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

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

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!

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)

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

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.

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

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)

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.

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

Timeline: 2008

Product: Specialty Structures