PCANY NEWSLETTERPCANY MONTHLY

PRECAST CONCRETE ASSOCIATION OF NEW YORK, INC. September 2009 Volume 20, No. 9

Focus of This Issue: Miscellaneous Products and Projects

The first field installation of the newest A-LOK Connector, the A-LOK Premium, was inJuly 2009. The stormwater job was atDelaware Creek in Toledo, Ohio. Watertightconnectors were chosen over grouting tospeed up the installation. The interesting thingabout this job was the 42” RCP (made byIndependent Concrete Pipe) had an OD of51.25”, which is the very biggest size sug-gested for the #1640 A-LOK connectors castinto these manholes, which were precast byMack Industries of Toledo. However, the extraflexibility of the A-LOK Premium connectormade the installation of the pipe, by contractorE.F.Zeiler, very simple and quick, requiringminimum force.

Tight fit easily accomplished

Photo and story by Wally Swiger, A-Lok Products

New WatertightConnectors

Congratulations to Professional Members CHA, Passero,CDM, and Dewberry for National Recognition

In ENR’s latest ranking, CHA was rated the 83rdlargest design firm in the U.S. based on 2008 revenue.They were also named among ENR’s Top US designfirms serving the manufacturing sector, ranking 12thbased on revenue from manufacturing clients in 2008.

Passero Associates Earns Spot on Zweig Hot 200Firms List — Mark Zweig says “Over the years, the “HotFirm” designation has become synonymous with suc-cess in the industry. Firms on The Zweig Letter Hot Firmlist are recognized the world over as well-managed com-panies that outperform their peers because they do abetter job for their clients.”

CDM is ranked #15 on ENR’s Top 200 EnvironmentalFirms, #10 in Engineering/Design, as well as appearing

in separate Top 20 Listings related to Water Supply/treatment, Wastewater Treatment, and yet again inHazardous Waste.

Dewberry has announced that Andy Ko, PhD, PE,Director of Bridge Structures, has been selected to serveon the American Railway Engineering and Maintenance-of-Way Association’s (AREMA) Technical Committee 8,Concrete Structures and Foundations. This committeecontributes to the development and advancement ofboth technical and practical knowledge and recom-mended practices pertaining to the design, constructionand maintenance of railway infrastructure.

PRECAST CONCRETE ASSOCIATION OF NEW YORK September 2009 MONTHLY NEWSLETTER Page 2

Precasting …. Mass Producing Customized ProductsJail cells, single slope half barriers, sound walls, box culverts, special slabs for utility structures or highway seg-

ment night replacement….. the list would be endless.

Box Culvert with attached headwall, meeting NYSDOT moment connection requirements

Customized Headwall

DI and Top Slab with Galvanized Frame

(continued on page 5)

INTENSIVE MANAGEMENT UNIT, MONROE CORRECTIONAL COMPLEX– IMU/SEG Project Type: Correctional Location: Monroe, WA Owner/Developer: Washington State Department of Corrections, Olympia, WA Architect/Engineeer: INTEGRUS Architecture, Spokane and Seattle, WA Contractor: Absher Construction Company, Puyallup, WA Precaster: EnCon Washington, Puyallup, WA

OVERVIEW

The 140,000-square-foot IMU/SEG project, which scored 37 points on the USGBC LEED-NC rating system, consists of an Intensive Manage-ment Unit (IMU) and Segregation Management Unit (SMU). This new facility, constructed at a cost of $277 per square foot, houses inmates classified as Intensive Management Status (IMS) and inmates classified as Segregation Management Status (SMS).

Two housing wings on both levels of each building have 32 single-occupancy cells, and one housing wing on both levels of each building has 36 single-occupancy cells (four cells for handicapped use), resulting in a total of 100 single-occupancy maximum-security cells for each building. Each wing is located around a control room for optimum visibility. Each housing wing consists of a main level and mezzanine level, with two showers on each level. The wings are divided in half to provide a total of 12 individual pods of 8 cells, or 9 cells where accessible cells are provided. Each pod, including those on the mezzanine, has a dedicated entry door for inmate movement and delivery of services. The administrative-services wing provides support to the housing wings with correctional staff offices and break rooms, inmate visiting, counseling rooms, hearing rooms, storage space, food services and linen storage, and holding and isolation cells.

Because of the extreme security concerns, the structure consists of precast concrete exterior sandwich walls. All cells are constructed of precast concrete as well as bunks, tables, and stools within the cells.

(cont…)

PRECAST CONCRETE & LEED

25Amount of baseline energy- use reduction due to precast concrete panel design.

P E R C E N T 58 Reduction in potable water consumption.

P E R C E N T 60Distance from precast concrete manufacturing facility to the jobsite.

M I L E S

Color logos

Black only logos

Reverse logos

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PRECAST CONCRETE ASSOCIATION OF NEW YORK September 2009 MONTHLY NEWSLETTER Page 3

PRECAST CONCRETE ASSOCIATION OF NEW YORK September 2009 MONTHLY NEWSLETTER Page 4

209 West Jackson Boulevard I Suite 500 I Chicago, IL 60606Phone: 312-786-0300 I Fax: 312-786-0353 I www.pci.org

209 West Jackson BoulevardSuite 500 Chicago, IL 60606

Phone: 312-786-0300Fax: 312-786-0353

www.pci.org

209 West Jackson Boulevard I Suite 500 I Chicago, IL 60606Phone: 312-786-0300 I Fax: 312-786-0353 I www.pci.org

209 West Jackson BoulevardSuite 500 Chicago, IL 60606

Phone: 312-786-0300Fax: 312-786-0353

www.pci.org

209 West Jackson Boulevard I Suite 500 I Chicago, IL 60606Phone: 312-786-0300 I Fax: 312-786-0353 I www.pci.org

209 West Jackson BoulevardSuite 500 Chicago, IL 60606

Phone: 312-786-0300Fax: 312-786-0353

www.pci.org/sustainability

Interior, IMU/SEG

Exterior, IMU/SEG

Precast concrete sandwich wall panels

The facility is staffed to have a maximum number of 20 employees work in the building and house a maximum number of 200 inmates. Employees are encouraged to utilize the bus or ride bicycles to work, and all inmates either walk or are bussed to the facility. Van pools are also implemented on the campus to achieve ride sharing and other transportation alternatives. During the design phase, design teams worked with the campus to eliminate some existing parking stalls.

The design team also worked with mechanical and electrical engineers to implement better energy-saving strategies by increasing the R-value of the insulated precast sandwich wall panels, installing efficient HVAC control systems, introducing rainwater collection systems, and hiring a commissioning agent to monitor the system’s accuracy and efficiency.

The project was designed and specified to achieve a LEED silver rating. However the project actually achieved a gold rating. The project contract and documents include the elements of the project and materials that have a high recycled content and/or were manufactured in nearby neighborhoods. A sign-off letter system was also established in the contract documents to ensure that the awarded con-tract submitted correct information, recycled-content ratios, and distances from the manufacturers, in order to precede the work.

PRECAST CONCRETE’S CONTRIBUTION TO SUSTAINABLE CONSTRUCTION PRACTICES

Materials & Resources:

Precast concrete systems were incorporated that use a high fraction of local materials, including ag-gregates, steel, cement, and fly ash in the concrete. The precast concrete fabricator’s plant was less than 60 miles from the job site and panels were sized to allow for maximum stacking and a minimum amount of trucking.

The specific goal was to incorporate a minimum of 50% recycled materials, based on material cost. Approximately 97% of construction waste was diverted for repurposing and more than 99% of con-struction waste and debris was recycled. Additionally, more than 60% of construction materials were harvested or manufactured locally, including the precast concrete wall panels.

Energy & Atmosphere:

A thermally efficient precast sandwich wall panel shell was utilized. The precast concrete panels were designed to exceed the baseline model energy code by at least 25%, and use 27% less energy than comparable noncertified buildings.

Sustainable Sites:

The facility has on-site retention and treatment of stormwater. Precast concrete retention tanks were used as the collector basin.

Water Efficiency:

Rainwater collection is used by toilets in inmate areas. This feature contributes to a 54% reduction in water consumption and a 58% reduction in potable water consumption as opposed to a comparable facility.

Indoor Environmental Quality:

The precast concrete components produce no dust or airborne contaminants during construction or ser-vice because the precast concrete elements are fabricated and cured off-site. With the precast concrete components incorporated and the facility constructed, it offers natural lighting for more than 75% of the occupied space.

PRECAST CONCRETE & LEED

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The U.S. Army Corps of Engineers will use precast concrete modularconstruction for a new medium- and maximum-security correctional fa-cility.

Oldcastle Precast Modular is currently working with JE DunnConstruction, Kansas City, Mo., to provide 248-precast concrete cells atthe Fort Leavenworth Regional Correctional Facility in Fort Leavenworth,Kan., as part of the base realignment and closure program.

The new $150 million 2-story correctional facility will consist of 483beds, including a warehouse, engineering, and maintenance building aswell as a covered vehicle storage area. A new access road will lead tothe prison on its 40-acre site.

The medium-security general housing unit will consist of 200 cells,and the maximum-security single housing units will consist of 48 cells.

Oldcastle Precast Modular is supplying and installing the furniture in-cluding combination units. Production for the 248 cells began in lateOctober and will finish in February 2009. Erection will begin in Februaryand be completed in March.

The architect of record is HSMM/AECOM of Virginia.

PRECAST CONCRETE ASSOCIATION OF NEW YORK September 2009 MONTHLY NEWSLETTER Page 5

Correctional Facility Relies on Precast Concrete Modules

NECSA Integrates with PCAEffective January 1, 2009, NECSA (Northeast Cement

Shippers Association) was integrated with PCA (PortlandCement Association).

The integration will align promotion efforts on a national, re-gional and local scale. The relationship between PCA/NECSAand any of its prmotion partners should remain unchanged.PCA/NECSA will be PCA in the Northeast Region and all requests for PCA resources should be directed to thePCA/NECSA office in Castleton, NY at (518) 477-4925 or hsteffek@cement.org.

Precasting …. Mass Producing Customized Products (continued from page 2)

Precast Modular Retaining Wall Units and Three-Sided Culverts All photos by Kistner Concrete Products

PRECAST CONCRETE ASSOCIATION OF NEW YORK September 2009 MONTHLY NEWSLETTER Page 6

Precast Concrete Association of New York, Inc.2829 East AvenueRochester, NY 14610Tel: 585-249-9564 • Fax: 585-381-0945Email: pcany@aol.com Web: www.pcany.org

PRODUCER MEMBERSA & R Concrete Products, New Windsor, NY, 845-562-0640Bayshore Concrete Products, Cape Charles, VA, 757-331-2300Binghamton Precast & Supply, Binghamton, NY, 607-722-0334J.P. Carrara & Sons, Middlebury, VT, 802-388-6361Coastal Pipeline Products Corp., Calverton, NY, 631-369-4000Dailey Precast, Shaftsbury, VT, 802-442-4418The Fort Miller Co., Inc., Schuylerville, NY, 518-695-5000Hanson Pipe & Products, Inc., Pottstown, PA, 800-970-2216Jefferson Concrete Corp., Watertown, NY, 315-788-4171Kistner Concrete Products, East Pembroke, NY, 585-762-8216Lakelands Concrete Products, Inc., Lima, NY, 585-624-1990Newcrete Products, Division of New Enterprise Stone & Lime

Co., Collegeville, PA, 484-902-0256Northeast Prestressed Products, LLC, Cressona, PA,

570-385-2352Oldcastle Precast, South Bethlehem, NY, 518-767-2116Oldcastle Precast Inc., Middle Island, NY, 631-924-7400Oldcastle Precast Inc., DBA Rotondo Precast, Avon, CT,

860-673-3291Roman Stone Construction Co., Bay Shore, NY, 631-667-0566Sunnycrest Inc., Auburn, NY, 315-252-7214LC Whitford Materials, Co., Inc., Wellsville, NY, 585-593-2741SEPTIC TANK PRODUCER MEMBERSBinghamton Precast & Supply, Binghamton, NY, 607-722-0334Burnett Concrete Products, Inc., Wolcott, NY, 315-594-2242Concrete Building Supply, Champlain, NY, 518-563-0700Cresset Chemical Co., Weston, OH, 419-669-2041R. Deso, Inc., Champlain, NY, 518-298-8411Eastern Precast Co., Inc., Brookfield, CT, 203-775-0230The Fort Miller Co., Inc., Schuylerville, NY, 518-695-5000Grimm Building Materials Co., Troy, NY, 518-272-1100Guardian Concrete Products, Schenectady, NY, 518-372-0080Jefferson Concrete Corp., Watertown, NY, 315-788-4171Keeler Vault Co., Inc., Hudson, NY, 518-851-6281Kistner Concrete Products, East Pembroke, NY, 585-762-8216Oneonta Block, Oneonta, NY, 607-432-6641Sunnycrest Inc., Auburn, NY, 315-252-7214United Concrete Products, Inc., Yalesville, CTWoodard’s Concrete Products, Inc., Bullville, NY, 845-361-3471Zeiser Wilbert Vault, Elmira, NY, 607-733-0568ASSOCIATE MEMBERSA-Lok Products, Inc., Tullytown, PA, 800-822-2565Amcrete Products, Newburgh, NY, 845-562-0010

American Spacer Technologies, Inc., Hudson, NY, 800-424-8557BASF Admixtures, Cleveland, OH, 518-232-1187Buzzi Unicem USA, Stockertown, PA, 610-746-6224Cemex, Inc., Wampum, PA, 724-535-4311Chase Specialty Coatings, Pittsburgh, PA, 412-828-1500Concrete Sealants, Inc., Royersford, PA, 610-948-7867Cresset Chemical Co., Weston, OH, 419-669-2041East Jordan Iron Works, Newark, NJ 973-350-0600Eastern States Steel Corp., Upper Saddle River, NJ,

800-327-8335Engineered Wire Products, Waynesville, OH, 937-433-9753Essex Cement Company, Port Newark, NJ, 973-344-5903Essroc Cement, Nazareth, PA, 610-746-3109The Euclid Chemical Co., Saratoga Springs, NY, 518-376-0871Federal White Cement Inc., Emmaus, PA, 610-966-9481Forta Corporation, Grove City, PA, 800-245-0306Grace Construction Products, Wynantskill, NY, 518-361-4335Helser Industries, Tualatin, OR, 503-692-6909Holcim (US) Inc., Saratoga Springs, NY, 518-376-0871Iron Horse Transport Inc, Smithtown, NY, 646-529-0336Jepco Sales, Royersford, PA, 610-948-7867JVI, Inc., Pittsfield, MA, 413-442-4147Keystone Cement Company, Exton, PA, 610-837-2100 Lafarge North America, Concord, Ontario, 888-523-2743 x 5034Lehigh Cement Company, Glens Falls, NY, 518-792-1137 x 303Meadow Burke, Billerica, MAMixer Systems, Pewaukee, WI, 860-798-7248Northeast Solite Corp., Saugerties, NY, 845-246-2646NPC, Inc., Milford, NH, 800-626-2180A L Patterson, Fallsington, PA, 800-332-7090Plant-Tech Concrete Solutions, LLC, Bladensburg, MDPolylok, Inc/Zabel, Wallingford, CT, 800-765-9565St. Mary’s Cement Company, Cleveland, Ohio, 216-579-1911Sika Corporation, Lyndhurst, NJ, 302-218-4987Spillman Co., Columbus OH, 614-444-2184Splice Sleeve North America, Irvine, CA, 949-861-8393Stelcrete Indust Limited, Niagara Falls, Ontario, Canada,

905-354-5691Stephenson Equipment, Inc., Syracuse, NY, 315-432-0779Superior Precast Consulting, Inc., Ardmore, PA, 610-715-1969Syracuse Casting Sales Co., Cicero, NY, 315-699-2601Tuf-Tite, Inc., Lake Zurich, IL, 847-550-1011PROFESSIONAL MEMBERSAbate Associates Engineers & Surveyors, Buffalo, NY,

716-632-2300Advance Testing, Campbell Hall, NY, 845-496-1600Atlantic Testing Laboratories, Clifton Park, NY, 518-383-9144Barton & Loguidice, PC, Syracuse, NY, 315-457-5200A.S. Bell Engineering, PC, Slingerlands, NY, 518-357-0313Bergmann Associates, Inc., Rochester, NY, 585-232-5135A L Blades & Sons, Inc., Hornell, NY, 607-324-3636C & S Engineers, Inc., Syracuse, NY, 518-455-2000CDM, Syracuse, NY, 315-434-3200

Clough Harbour & Assoc. LLP, Albany, NY, 518-453-3961Collins Engineering Inc., Albany, NY, 518-436-0392Delta Engineers PC, Binghamton, NY, 607-231-6612Dewberry, New York, NY, 212-685-0900Didonato Associates PE,PC, Buffalo, NY, 716-656-1900Earth Tech|AECOM, Latham, NY, 518-951-2200Edwards & Kelcey Engrs. Inc., Saratoga Springs, NY,

518-584-9733Erdman Anthony, Rochester, NY, 585-240-2666Finley Engineering Group, Inc., Tallahassee, FL, 850-894-1600Fisher Associates PE, LS, PC, Rochester, NY, 585-334-1310FRA/T Y Lin International, Henrietta, NY, 585-359-0280Greenman-Pedersen, Inc., Buffalo, NY, 716-633-4844Hunt Engr Arch Surveyors PC, Horseheads, NY, 607-358-1000Keystone Associates, LLC, Binghamton, NY, 607-722-1100LaBella Associates, PC, Rochester, NY, 585-454-6110Lamont Engineers, PC, Cobleskill, NY, 518-234-4028LEAP Associates International, PE, Tampa, FL, 813-988-6870Maser Consulting, West Nyack, NY, 845-727-1160McFarland-Johnson, Inc., Binghamton, NY, 607-723-9421O’Neill Consulting, Spring Lake, NJ, 732-974-0129Popli Consulting Engineers, Penfield, NY, 585-388-2060Ryan-Biggs Assoc., P.C., Troy, NY, 518-272-6266A H Sample, Inc., Ottsville, PA, 610-847-8945R Samsel Engineers, Henrietta, NY, 585-334-5549Shumaker Consulting Engineering & Land Surveying, PC,

Binghamton, NY, 607-798-8081Simpson Gumpertz & Heger, Inc., Waltham, MA, 781-907-9000SJB Services, Inc., Hamburg, NY, 716-649-8110Slocum, DeAngelus & Associates, PC, Latham, NY,

518-763-6000Steuben County DPW, Bath, NY, 607-664-2479Transtech Systems, Schenectady, NY, 518-372-4067TVGA Consultants, Elma, NY, 716-655-8842Watson Engineering, PC, Owego, NY, 607-223-4900Watts Architecture & Engineering, PC, Buffalo, NY, 716-206-1500WSP-Sells, Briarcliff Manor, NY, 914-747-1120Wilbur Smith Associates, Latham, NY, 518-783-1887OFFICERS, DIRECTORS AND STAFFPresident: David Wan, Oldcastle PrecastVice-President: Joseph Amoia, A & R ConcreteSecretary: Mike Weigand, J.P.Carrara & SonsTreasurer: Todd Clarke, Lakelands Concrete ProductsImmediate Past President: Tom Montalbine, Roman Stone

ConstructionAssociate Member Director: Wally Swiger, A-LokProfessional Member Director: Doug Vandeusen, Lamont

EngineersSeptic Tank Group Director: Ed Pennypacker, Jepco SalesNECSA Director: Ric Sullivan, Lehigh Northeast Cement Co.Executive Director: Carl Buchman, PCANY, 585-249-9564

PCANY MeetingsOctober 29

We are planning a Joint PCANY/NYSDOT Materials & Structures meet-ing in the afternoon of October 29 at 50Wolf Road in Albany. And since the jointmeeting concept works well, we’ll alsohold a joint Association/Board Meetingin the morning, at the AGC ConferenceRoom, 10 Airline Drive. We will probablyarrange to teleconference, if anyone sodesires this convenience. Details will beon our website.

Connection Details for PrefabricatedBridge Elements and Systems