Portsmouth, NH Project
DESIGN & CONSTRUCTION TEAM
Owner: Paul McInnis, Inc
PA DOT Contract Amount: Stoltze & Ehre LLC/Summit Engineering
Precaster: Oldcastle Infrastructure
Manufacturing Facility: Oldcastle Infrastructure, Auburn, ME & Rehoboth, MA
10 State Street Condominiums is a 10,000- SF, three-story, four unit condominium building built on a precast concrete pier constructed of precast pile caps, beams and pre-stressed panels located over water at pier II/10 State St. in Portsmouth, NH.
The four units range in size from 3,542SF to 4,791SF. There is also a deck lounge area and garden rooftop area that can be used by all of the homeowners. Each unit with also comes with two garage spaces and offers one-floor living with elevator access.
CONSTRUCTION CHALLENGE
Located over water, this project was challenged with fast moving currents, construction phasing to accommodate a small site, and coordination with concurrent abutting construction projects.
PRECAST SOLUTION
Precast concrete beams, pile caps, and pre-stressed slabs were selected for the construction method due to their structural strength and durability.
Oldcastle Infrastructure Provided:
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Oldcastle Infrastructure has the expertise to set your shelter in some of the roughest terrain where conventional deliveries just cannot be done. What we can do for you: Bring in a crawler to site that can navigate up to a 30% grade; Navigate hairpin switchbacks; Unload shelter on foundation without the use of a crane.
Oldcastle Infrastructure is capable of leading and executing some of the most logistically challenging remote construction projects. Our professional team has successfully delivered projects in Oregon, Colorado and California.
Even the most logistically challenging projects and schedules are handled deftly thanks to the practical skill, technical insight and organizational prowess of the Oldcastle Infrastructure team.
Our team’s experience with managing operations to high environmental standards, and safety commitment has given us a solid reputation for safely completing logistically challenging projects, often in remote areas, with great quality, on time and within budget.
Oldcastle Infrastructure recently completed the challenging co-location site at Walker Mountain, Chemult, Oregon for American Tower Corporation.
Oldcastle Infrastructure provided turnkey deployment of a 20’ x 49’ co-location shelter.
Attention to quality and detail was central to completing a new substation communications site on top of Baker’s Peak, Slide Mountain, Yuma, Arizona for the U.S. Military and the Co-location Shelter on Iron Mountain, California for Motorola.
“I have no words for you guys but THANKS….Downy and Boise sites wouldn’t have been possible without your help and professionalism.”
Alex Mouledous
Network Deployment Engineer-Aircell LLC
COMMUNICATIONS SUB-STATION – BAKERS PEAK COMPLEX
Slide Mountain, Yuma, Arizona
Oldcastle Infrastructure provided full turnkey services for the Marine Corps Air Station-Yuma, Arizona Bakers Peak Complex which included a 30 x 32 communications shelter and precast modular foundation blocks known as Cell Blocks.
Although Baker’s Peak was on a remote mountaintop with limited access Oldcastle Infrastructure demolished the old site and towers, prepared the new site, installed a precast cell block foundation, three communications towers and a precast 110 m2 Maxi-Mod Shelter. Each of the Maxi-mod sections brought up weighed 25 tones. The project was completed in eight working days and the clients were so pleased with the results that Oldcastle Infrastructure was awarded two further projects.
- Communications Shelter = (3) three piece ( 10’w x 32’L per section) precast concrete sectional building
- Shelter was fully outfitted with electrical, HVAC, alarms
- Three Towers: (2) two 50’ tower poles and (1) one 75’ tower pole
CO-LOCATION SHELTER AT WALKER MOUNTAIN
Chemult, Oregon
Oldcastle Infrastructure recently completed the challenging co-location site at Walker Mountain, Chemult, Oregon for American Tower Corporation. Oldcastle Infrastructure provided turnkey deployment of a 20’ x 49’ co-location shelter.
The 20×49 five piece co-location shelter was engineered and manufactured by Oldcastle Infrastructure for seismic zone: 150% G. The outside dimension is 50’-10” long x 20’-10” wide x 11’-2” high and the finished inside dimension– 50’-0” long x 20’-0”wide x 10’-6” high.
The turnkey project included total outfitting of the co-location shelter from installation of all electrical, environmental systems, alarms, lighting and on-site delivery and installation, in addition to on-site architectural enhancements.
IRON MOUNTAIN
Oldcastle Infrastructure completed the challenging turnkey deployment co-location site at Riverside County on Iron Mountain, CA for Motorola. In addition, Oldcastle Infrastructure erected a Motorola supplied 80’ Saber tower on site.
“My thanks for allowing me to watch them setting the maxi-mod at Black Mountain. It was very impressive and obvious that you guys can put a building anywhere.”
Olan J. Wade, CISSP
MUOS Site Planning Engineering IPT Lead – General Dynamics C4 Systems
SAMPLE OF ADDITIONAL PROJECTS
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Discharge / Re-route to Toketee Lake, Douglas County, Oregon
Components
96” ASTM C-76 Class III – 882 LF
96” ASTM C-76 Class III T-Lock – 1,709 LF
108” ASTM C-76 Class III – 288 LF
108” ASTM C-76 Class III T-Lock – 144 LF
48” Tee Manholes – 3 Each
Oldcastle Infrastructure Nampa, Idaho Supplies 3,000 foot pipeline for Lemolo No. 2
Hydroelectric Development Project
OCTOBER 2011 – Douglas County, Oregon:
Oldcastle Infrastructure supplied 3,000 feet of precast concrete pipe, elbow , transition pieces and manholes for the out-flow pipe and the in-flow pipe of PacifiCorp’s Lemolo No. 2 tailrace re-routing project in Douglas County, Oregon . PacifiCorp, a PacifiCorp Company, was required to reroute the Lemolo No. 2 powerhouse discharge to Toketee Reservoir in accordance with the North Umpqua Settlement Agreement Section 5.4. After a seven year design process, construction of PacifiCorp’s Lemolo No. 2 tailrace re-routing project is almost complete.
Oldcastle Infrastructure provided a 108” diameter concrete pipeline that transitioned into 96” diameter concrete pipe and then back into 108” concrete pipe. The pipe is t-lok lined pipe in portions to meet hydraulic design criteria. The precast concrete pipe was manufactured in 12 foot lay lengths with numerous custom castings. The pipeline makes multiple turns and grade changes. Inlet and outlet pieces were poured with a steel rings cast into the pipe for their connection to a cast in place head wall. In addition, Oldcastle supplied three T-Top manhole pipe sections with 48” manhole being cast into the pipe section for access to pipeline.
The Lemolo No. 2 tailrace re-routing project consists of in-water construction of the cofferdam for the inlet and an outlet structure. To stay on schedule, they were built from both ends. The 3000 feet of pipe was buried along the Toketee-Rigdon road and across the Toketee recreation area. The pipe will carry 700 cfs from the Lemolo 2 plant tailrace and eliminate ramping in the Lemolo 2 full flow reach of the North Umpqua River. Weekly Brothers, Inc. is the general contractor overseeing the construction and McMillen LLC is the project engineer. The project is scheduled for completion at the end of October, 2011.
PROJECT DESCRIPTION
Construction of a 108” diameter concrete pipeline transitioning into 96” diameter concrete pipe and then back into 108” concrete pipe, providing a new tailrace water discharge reroute from the Pacificorp Energy’s Lemolo #2 powerhouse to Toketee Lake. The pipe is t-lok lined pipe in portions to meet hydraulic design criteria. Pipes are being wet cast in standard 12’ lay lengths, with numerous custom castings required. The pipeline makes multiple turns and grade changes. Inlet and outlet pieces are poured with a steel rings cast into the pipe for their connection to a cast in place head wall.
DESCRIPTION OF WHAT OLDCASTLE DID FOR THE PROJECT
Oldcastle Infrastructure purchased 4 new 12’ long forms, 3-96” and 1-108” diameter pipe forms. Oldcastle produced 4 pieces of pipe a day utilizing an elliptical cage for reinforcing. Two single miter elbows for pipeline turns were made and two transition pieces going from 108” to 96” pipe were also made. Three T-Top manhole pipe sections were made with 48” manhole being cast into the pipe section for access to pipeline. 8 ton Meadow Burke lifting inserts were cast into the pipe to facilitate handling, both in the factory and at the jobsite. Hydrostatic joint tests Were required on the pipe so we had to build massive bulkheads and hydrostatic test the joints. It required over 11,000 gallons of water for 108” pipe test. We also had to D-load test the pipe, which had to be performed in our Utah facility with shorter 8’ lengths. Total D-load requirement was over 100,000 lbs of force put onto the pipe. The contractor is providing their own transportation, hauling one pipe per load. The contractor is required to successfully joint test, in the field, each piece of pipe prior to installing the next pipe.
Find out more about Oldcastle Precast Concrete Pipe Products.
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HIGHLIGHTS
Project Location: Contact, Nevada
Owner: Verizon Wireless
Construction Manager: Complete Wireless Consulting
Design Engineer: PJ Ford Engineers
Oldcastle Product(s):
- Precast Concrete Manufacturer
- Pleasanton, California
- Precast Concrete CELL BLOCKS® Foundation
- 25 CELL BLOCKS Foundation
Telecommunications Site
- 81 Foot tall self supporting tower with 15-feet face width.
- 125.3 Inch diameter microwave dish at 59-feet AGL with ice shield.
- 103.4 Inch diameter microwave dish at 29-feet AGL with ice shield.
- Three wireless sectors with three antennas each at 77’ AGL.
- 11’-6” X 16’-11” equipment shelter.
- 1000 Gallon propane tank.
- 60 KW standby propane generator.
Complete Wireless Consulting Inc. was tasked by a major telecom carrier to secure a lease and entitlements for the installation of a wireless cell tower on Ellen D. Mountain near Contact, Nevada. At an elevation of 8614 AMSL, the site was located in the northeast corner of Nevada on land overseen by the Bureau of Land Management (BLM). The proposed lease area for the major telecom carrier was 35’ x 35’. All parties desired a dependable solution that required a minimal amount of equipment and labor resources.
The BLM would only permit a foundation that minimized disruption to the existing ground and allowed for future site removal with less impact on the land. The precast concrete, post tensioned, Cell Blocks patented foundation system met this criteria and was selected for this site to support the telcom equipment conditions and, in turn, minimized the safety concerns about unknown underground hazards at the auto repair garage. The business interruption was minimal.
Cell Blocks are an engineered foundation system made from individual precast concrete blocks that are assembled in various configurations and post-tensioned providing a foundation for a monopole and equipment.
THE DESIGN
Designed by engineering firm PJ Ford Engineers, 25 Oldcastle Infrastructure CELL BLOCKS were manufactured to create the 35-foot by 35-foot foundation for the major telecom carrier’s wireless cell tower, microwave dishes, antennas, equipment shelter and generator.
THE SOLUTION
Structural drawings and calculations were first provided to the carrier’s construction manager, Complete Wireless Consulting, and the precast foundation blocks were then fabricated at the precast manufacturing facility near Pleasanton, CA. Anchor bolts and templates were provided to the precast facility by the self-supporting tower fabricator. The post tension GR 150 galvanized steel bars, hex nuts and plates were ordered from DSI America, Inc.
Special equipment (straight truck with 4 drive axles) was used to expedite delivery of the blocks to the mountain top.
With the precast blocks fabricated, the post tension steel ready, the shelter set to ship and the tower fabrication completed, the installation date was set.
On that day, a crane was set up and the crew placed twenty-five Cell Blocks, within 6 hours, atop the 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 which took two hours. Oldcastle Infrastructure provided a certified hydraulic pump and 100 ton jack to post tension the steel bars to the specified tension force.
The shelter, generator, tank and tower were set immediately after the blocks were post tensioned.
The advantage of the Cell Block foundation was that, once post tensioned, the foundation was instantly full strength. Oldcastle Infrastructure 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.
One crane set the blocks, shelter, generator, tank and the tower on a foundation that was immediately full strength.
COMPLETION
Complete Wireless Consulting was then provided with a final certification package that included: certification of all materials, structural design permit drawings, calculations and jacking forces. The foundation was designed to support loads per ANSI/TIA 222- Rev G, Structure Class II, Exposure Category C, Topographic Category 3 and wind velocity of 120 MPH.
Using post tensioned precast concrete CELL BLOCKS for this wireless facility helped to ensure the installation was extremely predictable and required a minimal amount of resources. A one-day foundation installation process meant the entire site could be built in less than one week.
OldcastleInfrastructure.com
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