815-416-1000Projects
Electrical
Drainage
Custom Junction Chambers
As part of the Village of Oak Lawn’s ongoing efforts to address long-standing flooding concerns, a new stormwater detention system is being constructed to manage high-volume storm events and improve overall system performance. This work includes the fabrication and supply of custom precast junction chambers by Utility Concrete Products, designed to accommodate major flow transitions between existing infrastructure and the new system.
UCP produced two custom junction chambers, with the larger of the two measuring 28’ x 14’ and engineered to connect multiple large-diameter storm lines. These units serve as key distribution points, directing flow and managing system capacity within the detention network.
The size and complexity of the pipe penetrations, combined with strict coordination requirements for inverts, rims, and elevations, required fully custom fabrication using Symons panel formwork rather than standard precast forms. The heaviest section of this structure alone weighed approximately 59,550 pounds, with the full assembly weighing upwards of 183,000 pounds.
This type of infrastructure demands careful planning and precise execution at every stage. Projects like this continue to influence how large-scale stormwater systems are designed, coordinated, and constructed in the field.
I-294 Precast Trench Drains
I-294 Precast Trench Drains
Timeline: 2023
Product: Specialty Structures
Faced with a tight schedule, the installing contractor partnered with UCP to develop a precast trench drain in order to accelerate their installation timeline. Our in-house forming team designed and fabricated special formwork to produce the 3,812 lineal feet of trench required for this project. In just a matter of weeks, our production group was able to produce over 255 sections in both 16 foot and 4 foot lengths. The top concrete surface was poured with a textured, non-slip finish which sloped towards the cast-in HDPE channel to facilitate the necessary drainage. The design also incorporated a basic shiplap joint allowing the contractor to slide the sections together with ease and place several hundred linear feet per day.
Have a job that requires cast-in-place trench drain? Give us a call so we can develop a precast trench alternate that meets your project's requirements!
O'Hare Stop Valve Structures
O'Hare Stop Valve Structures
Timeline: 2022
Product: Drainage Structures
Another beautiful day to get out and install some precast! Check out this custom Multi Oil Stop Valve Structure that was just installed at O’Hare. While originally detailed as cast in place our engineering team was able to design a precast alternate structure that was installed in a fraction of the time it would have taken to pour in the field. Give us a shout if you interested in pursuing precast to save time and money on your next project!
Pekin CSO Improvements
Pekin CSO Improvements
Timeline: 2021 Product: Specialty Structures UCP recently produced and delivered a 10'-6''x8'-6''x14'-7'' HS20 Rated Overflow Structure to Pekin, IL. This large custom structure consisted of seven pieces and featured a 60” diameter opening. Effective communication and coordination between the UCP team and the contractor resulted in a smooth install of the precast vault versus a complicated cast in place option.
BNSF Corwith (Lift Station)
BNSF Corwith (Lift Station)
Timeline: 2021
Product: Custom Underground Vaults
Utility Concrete Products was recently chosen to design, fabricate and deliver a precast concrete Lift Station to Chicago, Illinois as part of the BNSF Railway Service Track Expansions.
This massive structure was 14’-6” long x 12’-0” wide and over 22’ tall, weighing just under 215,000 pounds when fully assembled. In order to deliver and install a structure of this size with tight jobsite conditions, it was designed in multiple segments including a base/wall section, two 8’ tall barrels and separate roof slab. Each section was match cast with a shiplap joint between them to ensure a snug, interlocking fit when installed in its final location. Due to the proximity to the tracks, permanent steel sheet pile shoring was constructed around the lift station to handle some of the lateral loads that would otherwise be applied directly to the structure.
Although originally detailed as cast in place the contractor elected to utilize a precast alternate design which reduced the overall footprint and allowed them to install the entire structure in just a few hours. This Lift Station is another great example of how UCP continues to be the leading precast concrete producer in the Midwest, providing both innovative and cost-effective solutions for our customers.
Village of Berkeley Flood Control
Village of Berkeley Flood Control
Timeline: 2018 Product: Specialty Structures UCP continues to succeed at providing precast solutions to cast-in-place designs as demonstrated by our recent completion of a Precast Concrete Pump Station for the Village of Berkeley’s Flood Control Project. This enormous structure was over 20’ long x 17’ wide x 30’ tall and weighed just under 550,000 lbs when fully assembled. In order to ship this to the jobsite in manageable pieces, our engineering team had to come up with a design that allowed us to split the structure both horizontally and vertically utilizing mechanical connections between each section. In total there were three base/wall sections, six barrels, three baffle walls and three roof slabs. To reduce the weights of the base/wall and barrel sections, the three baffle walls were produced as separate sections rather than poured integrally with the structure. Slotted inserts were used in conjunction with galvanized steel angle to secure the baffles in place after the barrel sections had been installed. With pre-planning and coordination between UCP and the contractor, all fifteen sections were delivered and offloaded on the jobsite in under four hours. The use of precast for the pump station allowed for the size of the excavation to be reduced using shoring boxes, which was critical due to the tight site conditions and resulted in a successful project for all parties.
O'Hare Central Deicing Facility
O'Hare Central Deicing Facility
Timeline: 2018
Product: Specialty Structures
Utility Concrete Products recently completed delivery of a Glycol Diversion Structure and (17) Precast Concrete Junction Chambers as part of O’Hare International Airport’s Central Deicing Facility – Paving & Utilities project. The Glycol Diversion Structure weighed over 216,000 lbs and was 14’-4” x 14’-4” x 18’-5” tall when assembled. UCP coordinated with the mechanical contractor on the project and provided integral weir walls in the structure that were required for the installation of a sluice gate.
The (17) Junction Chambers varied in overall size and weight ranging from 11’-0” x 16’-0” x 16’-7” (164,015 lbs) up to 13’-8” x 15’-8” x 22’-8” (233,100 lbs). To assist with the production and delivery of structures, they were designed in multiple segments consisting of a base/wall section, barrels, roof & risers, of which the largest individual base/wall section weighed just under 100,000 lbs. A substantial amount of engineering was required for each junction chamber as they all required an aircraft rated loading design. The majority of the structures had two 90” diameter openings in the walls for large drainage pipes that penetrated the chambers.
By accelerating production with precast, the contractor was able to get the excavations done ahead of time and install multiple structures per day to minimize on-site cost while meeting the tight project schedule.
Essex Sanitary Sewer Extension
Essex Sanitary Sewer Extension
Timeline: 2017
Product: Specialty Structures
Utility Concrete Products recently completed two 16,000 gallon precast septic tanks for the Sanitary Sewer Extension Project in Essex, Illinois. These enormous structures measured 41’-6” x 9’-2” x 8’-0” and weighed 114,000 pounds each. The precast tanks were produced as an alternate option to a fiberglass septic tank design. Precast was a superior option to fiberglass, as UCP’s top-notch production team was able to build these structures as a two-piece system that incorporated a large concrete deadman slab to prevent floating. Typically, the slab is poured separately in the field when a fiberglass tank is used, but precast tanks eliminated that step, and saved the contractor time in the field during installation.
Gatz Pond Outfall Improvements
Gatz Pond Outfall Improvements
Timeline: 2017
Product: Drainage Structures
We recently completed a combined sanitary and storm sewer junction chamber for the Gatz Pond Outfall Improvements in the Village of Lombard. This massive chamber measures 23'-0" x 16'-0" x 17'-0" and weighs 193,000 pounds. It accommodates the intersection of a 48", 60", and 92" pipes in the sewer system.
Precision and timing were key since many of these sewers were active during installation. To account for these facts, UCP worked with the contractor to successfully create a precast solution as an alternate to the original cast-in-place design. The contractor completed installation in only 2.5 hours, minimizing disruptions and impacts to area residents. This chamber now provides easy access for municipal employees and engineers at a critical juncture of the sanitary and storm sewers.
East Side Waste Water Treatment Plant Expansion- Morris, IL
East Side Waste Water Treatment Plant Expansion- Morris, IL
Timeline: 2016
Product: Custom Underground Vaults
UCP provided a precast valve vault as an alternate to cast in place for the East Side Waste Water Treatment Plant Expansion in Morris, IL. Weighing nearly 50,000 pounds, this vault helps control the flow of waste water between the aerators, clarifiers, and digesters during the treatment process. The design uses thrust collar wall sleeves to simplify the installation of the corresponding pipes for the installing contractor.
Morris Long Term Control Project
Morris Long Term Control Project
Timeline: 2016
Product: Custom Underground Vaults
UCP was contracted to design and build a precast concrete alternate to cast in place designed manholes as part of the Morris Long Term Control Project. These structures are designed to be part of a solution to control and reduce water runoff from flowing into nearby rivers and creeks when heavy rains test and overcome the capacities of the drainage systems in place. These custom manholes include a three piece design and utilize a grout ring depression for pipe connections. Coordination and communication between the contractor and UCP allowed for our precast design to include precise locations of exposed rebar and mechanical couplers for wall and column sections to be poured in place in the field.
O'Hare 9C-27C East Package Project
O'Hare 9C-27C East Package Project
Timeline: 2016
Product: Specialty Structures
We were recently challenged to create a precast concrete alternate design for Junction Chambers specified as cast-in-place concrete for the O’Hare 9C-27C East Package Project. Both UCP and the contractor had many factors to consider when putting the design together, which included loading forces, strength, size, weight, assembly, shipping, and the required delivery date. After much discussion, a design was agreed upon, which included UCP building complete structures utilizing multiple pieces, while incorporating both horizontal and vertical construction joints with mechanical connections to allow for large pipe openings, and still maintain a reasonable picking weight, which the contractor required. Yet one more example of great communication, start to finish, between the contractor, engineers, the owner, and the UCP team.
Wescott Park- Northbrook, IL
Wescott Park- Northbrook, IL
Timeline: 2016
Product: Specialty Structures
UCP provided four Junction chambers and (35) backstop foundations for the Wescott Park Stormwater Management project in Northbrook, IL. The design for both the junction chambers and foundations were a precast alternate to what was shown on the contract documents, saving the contractor time during installation. This area has experienced significant flooding in the past, and our structures, along with a precast modular stormwater detention system provided by our partner, StormTrap, will provide relief from flooding for Wescott Park and the surrounding residences.
Rock Island, IL Junction Chambers
Rock Island, IL Junction Chambers
Timeline: 2016
Product: Drainage Structures
UCP recently produced several large junction chambers for a relief sewer project in Rock Island, IL, with the largest being 18'-3"x17'-9"x9'-6". Production included multi-piece structures with the heaviest section weighing in excess of 61,000 lbs. Coordination and communication between the contractor, UCP’s Project Management, and Production teams lead to a successful project. We continue to seek out challenging projects of this nature where UCP’s experience and dedication to providing exceptional product quality solidifies the precast concrete option as a superior one.
O'Hare Airport Northeast Cargo Site Drainage
O'Hare Airport Northeast Cargo Site Drainage
Timeline: 2016
Product: Drainage Structures
Chicago’s O’Hare International Airport is revered as the transportation hub of the United States. The Northeast Cargo project is part of the Chicago Department of Aviation’s ongoing commitment to improving infrastructure and promoting economic growth for the Chicago region. UCP was contracted to supply precast manholes for the drainage portion of this project which included a very aggressive construction schedule. The installing contractor and UCP had a clear line of communication enabling this portion of the project to be completed on time.
BARRIER
BNSF Wide Span Crane (Concrete Barrier)
BNSF Wide Span Crane (Concrete Barrier)
Timeline: 2017
Product: Barrier
UCP provided over two miles of precast concrete barrier for the BNSF Wide Span Crane project in Elwood, IL. A majority of the barrier is painted yellow and contains a sign saying "High Voltage Keep Out". Lining the tracks with concrete barrier was a cost effective way to provide protection from the six, massive high voltage 12.5 kV cranes that were recently constructed to assist with unloading trains at the BNSF railyard. We also provided a large number of manholes and handholes for this project.
Des Plaines River Barrier
Des Plaines River Barrier
Timeline: 2010
Product: Soundwall
UCP produced both an aesthetically appealing and functional soundwall for the city of Des Plaines that was installed along the Canadian National Railroad between Oakton St. and Howard Ave. The city wanted the wall to appeal to nearby residents which is why they chose an Ashlar formliner on the residential side. There was also concern with the noise generated by the passing train traffic so they opted for an absorptive noise wall with a porous cementitious material (Soundsorb) that achieves a NRC (noise reduction coefficient) of 0.9 on the rail side which had a unique fluted formliner finish. As a result, the wall not only looked great, but did an amazing job of absorbing the noise of the train from the houses along the railroad tracks.
RETAINING WALL
Norfolk Southern Chicago Counterfort Retaining Wall
Norfolk Southern Chicago Counterfort Retaining Wall
As part of the Norfolk Southern Chicago Rail Expansion, ELEVATE Infrastructure delivered a highly specialized counterfort retaining wall system engineered to withstand extreme railroad loading within a constrained urban rail corridor.
While counterfort systems have been used successfully on prior rail-adjacent projects, the loading demands at this site exceeded previous applications. To meet these challenges, the team developed a first-of-its-kind base slab configuration, featuring an integrated shear lug connection designed to safely resist the high forces generated by railroad traffic.
The system includes five precast counterfort units and matching base slabs, spanning just under 60 feet, with individual counterfort elements rising 17'-6" tall. Each component was engineered to deliver long-term performance under heavy rail service while remaining constructible within tight right-of-way constraints.
As the precast manufacturing partner, Utility Concrete Products (UCP) supported fabrication and handling of these large structural elements. Installation required exceptional precision: each counterfort unit included pre-assembled reinforcing cages threaded into mechanical couplers cast directly into the precast, creating a challenging but highly effective structural connection.
This project underscores the evolution of ELEVATE’s counterfort retaining wall system, demonstrating its ability to adapt to higher loads and more complex applications while providing reliable, buildable solutions for critical rail infrastructure.
Illinois Tollway I-294 Counterfort
Illinois Tollway I-294 Counterfort
As part of I-294’s southbound reconstruction, performance-based retaining walls were specified to optimize costs and timelines while minimizing public impact. Just south of the Hinsdale Oasis, Elevate Infrastructure’s innovative Precast Counterfort Wall was selected to deliver maximum efficiency at the lowest installed cost.
Designed to reduce excavation and haul-off requirements, the wall utilizes on-site backfill, eliminating the need for costly select granular materials. Despite challenges such as tight radii, utility conflicts, and poor foundation soils, the 1,200-foot-long wall was completed in just eight working days. This accelerated construction timeline not only reduced dewatering efforts but also minimized disruptions to the traveling public.
Working in collaboration with Utility Concrete Products, the Installing Contractor, and the Illinois Tollway, Elevate Infrastructure ensured a seamless execution. The robust 45,000-pound precast units now stand ready to support I-294 traffic for generations.
Big Block Retaining Walls
Big Block Retaining Walls
Timeline: 2023 Product: Retaining Wall It’s easy to brag about 40’ tall retaining walls that hold up bridges and flyovers, but it’s important to remember that retaining walls come in all shapes and sizes! While MSE, Precast Counterfort, and Post & Panel are great solutions for grade separations over 15’ tall; “Big Block” gravity retaining walls are an amazing tool for retaining walls that are shorter in stature. The gravity retaining wall system of choice at Utility Concrete Products is StoneStrong. These blocks are truly massive—the standard measures 8’ wide by 3’ tall, and only weighs 6,000lbs. The real value, though, is in the design of the wall system itself. Because these blocks are so large, the StoneStrong Retaining Wall System can be designed without the use of expensive select granular backfill. This unique feature makes them a great option for navigating right of ways, utilities, and property lines. They can also be employed on taller applications (or heavy loading conditions) by incorporating geogrid or casting a small footing extension in the field. Over the last few months, Utility Concrete Products has engineered, manufactured, and delivered StoneStrong Retaining Wall solutions for the Railroads, Tollway, IDOT, and commercial owners alike. The first picture is from a railroad project in downtown Chicago where StoneStrong was chosen over the traditional railroad retaining wall provider. The second picture is from an IDOT trail project in Southern Illinois. Both projects were installed in record time, and thanks to our great customers, both walls are a shining example of how we provide accelerated retaining wall construction to any job no matter how big or small.
BNSF Mechanically Stabilized Earth Walls
BNSF Mechanically Stabilized Earth Walls
Timeline: 2022
Product: Retaining Wall
Utility Concrete’s ability to engineer, manufacture, and deliver Mechanically Stabilized Earth (MSE) Walls is a cost-effective solution for both private and public projects. While UCP has supplied hundreds of thousands of square feet to public infrastructure projects in Illinois, the photos featured here are from a private development in Berwyn with 900 precast panels for the BNSF Railway. Towering at over 40’, these walls allow for easy access between BNSF’s yarding facilities. UCP’s team of engineers and project managers worked with the Owner to provide a cost-effective solution that included a mix of traditional backfill and lightweight cellular fill to meet the finished grade while navigating the poor subgrade.
Tri State Corridor Value Engineered Retaining Walls
Tri State Corridor Value Engineered Retaining Walls
Timeline: 2022
Product: Retaining Wall
It’s a beautiful day in the neighborhood! UCP is providing around 50,000 sf of precast counterfort walls and close to 5,000 sf of StoneStrong walls to the Tri State Corridor as a value-engineered/time-saving alternative to a large number of cast-in-place soldier pile walls.
Norfolk Southern StoneStrong Wall
Norfolk Southern StoneStrong Wall
Timeline: 2021
Product: Retaining Wall
UCP recently produced (340) Stone Strong blocks for a block retaining wall that was erected in Chicago, IL. This project consisted of an install area close to 5,000 sf, with a wall length of over 300 ft. While Stone Strong is a great option for gravity-wall designs, this wall was designed using innovative Paraweb soil reinforcements. The Paraweb straps allow for Stone Strong to be used on a wider variety of retaining walls including railroad applications! For this job Stone Strong’s Tennessee Foothills formliner was used and the blocks were left unstained.
Tri State Corridor MSE Walls
Tri State Corridor MSE Walls
Timeline: 2021
Product: Retaining Wall
In 2021, UCP’s operations team fabricated over 700,000 square feet of MSE (Mechanically Stabilized Earth) Retaining Wall across multiple IDOT & Illinois Tollway projects. Throughout the peak of the construction season, 50-60 panels were being produced on average each day. The walls this year were prominently featured along the ISTHA I-294 corridor from North of 95th St. to O’Hare Airport. In addition to the standard rectangular MSE panels, these walls showcase UCP’s ability to produce a wide range of configurations from aesthetic pieces, large architectural columns, and even crashworthy panels. We specialize in manufacturing a variety of aesthetic finishes including Random Cut Stone with a 2” relief, horizontal and vertical reveals, and custom municipal logos. These MSE walls are built to last, and with the help of our local contractors, they will revitalize Illinois' roads and bridges with beautiful concrete structures for many years to come.
Precast Counterfort Retaining Wall in Justice, IL
Precast Counterfort Retaining Wall in Justice, IL
Timeline: 2021
Product: Retaining Wall
Our innovative Elevate precast counterfort retaining wall system is being utilized on several jobsites across the Illinois Tollway’s Central Tri-State Project. The Elevate walls are designed to support the future embankment using existing onsite soil eliminating the need for select backfill material. The system includes a precast concrete base and a precast concrete face with integral counterforts. Low strength material is pumped under the base to ensure proper bearing on the foundation soils while high strength grout is utilized at the joints between the base and face. This grout mechanically fastens the sections together along with the use of cast-in bar anchors.
Precast counterfort walls are a great alternative to other retaining wall designs, eliminating the need to drive piles, pour concrete in the field, or employ other construction methods with long lead times and higher installation costs. The overall ease of installation and an accelerated construction schedule exceeds the expectations of both the installing contractor and owner.
UCP’s precast counterfort retaining wall is an approved proprietary retaining wall system under IDOT & ISTHA. Call us to see how we can help lower your installed retaining wall costs!
Union Pacific North Line Precast Counterfort
Union Pacific North Line Precast Counterfort
Timeline: 2018
Product: Retaining Wall
Commuters heavily rely on the popular Union Pacific / North Line, a Metra line running through the Chicago metropolitan area. Metra recently commissioned the reconstruction of this line due to the overall age and associated strenuous use. This reconstruction included a retaining wall by Elevate Infrastructure from Fullerton Avenue to Webster Avenue with the purpose of building up and supporting future railway.
The original engineering plans specified this wall as cast-in-place. Upon learning about Elevate's precast alternative, the general contractor, Kenny/Granite Construction, proposed the precast option to better align with the project’s accelerated schedule. According to Bill Moore of Kenny/Granite, “Once we learned the Elevate wall system did not require special backfill, we could easily see its advantage.”
Elevate’s innovative, patent-pending, precast counterfort system was designed to support the future embankment using backfill onsite. The system includes a precast concrete base and a precast concrete face with integral counterforts. Low strength material is pumped under the base to ensure proper bearing on the foundation soils while high strength grout is utilized at the joints between the base and face with integral counterfort. This grout mechanically fastens the sections together along with the use of cast-in bar anchors. The overall ease of installation surpassed the expectations of both the general contractor and owner.
Elevate offers various sized pieces depending on a project’s criteria. The pieces used for this project were 12’-11” wide and 15’-0” to 18’-4” in height. Special consideration was given to pieces in close proximity to the existing buildings along Fullerton Avenue, where space was limited. Kenny asked if Elevate could provide lighter weight units due to the restricted access. Since our units are easily customizable, we were able to accommodate, by providing smaller width, lighter units. Bill Moore explained, “It was very easy to work with Elevate’s engineering team to customize the wall during the original design as well as during installation when unique situations occurred due to the nature of this site in a highly established urban environment.”
Notre Dame University Retaining Wall
Notre Dame University Retaining Wall
Timeline: 2016
Product: Retaining Wall
A beautiful gravity retaining wall utilizing precast blocks produced by UCP was recently constructed at Notre Dame University as part of a three year project to expand and improve the area around the football stadium. The wall is 6,000 square feet, 23' tall, and 200' long with a custom formliner and added color. The use of precast blocks allowed for a reduction in installation time while providing superior durability, aesthetics, and safety.
Red Gate Bridge Retaining Wall
Red Gate Bridge Retaining Wall
Timeline: 2012
Product: Retaining Wall
The Red Gate Bridge in St. Charles, IL is a new two lane bridge and pedestrian walkway which will cross the Fox River to connect Route 31 and Route 25. Utility Concrete Products, LLC worked with the General Contractor and retaining wall installer, James McHugh Construction, to come up with an engineered solution to provide a new retaining wall system that will stabilize the embankment on the bridge approach. Weekly news on the project can be found at: http://www.redgatebridge.org/news
CTA Purple Line (Retaining Wall)
CTA Purple Line (Retaining Wall)
Timeline: 2011
Product: Retaining Wall
This post and panel retaining wall was installed in Chicago, IL and runs along the CTA Purple Line railroad.
Vulcan Quarry (Stone Strong Systems)
Vulcan Quarry (Stone Strong Systems)
Timeline: 2011
Product: Retaining Wall
Stone Strong gravity wall blocks were selected to retain the earth along a new ramp at the Vulcan quarry in McCook, IL. ECI Concrete was able to deal with the unique engineering requirements required for the application making Stone Strong the perfect fit for this particular project.
SOUND WALL
Multi System Noise Walls
Along McLean Boulevard in South Elgin, IL, three distinct noise abatement wall systems were constructed as part of Illinois Department of Transportation Contract 61J65. For Utility Concrete Products, the work represented a more complex variation of a familiar product line.
Within a single project scope, the team produced panels with both standard reflective finishes and absorptive surfaces—each demanding different forming methods and material considerations within the same production schedule. Select sections also incorporated earth retention panels with an 8-inch structural thickness, doubling the standard profile to accommodate the lateral earth pressures.
Multiple alignments and transitions across the site made it essential to maintain consistent panel geometry and elevation throughout all systems. Careful planning ensured each variation was fabricated and installed to specification without interrupting overall progress.
The project reflects a balanced approach to meeting evolving DOT requirements while maintaining efficiency in production. From reflective walls to absorptive and structural applications, each system was delivered to perform within its specific design conditions.
Elk Grove Security Screen Wall
Elk Grove Security Screen Wall
A major expansion of the Elk Grove Village electrical substation is boosting transmission capacity and enhancing system reliability across the growing northwest suburban business corridor and the Western O’Hare region. This investment supports existing customers and accommodates energy growth driven by the region’s expanding data center demand.
As part of this effort, UCP provided an architectural precast security screen wall along the substation perimeter, enhancing site security while creating a visually appealing presence within the community. The wall features custom precast panels and columns with a brick formliner and a specially developed color blend.
Spanning approximately 500 linear feet, the wall includes special-height panels measuring 10'-4" tall, requiring a fully customized solution. Close collaboration with project partners ensured the panels met both the aesthetic vision and the functional security needs of an active utility facility. Construction sequencing was carefully coordinated to maintain safety, access, and ongoing operations, allowing seamless installation without disrupting substation functionality.
This project highlights our expertise in delivering custom architectural precast solutions on complex, high-profile sites. By combining design flexibility, precise attention to detail, and strong teamwork, we continue to provide durable, visually refined wall systems that meet the evolving needs of utility and infrastructure clients.
IDOT 61H20 Laraway Road NAW
IDOT 61H20 Laraway Road NAW
Will County is currently underway with their five-year transportation improvement program consisting of multiple contracts but most noteworthy are the NAW systems on Laraway and Bell Road. With the Laraway NAW designs being completed earlier this summer the major 8-mile reconstruction is well under way and will help improve the developing community by accommodating future traffic demands while ensuring a safe and efficient traffic flow.
Utility Concrete Products is the leading precast supplier of noise wall products with hundreds of thousands of square feet projected for DOT projects over the next few years. On this project alone we delivered roughly 400 noise wall panels and 200 precast concrete columns with even more sections to be installed next year on Bell road. Not only can we deliver high volumes, we are also exceptionally well at implementing unique aesthetic features as can be seen with the fence stone texture with the multi-stain and anti-graffiti component. The featured photos don’t do the panels justice with how well the overall NAW system blends into the surrounding community so take a look for yourself next time you are heading down Laraway road!
Substation Perimeter Wall & Firewall
Substation Perimeter Wall & Firewall
Timeline: 2023
Product: Soundwall
When power supply companies require security walls that are structurally sound AND aesthetically attractive they turn to Utility Concrete Products. As part of our 53+ year history, we have partnered with Midwest power companies to protect their investments and provide reliable customer service.
Whether it is a firewall to mitigate potential disaster, a perimeter wall to protect sensitive equipment, or a sight screen to avoid a neighborhood eyesore, the team at Utility Concrete Products works to exceed expectations from design through supply.
Recently, we engineered and manufactured a firewall as well as a perimeter wall in downtown Chicago to protect a high profile power supply station. The perimeter wall stretches over 22,000 lineal feet and features a simulated brick aesthetic designed to mimic the surrounding architecture. The unique subsurface of downtown Chicago added an additional layer of complexity, which required a mixture of drilled piers and spread footings in order to avoid existing utilities. UCP’s team continued to be on call during construction as the installation contractor continued to unearth more unknown utilities requiring multiple redesigns.
On a project-level, Utility Concrete Products delivered an aesthetically pleasing and structurally sound security wall. But more importantly, UCP delivered in their promise to provide unmatched service, dedicated support, and a design to fit within budget.
Noise Abatement Walls (Lake Cook Road)
Noise Abatement Walls (Lake Cook Road)
Timeline: 2022 Product: Soundwall Our team has over a decade of experience in the design and supply of noise abatement walls making us the leading supplier in Illinois. That experience affords us the ability to provide unique noise wall solutions for various entities including IDOT, ISTHA, County DOTs, and private developments! Look no further than this custom noise wall system we built this year for the Lake Cook Road reconstruction project in Buffalo Grove, IL. The project required two walls with a total of 143 precast concrete columns and 141 precast concrete panels. What made this one special is the English Drystack formliner used to create the natural stone aesthetic along with a three-color paint system applied by hand in our production facility. Special consideration was given to the wall alignment which required custom columns to accommodate various wall kinks and turns. The use of precast concrete allows for a wide range of aesthetic treatments to provide the appearance the Owner and surrounding community desires all while reducing noise!
Bolingbrook Sound Walls
Bolingbrook Sound Walls
Timeline: 2021
Product: Soundwall
UCP produced a soundwall for two IDOT projects that was recently installed along Weber Rd. in Bolingbrook, IL. This multicolored noisewall, with columns to match, has a 1” Reveal Fence Stone texture finish, with a 4” solider course at the top of the wall. The multi-color paint system was hand painted and chosen to match similar wall systems in the community. These two walls will both look great alongside the recently widened Weber Rd., as well as block the sounds of traffic and add privacy to the nearby residential neighborhoods.
California Substation Security Walls
California Substation Security Walls
Timeline: 2020
Product: Soundwall
UCP has a long history of providing vertical architectural panels for numerous projects ranging from public contracts with ISTHA/IDOT to the private sector as well. We recently provided a security wall for a substation at the intersection of California and Addison in Chicago, IL. The owner envisioned a wall that would complement the brick exterior of the existing building, and the final product fabricated and delivered by UCP did this and more. The red brick texture accompanied by the random stone pattern gives the system a sharp and distinguished look that sets it apart from other wall designs.
IDOT Soundwalls in Bartlett
IDOT Soundwalls in Bartlett
Timeline: 2019
Product: Soundwall
In the first quarter of 2019 Utility Concrete Products completed over 2,000 linear feet of ground mounted noise abatement wall for IDOT Contract 60V57 in Bartlett, IL. This NAW was split into two separate runs and contained a 1.5” random ashlar stone texture with a sand colored stain as specified in the contract documents.
As with any project, this job had its fair share of challenges along the way. A particular stretch had several 90-degree corners and kinks that required custom steel beams to be fabricated. With our extensive history of designing and supplying various types of wall systems this was easily coordinated between our designer and the contractor to ensure an efficient and smooth install.
Special consideration was given to the delivery aspect since electrical overhead lines needed to be switched off temporarily. These outages were only provided for a few days but through daily communication between the installing contractor and our freight team, all the panels within these spans were set in time. With all the necessary components, and an easy to follow installation guide provided by UCP, we truly offer a full comprehensive package for our customers to ensure we exceed their expectations.
IDOT Soundwalls in Moline
IDOT Soundwalls in Moline
Timeline: 2017
Product: Soundwall
The multi-colored Noise Abatement Wall pictured above was part of IDOT’s improvements near Moline, Illinois and was comprised of (28) ground mounted panels and (172) structured mounted panels. The structure mounted panels span between two steel beams that are anchored into the retaining wall below through threaded rods that connect to the base plate of the column. The ground mounted panels are also placed between two steel beams, but they are embedded into cast-in-place piers. A ¾” reveal ashlar stone texture with a 12” wide smooth coping along with a custom multi-color paint system was selected by IDOT to simulate limestone masonry.
Substation Firewall
Substation Firewall
Timeline: 2017 Product: Specialty Structures UCP recently designed and supplied a substation precast firewall system. This wall was designed for a minimum fire rating of two hours and consisted of three precast columns and a total of four firewall panels. Unlike typical firewalls that we’ve produced, the aesthetics of this wall were given consideration and the contractor choose a 1.5” ashlar stone texture for the panels and columns along with a gadget gray paint color. A smaller column design was used, keeping the panel to column connection snug, helping with ease of installation for the contractor.
Substation Security Walls
Substation Security Walls
Timeline: 2016
Product: Soundwall
UCP provided precast concrete columns and panels for a substation security wall in Will County, IL. The formliner on each face of the panels and columns has 1 ½” reveal ashlar stone texture. The precast columns have a 5” smooth concrete cap at the top, while the panels have a 1’-6” coping at the top. These walls not only provide added security for the substation, but are an aesthetically pleasing option for the surrounding community.
Crashworthy Noisewalls on I-90
Crashworthy Noisewalls on I-90
Timeline: 2016
Product: Soundwall
UCP recently supplied Noise Abatement walls for the Roadway and Bridge Reconstruction Project of Interstate 90. The panels were produced with a 1 ½” reveal stone texture on each face and were painted Siberian Haze. What makes this project unique is one of the walls is designed to withstand a TL-4 vehicle impact. The bottom panels have an increased structural thickness to withstand the crash loading while the top panels are standard and designed for wind loading only. We implemented an innovative design that utilized spliced steel columns which helped keep wall costs down for the contractor and owner.
Oswego Noise Abatement Wall
Oswego Noise Abatement Wall
Timeline: 2016
Product: Soundwall
We recently produced precast columns and Noise Abatement Wall panels for an IDOT project along IL 71 in Oswego, IL. The form liner on each face of the panel has a 1” reveal stone texture with a 4” soldier course at the top of the wall, and it has been painted a dark brown color. This wall was installed in a residential area as a means to protect the surrounding homes from the noise of the nearby roadway.
Substation Security Wall Panels
Substation Security Wall Panels
Timeline: 2015 Product: Electrical Products Installation of security fences around the perimeter of bulk power systems has been mandated by the North American Electric Reliability Corporation (NERC) and Federal Energy Regulatory Commission (FERC) nationwide. UCP supplied a protective enclosure for a project consisting of segments that were 8'-0" long by 24'-0" tall and weighed 24,000 lbs. The wall effectively prevents against theft, vandalism, protects sensitive equipment, and ensures employee safety. Additionally, our wall provides a level of mobility and customization not seen with traditional security fences. Our product provided an additional layer of protection by effectively meeting UL 752 Level 8 Bullet Resistant specifications. While this project required a smooth steel form finish, a variety of formliner finishes and stains can be added to one or both faces with ease.
ISTHA Noise Abatement Wall
ISTHA Noise Abatement Wall
Timeline: 2015
Product: Soundwall
We fabricated this precast concrete Noise Abatement Wall on an Illinois Tollway project which is currently installing at the new ramp connecting 290 to the EB Elgin-O'Hare Expressway. What makes this soundwall unique is the use of architectural formliners to create leaf patterns in the surface of the concrete. The leaves are visible on the residential side of the wall and provide an aesthetically appealing and noise reducing solution for the residents directly behind the new ramp.
Accelerated Bridge Construction
Oakbrook Full Depth Bridge Approach Slabs
Oakbrook Full Depth Bridge Approach Slabs
As part of the Illinois State Toll Highway Authority’s I-294 Corridor Bridge Improvements, full-depth precast approach slabs were used to accelerate construction and improve long-term performance at the bridge approaches.
Each of the 10 slabs was built to ISTHA standards, with the heaviest piece exceeding 77,000 pounds. Custom formwork was required to stagger exposed reinforcement in the keyway, which was filled with ultra-high-performance concrete (UHPC) to create a strong, durable connection between slabs. Because of their size and weight, delivery and installation required careful planning. Close coordination with the installing contractor and ISTHA management ensured overweight and over-width transport went smoothly and that each slab arrived ready for efficient placement.
Using precast elements instead of traditional cast-in-place methods reduced on-site work, minimized traffic disruptions, and kept the project on schedule along this busy tollway corridor. Give us a call to see how precast can save time on your next project’s schedule!
Metra UPRR West Line Expansion
Metra UPRR West Line Expansion
As part of Union Pacific and Metra’s expansion project crossing the Fox River, the project engineers designed a precast deck structure to enhance sustainability, accelerate construction, and improve safety. The innovative U-shaped precast deck panels were engineered to dry-fit in the field and mechanically connect to the steel superstructure, effectively retaining ballast and supporting the additional track over the river.
Utility Concrete Products manufactured 67 “mini-segments,” each complete with parapets, drain openings, and sleeves for rail mounts. These units were delivered in a carefully coordinated sequence to ensure a streamlined and efficient construction process.
The success of the project was driven by Utility Concrete Products’ proactive approach and the Installing Contractor’s expertise and dedication. Together the engineers’ vision was brought to life, balancing safety with speed to deliver a cutting-edge railway infrastructure solution.
Tollway Precast Bridge Approach Slabs (2022 ISTHA)
Tollway Precast Bridge Approach Slabs (2022 ISTHA)
Timeline: 2022
Product: Specialty Structures
Check out these full depth precast bridge approach slabs that were just installed on I-294 for reconstruction of the bridge carrying traffic over North Ave & Lake St! Special permitting and handling equipment was required to get these 13’ wide, 80,000lb pieces out to the jobsite.
I-294 Full Depth Precast Approach Slabs
I-294 Full Depth Precast Approach Slabs
Timeline: 2022 Product: Specialty Structures We recently shipped out the first stage of Full Depth Precast Bridge Approach Slabs for the Illinois Tollway’s Central Tri-State Tollway (I-294) project. These slabs average 12’-0" wide, 30’-0" long, and weigh up to 90,000 lbs. After all current project stages are complete in 2023, UCP will have produced and delivered 135 bridge approach slabs!
Precast Bridge Superstructure
Precast Bridge Superstructure
Timeline: 2021
Product: Specialty Structures
UCP produced six precast bridge sections for an equipment and pedestrian bridge in Joliet, IL. These precast bridge sections measured approximately 23’ long x 10’ wide x 0’- 8” thick and weighed nearly 14 tons each. Each bridge section included four steel beams with headed studs welded and braced with nine reinforcements cast into the underside of the precast deck. The exterior sections included weldable plates and brackets for guardrail post installation in the field. This bridge will have the capabilities of providing safe transportation for equipment up to 52 tons for many years to come!
IDOT Accelerated Bridge Reconstruction
IDOT Accelerated Bridge Reconstruction
Timeline: 2018
Product: Specialty Structures
As the nation's infrastructure continues to age, the number of bridges requiring rehabilitation, repair, or total replacement continues to increase. One of the greatest concerns with bridge construction and repair, along with varying types of new construction, is how the project will affect the surrounding community, with safety, quality of life, and economical impacts being major considerations. In densely populated areas, the effects of lane closures or complete shutdown of a bridge can result in a larger economic cost to the area than the project cost itself. This makes way for the increasingly adopted practice of Accelerated Bridge Construction (ABC). ABC is a method of bridge construction that uses innovative planning, design, materials, and construction methods in both a safe and cost-effective way to reduce onsite time that occurs during new builds, bridge replacement, and/or rehabilitation. The use of precast concrete is an integral part of the ABC process, as it allows for the infrastructure components to be cast off-site reducing congestion, impact on motorists, total project delivery time, and improves safety on site.
UCP was chosen to be the precast producer for IDOT’s first accelerated bridge construction project over Gar Creek in Kankakee County, IL. With UCP’s long history in supplying superior precast components for owners, including full and partial depth bridge approach slabs, wingwalls, abutments, and pier caps, we were selected as fabricator for this project. Precast was the clear option over cast-in-place since the installing contractor only had a 72-hour window to completely remove and replace the single-span bridge. Even though this was the first ABC project for IDOT, it was very successful paving the way for more opportunities to utilize this method of bridge construction on future projects.
UCP’s scope of work consisted of producing four precast wingwalls, two pier caps, two approach footings, and eight full-depth bridge approach slabs with integral parapets. The size and length of the pieces and the custom forming required to fabricate these structures were a few of the challenges that our highly skilled operations team overcame. The heaviest piece produced weighed nearly 78,000 lbs and spanned 39’-2”. It was cast with (11) 1’-9” diameter voids on the bottom surface ranging in height from 1’-6” to 2’-0” to fit over field-driven H piles. The voids were filled with high strength grout, allowing the load from the bridge deck to be transferred deep into ground. Strict tolerances were upheld by our top-notch, in-house quality control team to ensure exact dimensions of the precast components to avoid fitup issues.
IL-390 Full Depth Precast Approach Slabs
IL-390 Full Depth Precast Approach Slabs
Timeline: 2017
Product: Specialty Structures
UCP’s scope of work on ISTHA contract I-14-4642 consisted of fabricating and delivering (20) full-depth precast bridge approach slabs. The three interior slabs in each of the four sections consisted of 29’-11” long slabs ranging from 12’-0" to 14’-0" in width. The two exterior slabs had varying lengths from 29’-9” to 30’-1” and reached up to 15’-8” in width. Special consideration was given to the handling of the structures since the heaviest piece weighed nearly 95,000 pounds. Therefore, a total of (8) lifting inserts were used in each slab, along with equal lifting measures to ensure the load was distributed evenly. This was coordinated between UCP and installing contractor to maintain a safe and proper installation.
Although the Illinois Tollway has used full-depth slabs in the past, this job was unique due to the extensive testing performed by the University of Illinois at Urbana-Champaign. Forty-four embedded concrete strain gauges were installed throughout the five slabs at the east approach of the eastbound lanes. The gauges will be used to gather data on the stresses that the precast slabs undergo once fully installed and opened to traffic. This is part of an ongoing effort from the Tollway to eliminate the stress cracks that occur on the top surface of approach slabs from settlement or lateral movements. It took a team effort and several meetings between the Tollway, the student research team from UIUC, the contractor, and UCP to ensure the testing gauges were properly located and installed. We were happy to work together with the Tollway and The University of Illinois to ensure that this essential testing could be performed.
WisDOT Zoo Interchange
WisDOT Zoo Interchange
Timeline: 2016
Product: Specialty Structures
We recently fabricated (66) precast sign columns for use on the WisDOT Zoo Interchange project in Milwaukee, Wisconsin. The original design intent was for these columns to be formed and poured on site, however, the installing contractor opted to value engineer the columns with precast from UCP. The columns range in height from 20'-8 1/2" to 40'-11 1/2" and weighed from 31,160 lbs to 94,260 lbs. A cast-in-place footing is poured with exposed rebar that connects to the precast through the use of splice sleeves which are filled with high strength grout. The splice sleeves are oversized to allow for extra tolerance to aid with ease and speed of installation. The overhead sign structures are secured to the precast through use of anchor bolts cast into the top of the column during the precast production process. The choice to use precast for this application saved the contractor a significant amount of time and money as forming these sign columns onsite is difficult and labor intensive.
Chicago Precast Bridge Approach Slabs
Chicago Precast Bridge Approach Slabs
Timeline: 2016
Product: Specialty Structures
For the reconstruction of the Torrence Avenue Bridge spanning the Grand Calumet River, UCP provided 22 partial depth precast approach slabs. The precast spans from the approach footing to the bridge abutment acting as a land bridge, which combats the issues seen with cast-on-grade applications, including settlement and cracking. A 5" concrete wearing surface is poured in the field, which is tied to the precast through exposed, epoxy coated u-bar cast during the precast process.The purpose of this project was to replace the existing bridge structure, as it was severely deteriorating. The new bridge will enhance safety, improve mobility of traffic, and reduce short/long-term maintenance cost. The use of precast for the approach slabs will decrease settling, providing a smooth transition for the driver from the roadway to the bridge deck.
Blue Island Precast Bridge Pier Cap
Blue Island Precast Bridge Pier Cap
Timeline: 2016
Product: Specialty Structures
We supplied a 48’ long x 1’-8” wide x 3’-9 5/8” tall precast concrete pier cap for the Illinois Department of Transportation. This pier cap was used for a Bridge Rehabilitation Project in Blue Island, IL and was installed as a structural component of the Division St. Bridge over the CAL SAG Channel. The use of precast concrete elements, such as this precast concrete pier cap, for bridge construction projects is a key aspect of the Accelerated Bridge Construction (referred to as ABC), which decreases on site construction time and saves money for the contractor and owner. This is one of the first projects IDOT has used precast concrete for the pier caps for a bridge project.
Precast Concrete Deck Panels
Precast Concrete Deck Panels
Timeline: 2015
Product: Specialty Structures
Reconstruction of the Peoria Street pedestrian bridge spanning I-290/Congress Parkway and adjacent to the rebuilding of the busy circle interchange in downtown Chicago, IL, capitalized on innovative precast concrete Accelerated Bridge Construction (ABC) techniques that allowed for high strength, thinner bridge sections and reduced delays and lane closures. The innovative, 271-linear-feet bridge, completed in the summer of 2015, includes 15,272 square feet of 8-inch precast deck panels that were set transverse to the main longitudinal I-beams in just four working days. The panels were formed with exposed vertical rebar and light pole anchor bolts so the contractor could pour a concrete parapet structurally integral with the deck. "Typically, this would have been a full depth cast-in-place deck," says Tom Heraty, VP of Sales and Engineering for Utility Concrete Products. "Utilizing precast, we were able to pour the slabs at our own pace in a controlled environment without the high cost of jobsite delays. It is also much safer to produce these slabs in a plant versus above the high-traffic I-290 expressway." Producing the precast concrete deck panels in a controlled setting with high strength, 5,000 psi concrete allowed for a thinner section than typical deck panels with less rebar clearance, but with the same or better durability and structural capacity. The precast panels were produced with a raked finish to create a rough pouring surface for the 2¼” overlay. Tapered pockets were formed into the panels allowing rebar to pass through. These pockets and the edges of the panel were treated with retarder to create a porous surface for bonding. The edges were formed with shear keys and exposed rebar to help create a continuous structural connection across joints. Panels were aligned so the pockets were set over vertical headed anchor studs from the top flange of the I-beams below. Rebar extending horizontally out of the edges had to be staggered such that it did not interfere with the overlapping bars from adjacent panels. Panels also included cast-in inserts with leveling bolts for vertical adjustability. Ductal (Lafarge), ultra-high performance concrete, was used to fill the pockets and joints to ultimately create a composite section.
Concrete Bridge Panels
Concrete Bridge Panels
Timeline: 2015
Product: Specialty Structures
UCP recently produced 3 concrete panels for a pedestrian bridge in Joliet, IL. The slabs were 20’6 ½” long, 9’7 ½” wide and 7 3/4" thick. They each had 2 embed steel beams with headed studs cast into the underside to span the void as well as embed angles on each edge along with rail mounts running parallel to the road. We worked closely with the contractor to ensure that the embed components of the panels were placed at the correct locations to ensure a smooth installation in the field.
Willow Road Bridge
Willow Road Bridge
Timeline: 2014
Product: Specialty Structures
Architectural Precast Concrete Panels affixed to the North & South side of the Willow Road Bridge spanning over the Chicago River (North Branch). These architectural precast panels are part of a complete redesign of the bridge in an effort to help beautify the surrounding area. The distinct curvature and required precision of these architectural panels presented new challenges for UCP's production team that we were able to overcome through an innovative forming design. By choosing precast for this application, the customer saved time on the jobsite and received a ready-to-install bridge facing meeting the requirement of IDOT.
Brier Hill Road Precast Approach Slabs
Brier Hill Road Precast Approach Slabs
Timeline: 2013
Product: Specialty Structures
Precast Bridge Approach Slabs being installed at the Brier Hill Road Interchange at I90 in Elgin, Illinois, ISTHA Contract I-13-4129. Precast bridge approach slabs are a new product for the Illinois Tollway. Previously, approach slabs were poured in place, which over time would settle and separate from the bridge deck causing issues for flow of traffic. Utilizing precast bridge approach slabs saves the installing contractor time and accelerates the schedule for bridge reconstructions, provides increased durability and enhances user comfort. Due to the reputation that Utility Concrete Products has, we were selected to be the first precaster to produce precast bridge approach slabs in the state of Illinois.
CTA Purple Line Viaduct (Precast Bridge Abutment)
CTA Purple Line Viaduct (Precast Bridge Abutment)
Timeline: 2011
Product: Specialty Structures
The precast bridge abutment that UCP produced for the Purple Line Viaduct in Chicago was the heaviest precast structure to ever come out of the UCP plant.
INNOVATIVE SOLUTIONS
Engineered Precast Blocks
Rehabilitation of the Chicago Harbor Lock required specialized structural components capable of withstanding extreme hydraulic forces and continuous vessel traffic. As part of this effort for the U.S. Army Corps of Engineers, Utility Concrete Products fabricated critical precast elements for the lock chamber floor system.
The scope included three specialized precast structural blocks designed to function as load-transfer elements within the system. Each unit was coordinated with a micropile foundation network, requiring precise alignment, tight tolerances, and no opportunity for field modification once installed.
Every block incorporated dense embed configurations, including leveling shoe assemblies, grout ports, coil inserts, and custom steel plates. Measuring up to 49 feet in length, the units required exact placement of the embedded components to ensure compatibility with the field-installed micropiles and adjacent structural systems. One block also featured a sloped bottom geometry, adding complexity to both forming and production.
Work of this nature extends beyond standard precast applications, requiring a high level of coordination, fabrication control, and execution discipline. Projects like this illustrate the demands of delivering custom-engineered components in highly constrained and performance-critical environments.
CTA 95th Street Station
CTA 95th Street Station
Timeline: 2018
Product: Specialty Structures
The terminal improvements at the 95th/Dan Ryan Red Line Station are part of CTA’s “Red Ahead" Program, which is a comprehensive plan for maintaining, modernizing, and expanding Chicago’s most-traveled rail line. The program includes three major improvement projects on the Red and Purple Lines between the Linden terminal on the North and the proposed 130th Street terminal on the South. These modifications are part of CTA’s ongoing effort to keep their current infrastructure updated for daily commuters.
The scope of work at the 95th Station was a massive redesign of the South and North terminals, which included a brand new platform system at the South terminal. The details and specifications called out for these items to be precast, and who better to provide these than Utility Concrete Products with our outstanding record of quality platform systems at several existing CTA stations including CTA Washington Wabash and CTA Wilson.
Careful consideration was taken during the fabrication process to ensure that all the connections aligned in the field. Strict dimensional tolerances are nothing new to UCP’s quality control/production team, which was evident when the platforms and trenches were assembled without issue.
Another noticeable difference on this station was the alignment of the track, which had a slight radius when adjacent to the platform. Custom block outs were fabricated for each piece to create tapered edges and achieve this curvature across the panels. A total of (73) trenches and (77) platforms, finished with an architectural sandblast finish, were built to encompass this new area. The length of the pieces running parallel with the track varied from 1’-6” to 10’-6” which was driven by site restrictions including tight installation conditions under the 95th Street bridge.
The project also included (50) moment slab structures which served to extend the bus terminal over the existing retaining walls on both sides of the station. The slabs were 9'-6" long and included a parapet located on the edge overhanging the Dan Ryan Expressway for the installation of safety fencing. With the parapet having a customized shape, and the haunch height varying to follow the sloped surface of the retaining wall, the forming was modified on a day by day basis to make each customized panel. In addition, coordination with the electrical contractor was crucial for the installation of multiple cast-in conduits that terminated into the equipment that was installed on top of the precast platform.
The installation of the moment slabs and platforms was a remarkable success, and the South terminal is now fully open to the public and will serve the surrounding community for decades to come. UCP looks forward to continuing to provide quality precast solutions for the CTA on future projects.
Northwester Ryan Walter Athletic Center
Northwester Ryan Walter Athletic Center
Timeline: 2018
Product: Specialty Structures
A prominent feature of Northwestern’s new Ryan Walter Athletic Facility is a unique Retaining Wall which compliments the Wave Wall featured in our 2017 Holiday Newsletter. Although originally designed as cast-in-place, a tight timeline and the recent success of the Wave Wall drove the contractor to decide that precast was the best solution to getting this wall constructed. While its main purpose is to serve as an earth retention system, the high side of the wall adjacent to the building was designed with a bench shape for students and visitors to sit and relax.
Some of the distinct features of this wall are the curvature in multiple planes and the skate deterrent voids, which were created to prevent individuals from damaging the bench sections. The 366’ long wall consists of 38 segments at approximately 10’ long each. Our Self Consolidating Concrete mix design included Scofield SG "Sand Buff" liquid integral color which was altered to match a sample of existing building limestone. The segments were sandblasted by UCP’s skilled architectural finishing team for a final product that achieved the architect’s desired appearance and matched the adjacent Wave Wall.
The Bench Wall also shares a similar connection to that of the Wave Wall, which consists of both column base connectors and splice sleeves. This unique connection was specifically designed by UCP's engineering team for this project. The column-base connectors are typically used for precast columns, while the splice sleeves are a fairly recent technology coming to the forefront of precast due to Accelerated Bridge Construction. The splice sleeve is a mechanical coupler that is embedded in the precast wall segments and fits over a CIP dowel bar in the field. The sleeve is grouted through PVC ports that extend to the exterior face of the precast wall. Due to our design, the contractor was able to expedite installation by bolting down the wall at the base connectors and continue with the installation instead of using a bracing system and waiting for the grout in the sleeves to set up. Our skilled labor force gave special consideration while securing the connection elements as their locations were extremely critical and required very tight tolerances. As expected, these pieces were set with no issues as precision is a fundamental part of UCP’s quality control plan.
With the opening of the facility dependent on the completion of the Bench Wall, UCP fabricated multiple forms and coordinated with the contractor to accommodate the rapid production schedule. This allowed the contractor to maintain a consistent installation pace and exceed the project's deadlines while remaining under budget. Our constant drive to push the boundaries of what can be achieved through precast continues to grow over time, and is what sets us apart from others.
Northwestern University Ryan Walter Athletic Center
Northwestern University Ryan Walter Athletic Center
Timeline: 2017
Product: Retaining Wall
A new Northwestern University athletic facility built along Lake Michigan’s shoreline has panoramic views over the water but has a fundamental problem with exposure to waves. The solution was a wall designed to structurally withstand the harsh wave impact while mirroring the naturally curved layout of the beach. The wall needed to serve two purposes, stop the powerful wave’s horizontal force from causing damage to the building’s foundation and to provide a shield to pedestrians passing along the front of the building on a multi-use path.
The architect envisioned a wall with distinct curves that replicated the appearance of a wave. To achieve an extensive wall with multiple tapering curves that included integral pigment coloring and an architectural, durable finish, the designers knew that a cast-in-place design would be nearly impossible. Something this unique needed to be built to last while aesthetically pleasing and could only be achieved in a controlled environment with precise forming. The solution was precast! Utility Concrete Products was the precaster of choice given our longstanding history of quality products and service, our top-notch engineering team’s vision and expertise in the field, and our production staff and facility that is second to none.
Consisting of (109) 5'-0" wide segments, the wall was designed to stand at 20' tall and taper at each end where it begins to flatten, similar to a wave. The Self Consolidating Concrete mix design included Scofield SG "Sand Buff" liquid integral color which was altered to match a sample of existing building limestone. The segments were sandblasted by UCP’s skilled architectural finishing team for a final product that achieved the architect’s desired appearance.
Considering the powerful waves crashing against the wall and the freeze-thaw environment of Lake Michigan, designers knew that precise placement of epoxy reinforcement, embedded stainless steel angles, and hot dipped galvanized/epoxy connectors within the high strength concrete would require a precaster that had a long-standing history of top-notch performance.
The precast units sit on top of a cast-in-place knee wall that utilizes both column base connectors and splice sleeves to complete a unique connection developed specifically by UCP’s engineering team for this project. The column-base connectors are typically used for precast columns, while the splice sleeves are a fairly new technology coming to the forefront of precast due to Accelerated Bridge Construction. The splice sleeve is a mechanical coupler that is embedded in the precast wall segments and fits over a CIP dowel bar in the field. The sleeve is grouted through PVC ports that extend from the sleeve to the exterior face of the precast wall. Due to our design, the contractor could bolt down the wall at these shoes and continue with the installation instead of using a bracing system and waiting for the grout in the sleeves to set up in order to expedite installation. The location of the connection elements was extremely critical and required a very tight tolerances. All of the segments showed up to the site and were placed with no fit-up issues, a nod to UCP’s production staff and quality control department.
Getting the wall installed as efficiently and quickly as possible was a top priority for the contractor. The wall's location on the site made it a critical item since building erection couldn't continue until the wave wall was completed due to a tight site and the necessity for crane space.
After considerate design and coordination between all involved parties, and a quick fabrication timeline by UCP, the wave wall was erected on time, and within budget. Construction at the athletic facility continues, and is on pace to finish on time. The architect's choice to use precast to meet their vision and the contractor’s choice to use Utility Concrete Products as the fabricator resulted in success on this difficult, yet rewarding project!
CTA Washington Wabash
CTA Washington Wabash
Timeline: 2017
Product: Specialty Structures
The new CTA Washington/Wabash station includes (168) track level precast platforms, which feature a special architectural, deep sandblast finish. Details such as openings for the canopy columns/fire hydrants/wind barrier posts, locations of stainless steel embed plates, and depressions for ADA tactile strips were incorporated into fabrication through extensive communication between UCP and the general contractor. With the elevated station set in the heart of Chicago’s Loop neighborhood, the tight schedule and jobsite conditions favored precast over forming and pouring concrete in place. Opened to the public in 2017, the new station enhances passenger convenience, improves train speeds, decreases operating costs, and provides ADA accessibility. This is part of CTA’s on-going goal to improve and renovate existing stations in its current system. UCP looks forward to providing many more precast solutions for the ongoing CTA modernization/improvement programs.
Navy Pier Precast Planters
Navy Pier Precast Planters
Timeline: 2017
Product: Specialty Structures
Navy Pier celebrated its 100th birthday in 2016, and has been a centerpiece of the Chicago tourist industry since its inception. This iconic Chicago landmark is host to over three million visitors annually. We at Utility Concrete Products are proud to have been selected to help design, produce, and deliver precast concrete block planters which line the north side of the pier. Two different styles have been incorporated into the project, with one displaying the Navy Pier logo, and the other incorporating the four stars found on the City of Chicago Flag. Navy Pier was originally designed in way which form meets functionality, and it’s evident that this tradition continues with these block planters.
Chicago Riverwalk (Precast Underbridge Tubs)
Chicago Riverwalk (Precast Underbridge Tubs)
Timeline: 2016
Product: Specialty Structures
The third and final phase of the Chicago Riverwalk construction project was recently opened to the public on October 22, 2016. This final phase extended the Riverwalk, located on the South side of the main branch of the Chicago river adjacent to Wacker Drive, from LaSalle Street to Lake Street putting the final leg on a continuous walkway from the heart of downtown to the lakefront.
In order to create a continuous path, the project required a means for pedestrians to pass under the bridges. Originally, the users path would be impeded once they’d reach a bridge at which point they’d have to use stairs to exit, cross the street, and re-access on the other side. The Riverwalk project alleviated this issue by including an underbridge concrete path which spans over submerged piles within the existing river’s right of way.
Utility Concrete Products was brought on to fabricate and supply the main precast structure for these paths, referred to as underbridge tubs. Each underbridge required three precast sections, which resemble a concrete bathtub, to provide the necessary structure to pour cast-in-place (CIP) concrete and create a composite connection to complete the underbridge. The tubs are 10’ wide x 4’ tall and varied in length from 38’ up to 86’-3 ¾” with the heaviest piece being at the LaSalle St. Bridge weighing in at nearly 164,000#. The longest tubs were poured with a precise camber that leveled out once the CIP concrete was poured within. Poured with a High Strength High Performance Concrete (HSHPC) mix, the tubs are designed to withstand the marine elements as they are constantly submerged in the Chicago River.
Each tub is heavily reinforced with large diameter epoxy coated rebar spanning the longitudinal direction, and was cast with either 6’ or 8’ diameter openings in the floor so that they could be installed on similar size piers in the field. In these openings are massive ½” steel embed plates to connect to the piers. Further, a post installed neoprene seal provided a watertight seal between the precast and shafts once installed.
To transport the precast tubs to the jobsite, they were delivered to an auxiliary site along the river and loaded onto specially designed barges with the largest capacity crane in the Chicagoland area. Once loaded onto the barges, the tub sections were welded together and floated up the South Branch of the Chicago River to the jobsite. The barges positioned the tubs over previously drilled piers that they set on prior to being lowered to final elevation by a complex jacking system. Once in place, the tubs were heavily reinforced and infilled with the HSHPC mix, which secured the tubs to the piers below and also created the final walking surface for the users. Each underbridge was ultimately outfitted with a guardrail and a stainless steel canopy system to shield from runoff of the bridge decks above. UCP is grateful to have been a part of such a high profile project for the City of Chicago.
IDOT Pavement Patching
IDOT Pavement Patching
Timeline: 2016
Product: Specialty Structures
We recently produced over 150 precast concrete pavement slabs for an IDOT pavement patching project throughout various locations in Cook and DuPage Counties. Precast pavement slabs help minimize construction related congestion and have a lower overall impact on the motoring public. By utilizing precast, the slabs are produced in a controlled environment and follow strict quality control procedures. This results in a final precast product that is more durable than a traditional cast in place patch. Competitively priced, precast slabs are quickly becoming the preferred choice for pavement repairs.
CTA Wilson Transfer Station
CTA Wilson Transfer Station
Timeline: 2016
Product: Specialty Structures
UCP has produced 67 precast concrete slabs for the CTA Wilson Transfer Station Project in Chicago. The job site photos show the installation of the west platform slabs, and there is an identical platform on the east side which will be installed at the beginning of 2017. There is still work to be done to finish the installation of the platforms, including installing the canopy columns, precast medallions (which UCP will also be providing), tactile strip, windbreak structures, and other items. Once the platform is complete it will be used by the surrounding community quite extensively, as it is located next to Harry S. Truman college and most of the residents in the area rely on public transportation.
We also fabricated 100 precast sound walls and 3 stair sections for this project.The job site photos show the installation of the west sound wall and pictures of the stairs in their final position. The stairs will serve as one of the ways to access the platforms in conjunction with the precast ramp slabs on the south end of the platform which UCP will also be providing. The texture on the street side of the sound wall panels is a formliner sandblast finish to closely match the light sandblast finish on the platforms and stairs. There’s also an east portion of the project which will include precast sound walls and stairs, which will be installed in 2017.
Precast Concrete Pilasters in Elk Grove
Precast Concrete Pilasters in Elk Grove
Timeline: 2015
Product: Specialty Structures
UCP supplied precast concrete aesthetic pilasters for the Illinois Tollway and Elk Grove Village. These pilasters were installed adjacent to the bridge abutments and piers at the I-90 overpass at Arlington Heights Road. These pilasters cover the structural components of the bridge while providing an aesthetically appealing look to the passing motorists.
CTA Shoring Blocks
CTA Shoring Blocks
Timeline: 2015
Product: Specialty Structures
UCP supplied 4x4x4 & 4x4x3 precast concrete blocks for use on the CTA Wilson Station project currently being constructed in Chicago. The precast blocks are a part of a shoring tower system that is used to support the steel framing of both the new and existing track structure. These modular shoring towers act as support columns for the track above as the contractor continues demo to make way for installation of the new steel framing.
CTA Green Line Platforms (Precast Concrete Slabs)
CTA Green Line Platforms (Precast Concrete Slabs)
Timeline: 2014
Product: Specialty Structures
UCP has produced 54 precast concrete slabs for the CTA Green Line Platform in Chicago with the installing contractor F.H. Paschen. The job site photos show the transition from the south to the center platform slabs. This is a brand new platform for the CTA, and while the plans called for cast in place concrete the contractor preferred using precast slabs for ease of installation. There is still work to be done to finish this project including installing the tube enclosure around the center slabs and tactile strip.
I-294 Roadway Replacement (Precast Pavement Slabs)
I-294 Roadway Replacement (Precast Pavement Slabs)
Timeline: 2012
Product: Specialty Structures
In December of 2011, the Illinois Tollway awarded contract RR-11-5637 to replace portions of the pavement on I-294 from Bensenville Bridge to Balmoral Avenue in Cook County. The project required the use of Precast Pavement Slabs in a variety of sizes to fit the specifications of the Illinois Tollway. Due to the high quality and stringent delivery timelines required for the project, Utility Concrete Products, LLC was selected to supply the Precast Slabs. The specially designed slabs were set in place during the nighttime hours resulting in minimal lane closure and reduced traffic concerns. The slabs were installed by R.W. Dunteman of Addison Illinois.
Deerfield Pedestrian Underpass
Deerfield Pedestrian Underpass
Timeline: 2011
Product: Tunnel
Construction of 72 feet of precast concrete tunnel built as a pedestrian underpass below existing Metra railroad tracks on Deerfield Road. The tunnel sections were designed for Cooper E80 rail loading.
Chicago Replacement Roof Slab
Chicago Replacement Roof Slab
Timeline: 2008
Product: Specialty Structures
The ComEd replacement roof slab was placed on top of an existing structure on Wells St. in downtown Chicago. Using precast concrete allowed the job to be completed quickly and efficiently.SEGMENTAL BRIDGES
CTA Red Purple Modernization
CTA Red Purple Modernization
Timeline: 2022
Product: Specialty Structures
The Chicago Transit Authority is currently constructing its largest capital investment project to date, Phase One of their Red & Purple Modernization (RPM) program! The two main components of this first phase are the Red-Purple Bypass (RPB) and the Lawrence to Bryn Mawr Modernization (LBMM).
Completed in two Stages, LBMM construction features a precast segmental bridge superstructure to carry new Red & Purple line tracks. Utility Concrete Products was selected by the project general contractor, Walsh-Fluor Design Build Team, to fabricate and deliver over 1,500 precast segments to the project site. The segments are being erected utilizing span-by-span segmental construction methods which includes a 300ft launching gantry running through the city of Chicago – conveintly named the Windy City Gantry! With over 1,000 segments complete, UCP began segment fabrication at our Morris, IL facility in June of 2020 and just completed shipping all 841 segments required for Stage A.
UCP also fabricated and delivered precast noise barrier panels for the RPB component of the project. These panels feature a unique wave pattern formliner which required a matchcast production process to ensure the pattern flowed correctly across the joints. The noise barrier panels were one of the final touches to the RPB which recently opened to train traffic in fall of 2021.
We are also in production of noise barrier panels for the LBMM portion of the job which will be installed on top of our precast segments and will soon start noise barrier for the North Main Line – over 2,300 pieces total!
Congratulations to the UCP RPM operations team for surpassing all expectations for quality, efficiency, and safety!
Data Centers
Data Center Infrastructure
The rapid expansion of data center infrastructure nationwide is driving demand for reliable, high-performance utility systems. As cloud computing, AI processing, and digital storage needs continue to grow, Utility Concrete Products is supplying critical components that support today’s digital economy.
In a major Illinois development, UCP is providing telecom and medium-voltage precast structures, including large-scale manholes, handholes, and equipment pads that support the site-wide electrical and communications network. Spanning multiple data halls, equipment yards, and phased buildouts, the scope requires exceptional precision and coordination. From complex penetrations to exact duct bank alignments and structural openings, production is aligned with a dense underground network that serves as the backbone of power distribution and data transmission across the campus.
Although many elements may appear standardized, the scale, sequencing, and integration on an active data center site introduce a higher level of complexity. Consistent quality and reliable delivery in this environment are critical to keeping development on schedule.
As data center construction accelerates, UCP continues to support this expanding sector with scalable production, technical expertise, and dependable execution.