Hunt Construction Group and WG Mills)
Owner: Chatham County Architect L. Robert Kimball & Associates based out of Pennsylvania
Precast Manufacturing Plant: Oldcastle Infrastructure (Jacksonville, FL), Oldcastle Infrastructure Modular (Precast Concrete Cell / building components contract award and Project Management)

The Chatham County Detention Center expansion project added 400,000 square feet to the detention center, bringing the total number of inmate beds to 2,300, nearly double the capacity. The project includes load bearing monolithically cast five sided precast prison cells to accommodate 852 new inmate beds in two and four level housing. It also includes a free standing Video Visitation building (which replaces in person visitation), Courtrooms, Court Holding, Pre-Booking, Medical Clinic and Infirmary, Laundry, Plating Kitchen, Street Operations, Warehouse and Commissary. Oldcastle Infrastructure, working with Hunt/ Mills, a Joint Venture, provided unique rear-chase precast concrete prison cells and modular building components for the new $71 million detention center expansion in Georgia.

PRECAST SOLUTION

The facility owner preferred a rear chase option for the prison cells, allowing maintenance personal to have access to the mechanical systems without having to disrupt the prison population’s daily routines.

Oldcastle Infrastructure offered a unique rear-chase precast concrete prison cell module that has the electrical and plumbing fixtures on the back wall and monolithic balconies on the front and rear of the module. The precast cells came fully out-fitted with electrical fixtures, detention furniture, plumbing fixtures and interior walls painted.

Each concrete unit weighs in excess of 50,000 pounds and contains two cells and front and rear balcony. The cells are stacked four stories high.

Oldcastle Infrastructure designed, manufactured and out-fitted 432 precast concrete modules. There are 176 Double Modules, 24 Single Modules, 144 Dorm Modules, 40 Double Plenums, 4 Single Plenums, and 44 Dorm Plenums. The 176 Double and Single modules account for 280 two–man cells. Of the 280 cells 32 are handicap accessible. The remaining rooms modules are set aside for Triage, Laundry, Video Visitation, and Janitorial rooms.

The precast modules for two housing facilities are made up of 4 pods each. Each Building is 4 stories with a Plenum Module separating the 1st and 2nd levels and at the roof for mechanical, electrical, and plumbing access.

In all, 628 lineal feet of cell plenums and 466 lineal feet of dorm plenums– all precast concrete — were manufactured and erected at the project site.

11,136 sq. ft. of day room balconies and 7,352 sq. ft. of chase corridor was created when installation of the front and rear balconied cell modules was complete.

OLDCASTLE INFRASTRUCTURE PRODUCTS USED

• (280) two-man rear-chase cells
• (144) four-man cells
• (16) multipurpose rooms
• (16) janitorial rooms
• (16) triage rooms
• (16) laundry rooms
• (16) video visitation rooms
• (628) lineal feet of cell plenums
• (466) lineal feet of dorm plenums

USE OF PRODUCTS

Construction of 380,000 square feet of detention housing units. (approximately 1,136 beds).

WHY SELECTED

Fully out-fitted, load bearing mono-lithically cast five sided, precast concrete prison cells reduced environmental impact, provided rapid construction, improved constructability, increased quality, lowered life-cycle costs and provided a sustainable solution towards achieving LEED Certification. Constructing the facility in this manner provided the most efficient and durable solution for Chatham County.

The project finished ahead of schedule and Chatham County was very pleased.

Find out more about Oldcastle Infrastructure Precast Concrete Correctional Facility Solutions.

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NORTH MILLIKEN AVENUE UNDERPASS

Value Engineering Redesign

Ontario, California

DESIGN & CONSTRUCTION TEAM

General Contractor: CC Myers Inc.
Owner: City of Ontario Design
Engineer: T. Y. Lin International El Cajon, CA
Oldcastle Infrastructure Precast Product(s): Precast Concrete Fascia Beams Prestressed Box Girders
Oldcastle Infrastructure: Perris, CA

2014 DESIGN AWARD WINNER: BEST NONHIGHWAY BRIDGE

Located less than a quarter mile (400 m) south of a major freeway interchange, this busy railroad crossing is at the nexus of a significant freight and commercial truck corridor. Prior to construction, truck traffic exiting the freeway had to back up onto the freeway when a train blocked the grade crossing, causing major delays and a significant safety hazard.

Initially, the design featured a steel plate girder bridge with a steel plate forming the deck, says Jay Holombo of T Y. Lin International, the engineer of record of the redesigned underpass bridge. During the bidding phase an alternate superstructure design using precast prestressed concrete adjacent box girders was evaluated. The new underpass includes a two-span bridge measuring 171 ft long × 52 ft wide (52 × 16 m). A precast concrete T-wall based retaining wall system extends a half a mile (800 m) in either direction on both sides of the tracks to elevate the line while meeting right-of-way requirements.

THE SOLUTION

The redesigned two-span underpass bridge consists of 26 precast, prestressed box girders supporting ballast, waterproofing, and two mainline tracks. Ballast curbs were cast as an integral component of the exterior girders. Each span is transversely post tensioned at the quarter points within each span. Each 4-ft-wide box girder contains fifty-six 0.6-in.-diameter strands and relatively thick bottom and top flanges of 9 and 10 in., respectively, to meet the stringent American Railway Engineering and Maintenance-of-Way Association (AREMA) strength, service, and deflection requirements. A net upward permanent deflection of 3 in. at midspan was anticipated after placement of ballast. A buildup of rubberized asphalt was used to ensure sufficient transverse and longitudinal slope to maintain drainage off of the bridge.

Fascia beams are conventionally, used to support pedestrian walkways and communication conduit. To minimize the amount of formliner needed, the precast fabricator developed an innovative approach where the exterior was cast as 7.5-ft-long panel segments. These precast panel segments were then placed in the forms and cast with the rest of the fascia box girder, resulting in significant savings while meeting the aesthetic requirements of the project.

The benefit of using a precast concrete box-girder superstructure is that bridge maintenance painting operations are not required, as would be necessary for the as-designed steel girder system.

The value-engineering redesign of the North Milliken Avenue Railroad Underpass Bridge demonstrates that high-performance precast concrete is ideal for railroad bridge spans greater than 80 ft, and has better economy and faster production than equivalent steel spans. The City of Ontario and the surrounding community further benefited from an accelerated construction schedule and reduced future maintenance costs.

KEY PROJECT ATTRIBUTES

• Precast box beams demonstrated significant cost savings and reduced fabrication time while compared to steel plate girders
• Designers achieved faster delivery of the project with minimal effects on traffic
• Net savings to the project was approximately $900,000

PROJECT AND PRECAST SCOPE

• Project Cost: $5 million
• Bridge Length: 171 ft (52 m)
• 7 Feet deep (2.1 m) precast concrete fascia beams support maintenance walkways, railings, and communication conduit and precast, prestressed box girders

Find out more about Oldcastle Infrastructure Bridge Solutions. 

U.S. ARMY CORPS OF ENGINEERS’

New Fish Transport Barge Moorage Wharf at Lower Granite Lock and Dam on the Snake River

Whitman County, Wash.

DESIGN & CONSTRUCTION TEAM

Project: USACE Lower Granite Dam Fish Barge Wharf
General Contractor: The joint venture team of Garco Construction, of Spokane, Wash. and Total Site Services, of Richland, Wash., (TSS/GARCO)
Owner: Walla Walla District United States Army Corps of Engineers
Precast Manufacturing Plant: Oldcastle Infrastructure – Spokane, Wash.,
Selkirk, New York and Edgewood, Maryland, Colorado

This U.S. Army Corp of Engineers’ project involves construction of a new moorage facility and mooring dolphin at Lower Granite Dam in Whitman County, Washington.

This new fish transport barge moorage wharf adds to the existing moorage facility located along the shoreline of the Lower Granite Dam earthen fill section to accommodate operations, maintenance, and repairs of the existing barge feet. The old wharf no longer had the maintenance capacity for the additional and larger barges being put into service the past few years, and crane access was limited. Lower Granite is the first salmon collector dam on the Snake River, and thus the primary component of the fish transportation program. The juvenile fish are barged around this dam and the others of the Snake and Columbia Rivers for release below Bonneville Dam to reduce their mortality.

The new barge mooring wharf is fabricated using a combination of cast-in-place and precast concrete. The 300 foot long by 40 foot wide moorage wharf rests on two rows of pilings — 32 steel drilled shafts, 54 inch in diameter and 41 feet in length.

Large cap beams sit side-by-side, over the pilings in the water. The bumpers on the outside face of the large pile caps protect the structure. The small cap beams also sit side-by-side, opposite the large ones, and run along the toe of the earthen fill section of dam. Pre-stressed slabs span between the cap beams. The on-shore and in-water pile caps and slabs are connected together by a final 6 inch thick cast-in-place concrete slab and closure pour tying the cap beams into the drilled shafts.

THE PRECAST CHALLENGE

“This project required precision precast manufacturing. The precast cap beams and slabs elements, which are very large pieces, had to be manufactured within exacting tolerances, within fractions of an inch, in order to site assemble the precast components and achieve the requirements of the wharf specifications”, said Chuck Prussack, P.E., for Oldcastle Infrastructure Spokane. “We created a 3D virtual mock up based on as-built information to ensure that when the large precast concrete pieces arrived at the site they would fit with precision. In addition, there were special transportation requirements. The large cap beams required a truck and trailer measuring 138 feet long, and the road into the construction area was a narrow, winding two-lane country road with switch backs and a steep grade to the river.”

Oldcastle Infrastructure manufactured and shipped the eight-36 foot long by 7 foot wide by 13 foot high precast concrete large cap beams (140,000 pounds apiece), eight-36 foot long by 7 foot wide by 9 foot high small cap beams (104,000 pounds apiece), and thirtytwo- 27 foot long by 9 foot wide by 1 foot-6 inch thick pre-stressed concrete slabs (56,000 pounds apiece), for the barge moorage wharf project.

OLDCASTLE INFRASTRUCTURE PRODUCT USED

• (8) 36 foot long by 7 foot wide by 13 foot high precast concrete large cap beams (140,000 pounds apiece)
• (8) 36 foot long by 7 foot wide by 9 foot high small cap beams (104,000 pounds apiece)
• (32) 27 foot long by 9 foot wide by 1 foot-6 inch thick pre-stressed concrete slabs (56,000 pounds apiece)

USE OF PRODUCTS

Construct a new dam moorage wharf

WHY SELECTED

Precast concrete products reduced environmental impact, provided rapid construction, improved constructability, increased quality, and lowered life-cycle costs. Constructing the over water wharf in this manner provided the most efficient and durable solution for the USACE.

DATE OF INSTALLATION

Last Pieces October, 2014

INNOVATION

Providing a high quality, durable precast concrete approach to an interesting construction challenge — limitations of working in the river, 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 $6.9 million U.S. Army Corps of Engineers state- of-the-art precast/prestressed concrete wharf system reduced environmental impact, provided rapid construction, improved constructability, increased quality, and lowered life-cycle costs. Constructing the over water wharf in this manner provided the most efficient and durable solution for the USACE in addition to allowing service cranes to access any barge that is moored there.

Find out more about Oldcastle Precast Concrete Solutions. 

RAPPAHANNOCK SHENANDOAH WARREN (RSW)

Regional Jail

Front Royal, Warren County, Virginia

DESIGN & CONSTRUCTION TEAM

General Contractor: Howard Shockey & Sons
Architect: Moseley Architects
Owner: RSW Regional Jail Authority
Precaster: Oldcastle Infrastructure
Manufacturing Facility: Oldcastle Infrastructure, Fredericksburg, VA

Construction of the new $82 million, RSW Regional Jail, serving Rappahannock, Shenandoah, and Warren Counties, with an initial capacity of 375 inmates, though approved for double bunking, with maximum capacity of 563 prisoners. The facility blends in with neighboring architecture without the visible features, such as razor ribbon, observation towers, or high mast lighting that is often associated with a correctional institution.

The 270,000 square foot, 2-story modern direct supervision facility contains a combination of medium and maximum security cell housing units and includes support services such as food service, laundry, intake and release, medical services, recreation, education, central storage, visitation, magistrate, administration, and staff services.

CONSTRUCTION CHALLENGE

The project schedule was critical and the maximum and medium security overall cell design was complex. Oldcastle Infrastructure was required to manufacture and out-fit (5) distinct types of precast concrete cells – some single or double cell modules, some with or without monolithic front and rear balcony — ranging in size from 70 square feet to 90 square feet per cell in dimension. The Shower Modules were 143 square feet modules.

Production of the precast units began in September of 2012 and erection of a modules completed February 2013.

PRECAST SOLUTION

Oldcastle Infrastructure was contracted to manufacture, out-fit and install 257 multiple type , pre-painted, rear-chase precast concrete jail cells and 12 shower modules complete with regular and ADA stainless steel combination lavatory and water closets, ceiling mount LED light fixtures with an LED night-light, wiring for light fixtures, receptacles and switches, stainless steel mirror, bunks, shelves and other amenities. The 7-foot by 10-foot cells manufactured were dimensions that are standard requirements of the Virginia Department of Corrections. The maximum security pods can house 16 inmates while the other pods hold more prisoners.

CONSTRUCTION SCHEDULE

Start Date: July 2012
Scheduled for completion: July 2014

PROJECT SIZE

270,000-square-foot jail; Housing Unit: 175,000 square feet; 1 and 2 levels

The RSW Regional Jail project is currently LEED® registered with the U.S. Green Building Council and will pursue certification.

Find out more about Oldcastle Infrastructure Correctional Facility Solutions. 

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MISSION CRITICAL FUEL SUPPLY

for California Healthcare Facility Emergency Power

Stockton, CA

DESIGN & CONSTRUCTION TEAM

General Contractor: Bergelectric Corporation, Donlee Pump Co.
Owner: State of California
Precaster: Oldcastle Infrastructure
Manufacturing Facility: Oldcastle Infrastructure, Stockton, CA

Bergelectric Corporation, a nationally recognized electrical contractor, recently finished on-site construction of the “mission critical” electric power emergency/ backup generation system for the new $700-million California Health Care Facility in Stockton, CA.

Bergelectric, responsible for feeding power to the 144-acre site, supplied the core support facilities that serve as the backbone of operations. One of the most significant aspects of Berg’s role on CHCF-Stockton was the integration of normal and emergency power. Oldcastle Infrastructure supplied the specialized fuel storage system that feeds the 2 MegaWatt Caterpillar generators for emergency power.

CONSTRUCTION CHALLENGE

Oldcastle Infrastructure/ConVault sales team collaborated with customer/partner, Rich Hamilton, Special Projects Manager for Donlee Pump Co. and Berg’s Dan Winkels, project engineer for this project. The team designed and constructed a custom, sitespecific fuel supply system to feed six – 2 MegaWatt Caterpillar generators.

PRECAST SOLUTION

The fuel supply system includes one 2,000 gallon ConVault day-tank which was supplied by four large 10,000 gallon ConVault auxiliary storage tanks. The 5-tank array is fully monitored and auto-managed to provide re-circulation of fuel product and re-fueling of the day-tank “on demand”. Rounding out the comprehensive system design is a unique fuel filtration system, using a Velcon 60 GPM aircraft style filter module and differential pressure gauging/ compensating systems, to ensure fuel quality and purity.

EMERGENCY BACKUP POWER SYSTEM

SCOPE OF WORK
Oldcastle Infrastructure provided:

• 1 – 2,000 gallon ConVault Protected Fuel Storage Tanks (for genset day-tank)
• 4 – 10,000 gallon ConVault Protected Fuel Storage Tanks (main fuel storage)
  All tanks systems are UL 2085 Listed per NFPA requirements, including fire, ballistic, vehicle impact and explosion protection.

Donlee Pump Co. provided and field installed all tanks, piping and equipment.

• ConVault meets uniform fire codes.
• Inspection for leaks is visual, which eliminates very expensive monitoring equipment needed to detect leaks underground.
• ConVault Vaulted Fuel Storage tanks are finished units – pumps and accessories are available – and can be set in place, ready for use.
• The ConVault tank can be customized to fit your needs. 250 – 500 – 1,000 – 2,000 – 4,000 – 5,200 – 6,000 – 8,000 – 10,000 – 12,000 gallons, split sizes also available.

Find out more about Oldcastle Vaulted Storage Tanks.

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