Precast Concrete Specialty Infrastructure Projects

This category encompasses structural concrete that would normally be cast in place. Garden State Precast provides engineered solutions to help sites achieve cost and time savings by producing material in a controlled environment. The time of open excavation is reduced along with numerous other site costs that are eliminated. 

Review the example projects listed below:

Solids/Floatables Screening Facility

 

(ACUA) Environmental Park PH I MSE BERM

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Solids/Floatables Screening Facility

Garden State Precast project #: 17-42161

Project Name: W1234 SOLIDS/FLOATABLES SCREENING FACILITY

Location: WEEHAWKEN, NJ

Project start date:  12-22-17

Project end date:  Aug 2018

Synopsys of Development:

Design-build of (2) Precast Netting Facilities, each 16’x16’x42’ id.

Technical challenges and project constraints: 

This project had the following constraints:

  • Designed as cast in place

  • Interconnecting 72” diam. Bypass piping and stop logs

  • Waterfront installation on Hudson River

  • Installation within a flooding cofferdam

  • Live Sewage flow unable to be bypass pumped

  • Small installation pad available

  • High Rise construction adjacent +/- 5’

  • Urban Setting with Heavy Congestion during working hours.

  • Partially designed civic park on top of units

Design, fabrication, and testing activities:

Design

  • 11 piece segmental units

  • Design of lifting and rigging

  • Design provisions for civic park

  • Design for Barge Loading

  • Design for  truck transportation

  • Design of engineered backfill CSM

  • Design of post tensioning

Fabrication

  • Match casting entire 400 ton plus unit all together in GSP yard

  • Unit staging for disassembly

  • Coordination of rigging and spreader use

  • Application of sealing membrane.

Testing

Site Water tightness testing

 
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(ACUA) Environmental Park PH I MSE BERM

Project Name: (ACUA) ENVIRONMENTAL PARK PH I MSE BERM

Location: Egg Harbor, NJ

Project start date:  May 2019

Project end date:  March 2020

Synopsys of Development:

Design, fabrication and deployment of a special drainage channel. The channel is located on top of an MSE containment berm with the Atlantic County Landfill.

Technical challenges and project constraints: 

This project had the following constraints:

  • Channel geometry with curves and changes in elevation

  • Location on top of MSE berm

  • Provisions for future work

Design, fabrication, and testing activities:

  • Purchase of new formwork

  • Development of lifting and rigging plan

  • Thin wall construction to maintain legal shipment load characteristics

  • Plan and Hardware for rolling product 180 degrees after production

Design

  • Traffic Loading

  • Joint Design

  • Layout to match proposed location

  • Design of radius curve sections to avoid large number of unique pieces

Fabrication

  • All units were poured inverted and required 180 rolling after production

  • Curved pieces required special tapers to allow for proper demolding

  • Purchase of curved formwork.