PRECAST CONCRETE ASSOCIATION OF NEW YORK, INC. December 2005 Volume 16, No. 11

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Specialty Concrete Products … From A Producer Near Yo u

Concrete precasters offer numerous catalogs of standardproducts. But the versatility of concrete allows them to accommo-date special designs for special situations. For example, there isa diverse array of pre-cast light pole foundations - round bases,square bases, star pedestals and pyramid shaped bases, all in awide array of sizes, to be used in a wide variety of applications.S p e c i f i c a l l y, the pyramid shaped foundation with an attachedfooting was designed to provide added holding power becausesoil and ground water conditions made it impossible to dig deep.

Another example are the star foundations, manufactured withvoids in them to accept a variety of different sweep sizes. T h e s efoundations were designed to provide greater holding power fortheir weight, as the voids tend to hold the compacted backfill overa greater surface area, and the projecting base engages moresoil weight against overturning.

Pyramid bases being unloaded at Hillview Reservoir.

Star shape foundation unit.

A special signal foundation developed by the Long IslandRailroad to enable installation with minimal equipment in lim-ited access sites. Each segment is small and light enough tobe handled and installed by two people. The base has insertsto receive four long anchor bolts. Next are placed the middleinterlocking sections at 90 degrees to each other, followed bythe top “donut”. With it’s unique geometry engaging the sur-rounding soil for stability, the resulting shape forms an easilyinstalled, sturdy foundation for signal lights at crossings.

Signal foundation from concrete ‘legos’.All photos by Roman Stone Construction Co.

Reef Ball Installation - Fish Condos.

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PRECAST CONCRETE ASSOCIATION OF NEW YORK December 2005 MONTHLY NEWSLETTER Page 2

Sound Absorptive Concrete Noise Barriers

Congratulations to The L.C. Whitford Co. Inc., on gainingrecognition under the Precast/Prestressed Concrete InstitutePlant Certification Program. Look for their listing in future PCIpublications as a PCI Certified Plant.

PCI Design Competitions for 2005-2006

Hanson Pipe & Products, Pottstown, PA recently suppliedover 200,000 s.f. of sound absorptive noise barriers to HowardC o u n t y, MD for two highway projects. This very attractive systemfeatured an ‘Ellicott Stone’ finish on the highway side and a dou-ble rake on the backside. The H columns were also precast,while the matching cap detail was cast monolithically with thepanels. All were stained in the field after installation.

The panels offer an NRC of 0.85. This is achieved usingDurisol in the first 3” of concrete cast against the stone form liner,and normal concrete on top of that.

Durisol sound absorptive noise barriers were first installed inCanada in 1977, and today can be found in the U.S. and all overthe world. A post and panel system, the vertical post is anchoredusing poured footings, driven piles or caissons. The panels spanh o r i z o n t a l l y between the posts and rest directly on the footings.Post spacings up to 24 feet can be accommodated, and wallheights over 35 feet have been constructed. Durisol absorptivenoise walls have been installed on highways, rail lines, masstransit lines, industrial and commercial complexes, residentialsubdivisions, electric utility stations, transformer enclosures, rooftop machinery surrounds, and tunnel entrances.

Concrete barriers absorp noise.

Noise Barriers AddBeauty to BQE

As shown in the Dec.‘04 PCANY N e w s l e t t e r, the noise bar-riers installed on the Brooklyn Queens Expressway, prove thatconcrete panels don’t have to be boring. The white stainedpanels shown here feature a green stripe arching across thebridge, and smaller indented arch reveals cast into each piece.Having eight different surface planes on both sides, the panelswere cast vertically with an SCC mix to obtain the near perfectexterior surfaces.

Hanson constructed a dual face rubber mold to produce theattractive architectural panels.

Photos by Hanson Pipe & Products

L. C. Whitford obtains PCI Plant Certification

The Precast/Prestressed Concrete Institute invites schoolsto participate in the Fifth Annual PCI Architectural StudentDesign Competition, which will focus on the design of a Schoolof Architecture and University Museum. In addition, collegegraduates in the Intern Development Program who are not yetlicensed architects may enter this competition. The design proj-ect must be completed and submitted by May 1, 2006.

And once again, the Engineering Student DesignCompetition – The Big Beam Contest – is underway. Each stu-dent team must work with a PCI Producer Member to build aprecast concrete beam. The beams will be tested and prizesawarded for best performance. Applications are due by March15, 2006 and results by June 15, 2006. (PCANY has applicationforms and details)

Situated on Long Island and surrounded by water and recre-ational opportunities, Roman Stone Construction, Bay Shore, NY,is concerned about the environment and the decline of the sur-rounding natural fisheries. Man’s activities and natural disastershave led to a reduction in natural reef systems.

Reef Ball Installation – Fish CondosGrowth in sport fishing, scuba diving and boating has in-

creased the pressures on these systems. The commercialseafood industry is dependent on the ocean to enable larger, yetsustainable harvests. Natural reefs cannot rebuild themselvesfast enough to meet human demands. Long lasting artificial reefsare useful tools for restoring reef systems to a natural and pro-ductive balance – which is why Roman Stone ConstructionCompany joined with The Reef Ball Development Group to sup-ply this unique product for installation in their nearby environs.

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PRECAST CONCRETE ASSOCIATION OF NEW YORK December 2005 MONTHLY NEWSLETTER Page 3

Visit www. p c a n y.org for more information on:• precast concrete products and their application• precast concrete producers with links to their websites• precast concrete association of New York, PCANY

If you would like to receive this newsletter via email instead ofhard copy in the mail, send your request and email address top c a n y @ a o l . c o m .

Not a football play, just the description of a very efficient andeconomical load bearing wall panel system installed on theAdler Warehouse in South Brunswick, NJ.

Oldcastle Precast supplied and installed 171 precast panels,totaling 82,100 sf, to complete the skin of this building. To im-prove energy efficiency and reduce roof insulation, the ownerspecified an R-24 value for the walls. The panels were madewith a 6” insulation core bonded to 3” inner and outer concretelayers. Carbon grid was used as the shear transfer material be-tween the layers.

The 13’-6” wide panels incorporated 9’ x 10’ overhead doorsto provide the owner with his required door spacing; typical pan-els were 10’–0” wide. The very handsome horizontal and verti-cal feature lines were achieved with magnetic strips attached tothe forms. The final finish was field applied masonry paint.

Carbon Grid R-24 3-6-3 13-6 10-0 171( h i k e ? )

R- Value of 24 achieved with 6” core insulation.

Core pieces layout for fit.

Inserting insulation blocks over first pour.

Close-up showing concrete, insulation, strand, and carbon grid.

Wall panels loaded for shipment to Cornell University Housing, Phase III.All photos by Oldcastle Precast

PRECAST CONCRETE ASSOCIATION OF NEW YORK December 2005 MONTHLY NEWSLETTER Page 4

Precast Concrete Association of New York, Inc.2829 East AvenueRochester, NY 14610Tel: 518-895-8352 • Fax: 585-381-0945Email: pcany@aol.com • Web: www.pcany.org

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P A I DPermit No. 76Albany, N.Y.

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Producer Member Companies:AFCO Precast, Middle Island, NYA & R Conc Specialties, New Windsor, NYBayshore Conc Prod, Cape Charles, VABinghamton Precast, Binghamton, NYCarrara & Sons, Middlebury, VTCoastal Pipeline Products, Calverton, NYConcrete Building Supply, Plattsburgh, NYWilliam E. Dailey, Shaftsbury, VTThe Fort Miller Co, Schuylerville, NYHanson Pipe and Products, Pottstown, PAJefferson Concrete, Watertown, NYKistner Conc Products, East Pembroke, NYNewcrete Products, Parsippany, NJ Oldcastle Precast, South Bethlehem, NYRiefler Concrete Products, Hamburg, NYRoman Stone Const Co, Bay Shore, NYRotondo Precast, Avon, CTSchuylkill Products, Cresona, PASunnycrest Inc. Auburn, NYUnistress Corp., Pittsfield, MALC Whitford Co., Wellsville, NYAssociate Member Companies:A-Lok Products, Tullytown, PAAmcrete Products, Newburgh, NYConcrete Sealants, Royersford, PACresset Chemical Co, Weston, OH Dayton Richmond Corp, Collinsville, CTdegussa.Construction Chemicals, Cleveland, OH Eastern States Steel, Upper Saddle Riv, NJ Engineered Wire Products, Upper Sandusky, OH Euclid Chemical Co, Saratoga Springs, NYWR Grace, Old Chatham, NYH & H Hulls, Hudson, NYHelser Industries, Tualatin, OR Henry Company, Houston, TXMeadow Burke, Merrimack, NHMixer Systems, Pewaukee, WI

Northeast Solite Corp., Saugerties, NYO W Hubbell & Sons, New York Mills, NYPolylok, Yalesville, CTPress Seal Gasket Corp, Boxford, MAJepco Sales, Royersford, PAJVI Inc, Pittsfield, MANPC Inc, Milford, NH A L Patterson, Fallsington, PARebar Systems, Cotuit, MASika Corporation, Fairless Hills, PASpillman Company, Columbus, OH Splice Sleeve N A, Bonita Springs, FLStelcrete Industries, Niagara Falls, OntarioStephenson Equipment, East Syracuse, NYSyracuse Castings Sales Corp, Cicero, NYTUF-TITE, Lake Zurich, ILUSF Fabrication, Durham, CTE-Z Set, Haymarket, VASeptic Tank Producer Companies:Burnett Concrete Products, Wolcott, NYButts Concrete Products, Masonville, NYEastern Precast Co, Brookfield, CTGrimm Build Materials, Green Island, NYGuardian Block, Schenectady, NYKeeler Vault, Hudson, NYOneonta Block, Oneonta, NYR Deso, Inc Champlain, NYWoodard’s Concrete Products, Bullville, NYZeiser Wilbert Vault, Elmira, NYProfessional Member Firms:Abate Engineers, Buffalo, NYAdvance Testing, Stockbridge, MABarton & Loguidice, Syracuse, NYBay Saver, Mount Airy, MD A.S. Bell Engineering, Slingerlands, NYBergmann Associates, Rochester, NYA L Blades, Hornell, NY

Clough Harbour & Assoc, Albany, NYCon/Span Bridge Systems, Dayton, OH Delta Engineers, Binghamton, NYDiDonato Associates, Buffalo, NYFinley Engineering Group, Tallahassee, FLFRA Engineering, Henrietta, NYGreenman-Pederson Inc, Albany, NYGreenman-Pederson Inc, Buffalo, NYHunt Engineers & Architects, Corning, NYLaBella Associates PC, Rochester, NYLEAP Associates, Tampa, FLMaser Consulting, West Nyack, NYMcFarland-Johnson, Inc., Binghamton, NYNussbaumer & Clarke, Buffalo, NYO'Neil Consulting, Spring Lake, NJ Popli Consulting Engineers, Penfield, NYQCQA Labs, Schenectady, NYRyan-Biggs Associates, Troy, NYA H Sample Engineers, Ottsville, PAR Samsel Engineers, Henrietta, NYChas H Sells, Briarcliff Manor, NYSimpson Gumpertz & Heger, Waltham, MASpectra Engineering, Latham, NYStromecki Engineers, PC, East Aurora, NYTVGA Consultants, Elma, NYEdward Watts Engrs, Williamsville, NYWilbur Smith Associates, Latham, NYOfficers, Directors and Staff:President: Scott Harrigan, The Fort Miller CoVice-President: Rick Martel, Unistress Corp Secretary: Tom Montalbine, Roman Stone Constr.Treasurer: David Wan, Oldcastle Precast Assoc Dir: Ed Pennypacker, Concrete Sealants Prof Director: Ron Thornton, Delta Engineers Imm Past Pres: Jay Abbey, Binghamton Precast Executive Director: Carl Buchman

BRIDGE DESIGN MANUAL SEMINAR7:30 to 8:30 Registration and refreshments 8:30 to 12:00 morning session with break12:00 to 1:00 Lunch (included) 1:00 to 4:30 afternoon session with breakPrimary Presenters:M r. Reid Castrodale, Ph.D., P.E., Carolina Stalite Company, Salisbury, NCM r. Eric Thornkildsen, P.E., Collins Engineering, East Greenbush, NYM r. Mark Hoover, P.E., Schuylkill Products, Cressona, PAMrs. Rita Seradarian, P.E., PCI NY/New England, Belmont, MA, moderator

Continuing Education Credits7.5 Professional Development Hours (PDH) will be awarded for attendance. Certificates of Completion will be given to all seminarparticipants. Complete information and registration form are inside this newsletter. Seating is limited. Payment or valid purchaseorder m u s t be received in advance. Dates/Places: January 11, 2006 in New York City & January 12, 2006 in A l b a n y.