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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Weigh Station Buildings Project
DESIGN & CONSTRUCTION TEAM
General Contractor: Telco Supply Co., Sulphur, OK
Owner: Oklahoma Dept. of Transportation
Precaster: Oldcastle Infrastructure
Manufacturing Facility: Oldcastle Infrastructure, Newnan, Georgia
Construction Services: Provided by Oldcastle Services
The Oklahoma DOT (ODOT) is constructing new state-of-the-art commercial truck weigh and inspection stations for heavy trucks entering Oklahoma. A total of nine POE weigh stations will be built along major highway entrances around the state’s border.
The $100 million dollar project consists of building eight permanent, manned stations at key ports of entry into Oklahoma, along with a ninth unmanned “virtual” station that will allow regulators to use special equipment to weigh and check trucks as they move along the highway.
CONSTRUCTION CHALLENGE
In collaboration with Telco Supply Company and the Oklahoma State DOT, Oldcastle Infrastructure provided a “turnkey” solution for the ODOT Port of Entry Precast Weight Station Buildings. Oldcastle Infrastructure’s turnkey scope of work consisted of the manufacturing, outfitting and installation of (2) two RCS 13830 Precast Concrete POE Buildings.
PRECAST SOLUTION
The ODOT, using metal office trailers in the past, knew it was essential, going forward, to provide a more secure and durable building to house the DOT employees that weigh and regulate the trucking industry on Oklahoma’s highways. They chose precast concrete construction as the solution.
The turnkey project involved the manufacturing and complete out-fitting of Oldcastle Infrastructure’s RCS 13830 Precast Concrete Buildings with all specified equipment. In addition, the fully out-fitted buildings were shipped, off loaded and installed at the POE sites near Oklahoma City. The RCS 13830 Precast Concrete Buildings were manufactured at our Newnan, GA facility.
SCOPE OF WORK
Precast Structure
A. STRUCTURE ENGINEERING
Detailed engineering and drawings
B. PRECAST CONCRETE SHELL
Size: (1) RCS 1430 Light Weight Precast Concrete POE Precast Office Building
Outside Dimension: 30’ Long x 13’ 8” Wide x 10.1’ High
Finished Inside Dimension: 29’ Long x 12’ 8” Wide x 9’ High
Weight: Approximate finished weight: ~82,700 pounds
Specifications:
Floor load: 200 PSF
Roof load: 60 PSF
Wind load: 150 MPH, Exp “C”, I=1.15
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. Higher ratings are available to 300% Gravity acceleration
C. FINISHES
Exterior Walls: Solid Precast Concrete, 4” Thick with Textured Thorocoat finish
Interior Wall & Ceiling: Nudo White 1/2“ FRP board
Insulation: R-11 in walls and ceiling
Floor: Vinyl composition tile with rubber base molding
Roofing: White Elastomeric coating
Stud Partition Walls: Restroom & Closet walls
D. DOORS AND OPENINGS
Doors: (2) 3’-6” x 7’-0” 16 gauge steel door with 14 gauge steel frame
Locks: High Security Lockset with changeable core and Panic hardware
Other Door Hardware: (2) NRP Stainless steel hinges, anti-pick plate; kick plate, hydraulic door closer, weather strip, aluminum threshold, door sweep
Door Hood: (2) 54’w x 30” d door rain hoods, (2) Door drip cap
Interior Doors: (2) 3’ x 7’ Interior steel doors with hardware
Windows: (5) 5’ x 4’ Shatterproof Tinted Windows rated 150 MPH with 1- 5/16” tempered, tinted, hurricane resistant glass
E. POWER
Power Service: 200A 1Ø 120/240V
Disconnect Switch: (1) SQ D, D224NRB, 200A Exterior Disconnect Switch
Main Distribution Panel: (1) SQ D NQ series, MB panel, 200A 1Ø, 40 space
Surge Suppression: (1) Raycap/AC Data B82XXR-G at MDP
Convenience Receptacles: (6) 20A, 125V
Dedicated Receptacles: (~32) 120V, 15A Receptacles
Exterior GFI Receptacle: (2) 20A, 125V
F. ENVIRONMENTAL SYSTEM
HVAC: (1) 3 Ton, 240V, 1Ø wall mounted HVAC system
Controls: (1) Auto heat/cool thermostat controller
Restroom Exhaust fan: (1) Restroom exhaust fan
G. ALARMS
Alarms: (1) 25 pair split 66 block in storage room with intrusion smoke
H. LIGHTING
Interior:
(4) 4’ 2 tube Lithonia fluorescent light fixtures with acrylic lens covers
(2) 2’ x 2’ surface mtd fluorescent fixtures
Exterior: (2) 100W HPS Exterior light with photocell Lithonia TWA series
Emergency: (2) Emergency fixture with dual flood lights
Switches: (2) 20A light switches
I. GROUNDING
Grounds: Standard Commercial service grounding per NEC.
K. ADDITIONAL ITEMS
Telco, Computer, Radio: Install other conduits only as required
Counter: Plastic laminate counter with ledge
Storage shelves/Cabinet: Plastic laminate storage shelves in storeroom & storage cabinet in restroom
Restroom: Block outs for plumbing & floor drain provided by Oldcastle
IT equipment box/cabinet: IT equipment box/cabinet in storage room
Find out more about Oldcastle Precast Concrete Building Solutions
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Surge Tank Vault Installation Project
Rockville, Maryland
DESIGN & CONSTRUCTION TEAM
General Contractor: CPP Construction
Owner: The City of Rockville – Public Works
Contract Amount: $275,000
Precaster: Oldcastle Infrastructure
Manufacturing Facility: Oldcastle Infrastructure, Fredricksburg, VA
The project consists of the manufacture and installation of a precast concrete vault for the new hyrdo-pneumatic surge tank at the Glen Mill Pump Station. The surge tank is a critical piece of the surge suppression system that protects the City’s 24- inch water transmission main and the Glen Mill Pump Station. The Glen Mill Pump Station has a capacity of 10 MGD and pumps through a 6-mile-long, 24” transmission main that operates at pressures up to 190 psi.
The surge tanks work in concert with air release valves, which protect the City transmission main from damaging pressure surges that may occur during service disruptions such as power outages at the water treatment plant or the pump station.
The surge tank was installed in an underground precast concrete vault at the Glen Mill Pump Station to avoid visual impact on the adjacent residential community.
PRECAST SOLUTION
Oldcastle Infrastructure manufactured the 12’ wide x 25’ long x 11’4” deep precast concrete tank vault at their Fredricksburg, VA precast plant.
The 102 ton structure was designed in three pieces with a 3 way split slab and separate sump pit. The largest piece was the 37 ton base.
Oldcastle Infrastructure, Inc. and CPP Construction installed the liquid containment vault in one afternoon using a 300 ton hydraulic crane.
AWARD OF CONTRACT
February 6, 2012
SCOPE OF WORK
Precast Structure
A. STRUCTURAL ENGINEERING
Detailed engineering:
Drawings: Detailed drawings
B. PRECAST CONCRETE PRODUCT
Size: 12’ wide x 25’ x 11’4” deep tank vault
Concrete: 5,000 psi concrete
Weight: Approximate finished weight: 102 Tons
C. INSTALLATION
(3) Precast concrete components using a 300 ton hydraulic crane
Find out more about Oldcastle Infrastructure Liquid Containment Vaults
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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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