UCP Holiday 2017 Newsletter – Utility Concrete

Please Check out our Special Holiday Newsletter!

Project Highlights

We have recently finished many exciting projects here at UCP. See some of the unique precast concrete solutions we created below!

Northwestern University Wave 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!

Click here to view a video of the Wave Wall

Click here to see additional Innovative Solutions projects

Full-Depth Bridge Approach Slabs

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.

Click here to see additional Accelerated Bridge Construction projects

Substation Roof Planks

Utility Concrete Products recently completed delivery of precast roof planks for an expansion project at the Hegewisch Substation in Chicago. These planks were 40′-0″ long, 4′-0″ wide, and weighed 13,360 pounds each. They were constructed with a 3 1/4″ camber to account for deflection after installation. They were also designed with a superior fire rating to protect critical electrical systems near the building.

Production was accelerated to meet tight schedules, and installation took less than a day, which prevented the contractor from experiencing delays and incurring additional costs, resulting in a successful project for all parties.

Click here to see additional Innovative Solutions projects

Gatz Pond Outfall 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.

Click here to see additional Drainage projects

Moline 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.

Click here to see additional Sound Wall projects

Proud Family Owned Business Since 1970

**From Left: Jamie Hawken, Bill Hawken, Russell Hawken**

Following a background in management and a solid foundation in a variety of industries (including precast), William “Bill” Hawken decided to go into business for himself. Bill discussed the idea with his friends and family and found that he had plenty of support to pursue this new endeavor. Several shareholders joined to serve as the financial backing for Utility Concrete Products, and during the early months of 1970 they poured their first structure. A fire destroyed the original plant in 1973 and threatened the future of the company. As always, Bill found a way to fight through the challenge, and drove Utility Concrete Products to an even higher level of excellence. With a decade of success under his belt, Bill Hawken became sole owner by 1980.

We have come a long way from our initial offerings, and UCP has grown and diversified to include a large variety of precast products. Since our beginnings with telephone and electrical manholes, UCP has grown to include widely diverse product offerings that are unrivaled in our industry, and certainly would have made Bill proud. Russell now holds the title of CEO, and Jamie is the President.
Click here to learn more about UCP’s history

Follow us on Social Media

Interact with us and learn about our recent projects and company news as soon as they are posted!

We are now on Instagram !