2O21 PCI

DESIGN
AWARDS RECOGNIZING DESIGN EXCELLENCE
AND CONSTRUCTION QUALITY WITH PRECAST CONCRETE
 2021
SPECIAL
PCI DESIGN AWARDS

4 Escondido Village Graduate Residences

ALL-PRECAST CONCRETE SOLUTION AWARD
AND MULTI-FAMILY BUILDING COWINNER

6 Juno Winter Park

BUILDING INFORMATION MODELING (BIM) AWARD AND
HARRY H. EDWARDS INDUSTRY ADVANCEMENT AWARD

8 County Administration South – Building 16

SUSTAINABLE DESIGN AWARD

2
2021 PCI DESIGN AWARDS
 SPECIAL
PCI DESIGN AWARDS
JURY
Marvin Hartsfield
PRESIDENT, HARTSFIELD & ASSOCIATES, SPRINGBORO, OHIO
Marvin Hartfield formed Hartsfield & Associates in 2005, where he provides consulting services
to building owners, architectural design and construction professionals, and precast concrete
producers/manufacturers. His firm has consulted on numerous architectural precast concrete
cladding projects throughout the United States.

Prior to opening his own firm, Hartsfield began his career in architectural precast concrete in 1978
as a design engineer for Concrete Technologies Inc. Over the years he worked on hundreds of
projects, moving steadily up the ladder. He was eventually elected president and chief operating
officer of the company.

Hartsfield has been an active member of PCI for more than 40 years. He has a bachelor’s degree
in civil engineering and a master’s degree in civil/structural engineering from the University of
Cincinnati.

ASSOCIATE VICE PRESIDENT, SENIOR PROJECT MANAGER,

Kyle R. Knop
HGA ARCHITECTS AND ENGINEERS, PORT WASHINGTON, WISC.
Specializing in corporate and public work, Kyle Knop is an award-winning, licensed architect and
project manager with more than 20 years of technical and construction experience. Throughout
his career he has worked on a broad range of healthcare, corporate, municipal, commercial, in-
dustrial, and retail projects.

He assists project stakeholders in the visioning of project goals and expectations, and helps build
consensus in finding solutions that best fit client needs and budgets. A collaborative leader, Knop
has demonstrated a successful history in coordinating project design and engineering teams
while actively managing budgets and work plans on $200,000 to $75 million projects.

Knop is a member of the American Institute of Architects. He has a bachelor’s degree from the
University of Wisconsin–Milwaukee and is a LEED-accredited professional.

Bob Konoske
RETIRED VICE PRESIDENT AND GENERAL MANAGER, CORESLAB STRUCTURES LA, PERRIS, CALIF.
Bob Konoske worked for 46 years in the precast concrete industry. He started his industry work
with Rockwin Corporation, where he held many positions and ultimately became vice president
and part owner. Rockwin was acquired by Coreslab Structures in 1995, and Konoske stayed on as
vice president and general manager of Coreslab Structures LA until his retirement.

During his career, he served on many PCI committees. He spent six years on PCI’s Board of Direc-
tors and was chair in 2007. He is also a PCI Fellow.

Konoske has a bachelor’s degree from California State University–Long Beach and a graduate
degree from the University of Southern California. After graduation, he joined the Army National
Guard and served for six years.

2021
 2021
ALL-PRECAST CONCRETE
SOLUTION AWARD
AND MULTI-FAMILY
BUILDING COWINNER
KEY PROJECT ATTRIBUTES
❚ More than 6700 windows
were installed in the precast
concrete plant.
❚ Choosing precast concrete helped
designers cut six months from
the schedule.
❚ Off-site fabrication resulted in
65,000 fewer worker-days on
the jobsite, reducing dust,
pollution, and safety hazards.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Build four campus housing
structures totaling 1,835,000 ft².
❚ The project used more than
14,000 precast concrete panels
produced at three local plants.
❚ All four buildings were
completed in 11 months.
“To complete the project on time,
the entire design and construction
team needed to begin detailed
coordination efforts very early
in the design process.”
— Ted Korth, KSH Architects
4
2021 PCI DESIGN AWARDS
ESCONDIDO VILLAGE
GRADUATE RESIDENCES
PALO ALTO, CALIFORNIA
Stanford University is a world-class institution that requires world-class
housing for its students. But in 2017, the campus was facing a housing shortage
that strongly affected its 9000 graduate students. Only 55% of postgrads were
able to secure on-campus housing, and more than 1000 were living in off-campus
accommodations subsidized by the school. The high cost and rapidly rising rents in
the area were creating financial stress for many students that the university want-
ed to solve.
The solution was to build four graduate housing buildings with 665 two-bed-
room apartments, 517 premium studios, and 292 junior studio apartments. The
structures would increase the university’s on-campus graduate housing rate to ap-
proximately 75%, while also providing computer labs, activity spaces, and laundry
facilities for students.
To meet the owner’s goals, the designers had to align their vision with several
aesthetic and structural requirements. The new buildings had to conform to campus
standards for unit size, dimensions, and layout, and they had to mimic the tradition-
al architecture of the campus. But they also had to use durable, cost-effective, and
easy-to-maintain materials, and be built while school was in session, to accommo-
date the next round of graduate students arriving in 2020. The architect chose pre-
cast concrete to address all of these requirements and worked closely with the pre-
cast concrete producer to accelerate results.
“To complete the project on time, the entire design and construction team need-
ed to begin detailed coordination efforts very early in the design process,” says Ted
Korth, design principal for KSH Architects. His team notes that many complex de-
cisions had to be made early on—“most sooner than a conventional project.”
For example, every penetration through the precast concrete floor system (over
14,000 in total) needed to be sized and located at a very early stage of design so the
precast concrete producer could begin production. All window openings and sizes
as well as detailed profiles for the exterior structural wall system also needed to be
determined very early on. “All of these early decisions enabled manufacturing and
erection of the building to proceed at a very rapid pace, with extremely high quality
control,” Korth says.
PROJECT TEAM:
OWNER: Stanford University, Palo Alto, Calif.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER AND PRECAST CONCRETE SPECIALTY ENGINEER:
Clark Pacific, West Sacramento, Calif.
ARCHITECT: Korth Sunseri Hagey Architects (KSH), San Francisco, Calif.
ENGINEER OF RECORD: John A. Martin & Associates, Los Angeles, Calif.
GENERAL CONTRACTOR: Vance Brown, Palo Alto, Calif.
PROJECT SIZE: 1,835,000 ft²
 Photos: Bernard Andre.

RICH AND VARIED DESIGN

The flexibility of precast concrete also allowed the design-
ers to produce the desired textures, finishes, colors, and
profiles to fit the campus design aesthetic. The precast con-
crete panels reference the original stone buildings on cam-
pus, with design details closely referencing the historical
features of existing campus buildings.
By creating a staggered design that steps down from
ten-story volumes to eight- and six-story sections, the
mass of the project was noticeably reduced and the effect
on neighboring areas was diminished. The first two floors of
each building also feature a horizontal “combed” texture to
add depth and character to the surface of the precast con-
crete panels.
Structurally, the building foundation system consists of worker-days on the jobsite. That reduced the risk of worker
large, continuous concrete spread footings under each injury, lessened the need for parking, and eliminated 65,000
frame. The roof of each residence building consists of a pre- days of dust, pollution, and other hazards on campus, says
cast concrete slab, tapered insulation, and then a built-up Bob Clark of Clark Pacific. “Because we were able to prefab-
roof system. The structural system is a special moment ricate everything off-site, at least 300 [fewer] employees
frame with exterior punched-window wall panels that are had to come onto the site everyday during a busy campus
nearly 2 ft thick and provide a seismic solution. season.”
“Utilizing the precast concrete system for both structure The precast concrete system ultimately provided the uni-
and architecture resulted in a rich and varied design,” says versity with a highly durable long-term facility with reduced
Amanda Borden, associate principal and project architect maintenance needs, and enhanced storm, fire, and seismic
for KSH. resistance. It also enabled designers to cut six months from
Choosing precast concrete also delivered many environ- the schedule, ensuring future graduate students will have a
mental and community benefits. By fabricating all of the safe, comfortable place to live.
elements off-site, the precast concrete producer estimates
they made 136,000 fewer road trips and had 65,000 fewer
2021
 2021
BUILDING INFORMATION
MODELING (BIM)
AWARD AND HARRY H.
EDWARDS INDUSTRY
ADVANCEMENT AWARD
KEY PROJECT ATTRIBUTES
❚ The use of BIM software reduced
errors and accelerated progress.
❚ Subsystems were produced and
installed using laser-guided
technology to enhance
precision.
❚ Rapid erection gave
subcontractors early access
to safely begin work.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Build a seven-story, 268-unit,
multi-family housing project.
❚ The project featured
a total–precast
concrete solution.
❚ The complex opened 11 months
after breaking ground.
“By designing the project virtually
in 3-D software, we answered
questions and instilled confidence
that the customer would get the
building he wanted within the
budget he required.”
— Allen Finfrock, Finfrock
6
2021 PCI DESIGN AWARDS
JUNO WINTER PARK
WINTER PARK, FLORIDA
Juno Winter Park is the place to be if you want to live a life of luxury. The sev-
en-story, 268-unit multi-family housing project offers a variety of spacious studio,
one-, two-, and three-bedroom homes with gourmet kitchens, spa-inspired bath-
rooms, and soaring ceilings. Within the complex, residents also enjoy resort-style
amenities, including a beach-entry swimming pool, a sky deck with panoramic
views, resident clubs, and private fitness studios. And all of this is packaged in a
beautiful, durable, and highly energy-efficient precast concrete package.
“The customer was initially skeptical that a beautiful building could be designed
and built with precast concrete,” says Allen Finfrock, chief executive officer of Fin-
frock, the designer, precast concrete producer, and contractor for the project. The
owner also wanted to lower financial risk on the project while accelerating con-
struction to meet a tight timeline. “Getting the building design right—and within a
specified time frame—was critical to their strategic plan,” Finfrock says.
The design team used building information modeling (BIM) software and Fin-
frock’s proprietary precast concrete products to prove that precast concrete could
deliver the beautiful structure they envisioned, and so much more.
The project team started by creating a virtual plan using BIM. “By designing the
project virtually in 3-D [three-dimensional] software, we answered questions and
instilled confidence that the customer would get the building he wanted within the
budget he required,” Finfrock says.
The team showed the owner how using a precast concrete building system
would allow rapid erection of the structure, giving subcontractors early access to
safely begin their work. Precast concrete also suited the minimal staging area of
the extremely tight jobsite and made it easier to integrate all of the subsystems,
Finfrock says.
As an added benefit, the nearly soundproof nature of precast concrete construc-
tion not only blocks the steady stream of noise from nearby traffic and road con-
struction but also provides a more resilient solution than other material options.
“Resiliency is always a concern for developers in central Florida,” Finfrock says.
BIM-DRIVEN INNOVATION
Once the client was convinced and the project was official, Finfrock’s team created
every precast concrete component using 3-D modeling software, allowing design-
ers to eliminate manufacturing and construction conflicts by integrating the struc-
tural and subsystems into one common model. “Conflicts were noted and solved
in the model by project designers rather than in the field,” he says. This approach
eliminated errors and change orders in the design phase and considerably reduced
PROJECT TEAM:
OWNER: Alliance Residential, Apopka, Fla.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER, ARCHITECT,
AND ENGINEER OF RECORD: Finfrock, Apopka, Fla.
PCI-CERTIFIED ERECTOR: Finfrock Industries, Inc., Apopka, Fla.
PROJECT COST: $47.1 million
PROJECT SIZE: 460,282 ft²
the on-site construction time as well as disruptions to sur-
rounding properties.
The design team coordinated with subtrades so the elec-
trical, plumbing, and heating, ventilation, and air-conditioning
could be manufactured in the plant within Finfrock’s pro-
prietary DualDeck Building System. The designers used 3-D
modeling software to combine design files into one space
for clash detection and to locate all penetration locations
required though the elements. As the structure was mod-
eled, the information was fed into the product manage-
ment software, PieceTracker, to manage and oversee pieces
Photos: Finfrock.
and erection plans.
During production, lasers were used to locate partition
layouts, and the product shipped to the site with lines for
field-installed partitions already indicated on the product.
This sped up construction and reduced on-site labor, Fin-
frock says. Biweekly meetings with all subtrades kept every-
one’s plans aligned.

2021
 2021
SUSTAINABLE
DESIGN AWARD
KEY PROJECT ATTRIBUTES
❚ Integral colored precast concrete
emulates the rich red color of
historic sandstone.
❚ Spray foam insulation applied to
thin shell precast concrete at the
plant enhances energy efficiency.
❚ The project was completed five
months ahead of schedule.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Build a six-story office
building and freestanding
conference center above a
two-level underground
parking structure.
❚ The project features
306 precast concrete panels.
❚ The project was completed
in two years.
“Our team’s challenge was to
design and construct a building
that combined high quality,
durability, and a long life with
minimal maintenance.”
— Deryl Robinson,
Griffin Structures
8
2021 PCI DESIGN AWARDS
COUNTY ADMINISTRATION
SOUTH – BUILDING 16
SANTA ANA, CALIFORNIA
When Orange County decided to build a new building as part of the OC Civic
Center in Santa Ana, Calif., they wanted it to be more than just another office
center. The owner saw the building as an opportunity to enhance the community,
says Deryl Robinson, vice president, senior program and construction manager, for
Griffin Structures. It was the first building Orange County had built in 40 years, and
they wanted it to reflect the elegant local architecture, which was dominated by a
120-year-old historic courthouse clad in natural sandstone.
“Our team’s challenge was to design and construct a building that combined
high quality, durability, and a long life with minimal maintenance,” Robinson says.
From the outset, the primary design objective was to create a beautiful and resil-
ient building that would be efficient and operational for generations to come. The
designers chose precast concrete because they knew it would deliver the desired
durability and timeless appearance that the client was seeking—while staying
within their budget.
The final $162 million design features a six-story office building on top of two
levels of underground parking, with a freestanding 7200 ft² conference center. The
owner originally wanted the feature walls to be made of sandstone to match the
courthouse; however, that wasn’t a cost-effective option, says the project’s archi-
tect, Melody Tang of LPA Design Studios. Instead, the design team elected to con-
struct the feature walls out of colored precast concrete that was designed to ex-
actly match the color of the sandstone while also meeting other project goals.
“The ability to seamlessly blend freestanding architectural precast concrete walls
around the site and ground floor with an efficient, lightweight, thin precast con-
crete shell was critical in achieving the overall design aesthetic,” Tang says.
INSULATED SKIN
The design team reviewed many material samples with the precast concrete fabri-
cator before finding the right match for the project. The final solution features an
integral colored precast concrete to emulate the rich red color of the historic sand-
stone, and thoughtful detailing of mitered corners and full returns of the panels
gives the precast concrete the appearance of natural stone.
PROJECT TEAM:
OWNER: Orange County, Santa Ana, Calif.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER: Willis Construction Co., Inc.,
San Juan Bautista, Calif.
ARCHITECT AND ENGINEER OF RECORD: LPA Design Studios, Irvine, Calif.
GENERAL CONTRACTOR: Swinerton Builders, Santa Ana, Calif.
PROJECT DEVELOPER: Griffin Structures, Inc., Irvine, Calif.
PROJECT COST: $162 million
PROJECT SIZE: 250,000 ft²

“This accomplishment was made possible thanks to
close collaboration between the construction manager, the
precast concrete producer, and the architect,” Tang says.
Weekly meetings throughout the course of construction
ensured that aesthetic goals were met while taking into
consideration the logistical challenges of casting the pan-
els at the plant, transporting them to the site, and install-
ing and aligning them in the field.
To enhance the energy efficiency of the design, spray
foam insulation was applied to the thin-shell precast con-
crete at the plant. Attaching insulation directly to the skin
of the panel minimized heat transfer between the exterior
and interior of the building,” says Jeremy Hart, director of
civic and cultural design for LPA Design Studios. That helped
the building receive a LEED silver rating and reduced its pro-
jected energy use from the baseline standard by 76%. “An
efficient building skin was critical to the ability to achieve
performance goals established by the owner and design
team,” says Hart.
Because the building is built in an active seismic zone, its
lateral resisting system is a buckling-restrained braced
Photos: LPA Inc. and RMA Photography.
frame structure (BRBF), which allows the building to move
as necessary and remain operational after a seismic event.
To accommodate the movement allowed by the BRBF sys-
tem, careful consideration was given to the precast con-
crete panels’ movement joints to ensure they could move
with the frame in an earthquake but not detract from the
overall design aesthetic.
Finally, the use of precast concrete mitigated construc-
tion challenges in the busy urban setting, allowing the
project to be completed five months ahead of schedule.
“We and our client love the fact that we were able to
achieve a natural look and feel in our building’s exterior en-
velope, while still adhering to budget realities,” says Robin-
son. “The client is extremely pleased with the outcome.”
2021
 26 Peabody Plaza
OFFICE BUILDING

28 Penn State Hershey Medical

Center Parking Garage
ALL-PRECAST CONCRETE PARKING STRUCTURE

30 University of Alabama Parking Deck

FAÇADE-ONLY PARKING STRUCTURE

32 Assembly Row Block 6 Parking Garage

HYBRID PARKING STRUCTURE

34 St. George Catholic Church

RELIGIOUS STRUCTURE

36 Nordstrom NYC Flagship

2021 BUILDING
RETAIL BUILDING

38 Smithfield Middle School –

Gymnasium Addition
PCI DESIGN AWARDS SCHOOL BUILDING (K-12)

40 Globe Life Field, Home of the

12 DC Blox Texas Rangers
DATA CENTER STADIUM AND ARENA STRUCTURE

14 FDNY Firehouse Rescue #2 42 Academy Museum of Motion Pictures

GOVERNMENT AND PUBLIC BUILDING THEATER STRUCTURE

16 Texas Health Frisco – New Bed Tower 44 Churchill Downs Colonnade and
HEALTHCARE/MEDICAL BUILDING AND
SUSTAINABLE DESIGN AWARD HONORABLE MENTION Infield Gate
CUSTOM SOLUTION
18 Boston College Recreation Center 60–69 Honorable Mentions
HIGHER EDUCATION/UNIVERSITY BUILDING

20 The Peyton House and Ocean House,

Ponte Vedra Inn & Club
HOTEL/MOTEL BUILDING

22 Clybourn 1200
MULTI-FAMILY BUILDING COWINNER

24 One South First

MIXED-USE BUILDING AND HARRY H. EDWARDS
INDUSTRY ADVANCEMENT AWARD HONORABLE MENTION

10
2021 PCI DESIGN AWARDS
 BUILDING
PCI DESIGN AWARDS
JURY
Timothy Cullen
VICE PRESIDENT, BLUE RIDGE DESIGN , INC., WINCHESTER, VA.
Timothy Cullen is vice president at Blue Ridge Design, where he is responsible for leading the de-
sign of precast concrete structures from inception to completion. Cullen has more than 13 years
of experience in the design, detailing, construction, maintenance, and renovation of precast con-
crete structures. He has worked on the structural design of a wide variety of structures, including
parking structures, bridges, food processing plants, dormitories, data centers, and architectural
cladding for multistory buildings.

Cullen is an active member of PCI, and currently serves on the Joint and Connection Design and
Industry Handbook committees. He attended Lehigh University, where he earned a bachelor of
science degree in civil engineering and a master of science degree in structural engineering.

Monty Overstreet
VICE PRESIDENT AND CO-OWNER, FDG, INC., BRIGHTON, COLO.
Monty Overstreet is vice president and co-owner of FDG, which provides planning and conceptual
design of precast concrete structures, and provides design, detailing and project-management ser-
vices to owners, developers, architects, and precast concrete producers. Overstreet has 30 years of
experience in precast concrete construction and has been a major contributor to some of the larg-
est precast concrete construction projects throughout the United States.

For the past 21 years he’s served in a variety of roles with FDG, and has worked on a several high-pro-
file projects, including the Maricopa County Courthouse in Phoenix, and the Burns & McDonnell
Corporate Campus parking structure in Kansas City. Most recently, he managed the precast con-
crete design for the $1.5 billion PennFIRST Patient Pavilion in Philadelphia, slated to open in 2021.

Overstreet earned a bachelor of science degree in architectural engineering technology from the
University of Southern Mississippi. He has served on several nonprofit boards and has been selected
to the board of trustees for the PCI Foundation starting in 2021.

Cheryl L. Rishcoff
PROJECT ENGINEER, TRC WORLDWIDE ENGINEERING, INC., ALLENTOWN, PA.
Cheryl L. Rishcoff has had a long career in the precast concrete industry. As a consultant and en-
gineer with TRC, she oversees a staff of design engineers in Allentown, as well as in Bangalore and
Mysore, India, to ensure every project is completed correctly, within budget, and on schedule. Her
responsibilities also include periodic visits to jobsites to observe construction, prepare cost esti-
mates, and oversee preparation of design packages. On many projects she is the engineer of re-
cord for the precast concrete elements, signing off on all drawings and calculations.

Rishcoff is a long-time member of PCI, and has served on a number of committees, including the
Professional Members Committee, Building Codes, Parking Structures, and the Fire Committee.
She is currently serving on PCI’s Board of Directors as a professional member director.

Rishcoff has a bachelor’s degree in civil and environmental engineering from Lafayette College,
where she graduated magna cum laude.

2021
 2021
DATA CENTER
KEY PROJECT ATTRIBUTES
❚ The precast concrete shell
provides blast security ratings and
the ability to withstand
150-mph winds.
❚ A light brush blast provided a
paintable surface for bold colors.
❚ Ready-to-erect panels sped
completion.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Build a 31,000-ft² highly secure,
highly resilient data center.
❚ The project included 168 pieces of
precast concrete.
❚ Precast concrete erection was
completed in 31 days.
“With security and reliability
being of the utmost importance,
precast was the clear first choice
for both the building enclosure
and structure.”
— Charles J. O’Brien III,
Pieper O’Brien Herr Architects
12
2021 PCI DESIGN AWARDS
DC BLOX
BIRMINGHAM, ALABAMA
DC Blox’s bold purple accent walls are just a small part of what makes this
precast concrete building special. The 31,000-ft² structure will become the cen-
terpiece for the DC Blox technology and innovation campus, giving employees a
state-of-the-art center to do their work.
The new building includes 18,000 ft² of “white space,” allocated for servers and
other information technology equipment, and another 13,000 ft² of office space,
conference rooms, workstations, and common areas. It features a fully protected
private network and 5 MW of customer capacity—all in a building designed to with-
stand 150-mph winds.
The decision to use precast concrete was central to achieving the project’s many
aesthetic and structural goals. “With security and reliability being of the utmost
importance, precast concrete was the clear first choice for both the building enclo-
sure and structure,” says Charles J. O’Brien III, president of Pieper O’Brien Herr Ar-
chitects.
From the start, the designers knew they wanted to create a building that would
convey a sense of strength and security, while also meeting considerable structural
requirements.
Both goals were accomplished with precast concrete serving as the primary
structure and focal building component. “Satisfying blast-rating and wind-load re-
quirements are inherently right in precast concrete construction’s sweet spot,”
O’Brien says. “The ability to combine the architectural fenestration, the necessary
blast and storm resistance, the insulation, and the fire resistance into a single
manufactured, ready-to-erect wall panel, was a clear demonstration of the effi-
ciency of precast concrete construction in this project.”
READY TO ERECT
On the façade, multiple precast concrete planes were used to create a contempo-
rary welcoming vibe for the flagship data center. Inside the building, the precast
concrete walls and underside of the precast concrete floors and roof were left ex-
posed and highlighted, serving as an integral showpiece for the industrial design
theme.
A custom precast concrete face mixture design was developed for the exterior
precast concrete of the data hall portion of the building, which consisted of two
PROJECT TEAM:
OWNER: DC Blox, Atlanta, Ga.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER: Gate Precast Company, Monroeville, Ala.
PRECAST CONCRETE SPECIALTY ENGINEER: Midwest Structure Engineering, West Allis, Wis.
ARCHITECT: Pieper O’Brien Herr Architects, Alpharetta, Ga.
ENGINEER OF RECORD: LBYD, Birmingham, Ala.
GENERAL CONTRACTOR: Brasfield & Gorrie, Birmingham, Ala.
PCI-CERTIFIED ERECTOR: Precision Stone Setting Company, Hiram, Ga.
PROJECT COST: $10 million
PROJECT SIZE: 31,000 ft²
 Photos: DC Blox.

different abrasive blast depths to achieve the contrast the

client was seeking. On the exterior of the office portion of
the building, the precast concrete producer gave a light
brush blast, which provided an excellent paintable surface
for bold colors.
Using precast concrete was also essential to accommo-
dating the very ambitious project schedule, O’Brien says.
“Having ready-to-erect wall panels delivered right to the
site was invaluable in meeting the deadlines to have the
building in place and able to receive equipment in time.”
The substantial coordination and teamwork that oc-
curred during the design and planning phases of the project
ultimately culminated with the high level of construction
quality and speed of construction to make this project a
success, says Joey Langham, senior project manager for
Gate Precast Company. “The project did a terrific job of
combining structural and architectural precast elements to
meet the needs of the client.”
2021
 2021
GOVERNMENT AND
PUBLIC BUILDING
KEY PROJECT ATTRIBUTES
❚ Precast concrete provides a
fire-resistant structure to run
complex rescue simulations.
❚ Insulated sandwich panels have
an R-value of R-16, which improves
the thermal efficiency of the
building envelope.
❚ Building information modeling
was used to coordinate
trades on the busy jobsite
to meet the tight schedule.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Build a three-story fire rescue
facility in a busy Brooklyn
neighborhood.
❚ The project included 95
precast concrete elements.
❚ Precast concrete erection was
completed over two months.
“Being fire-resistant was critical
in the use for training of the
company that is
utilizing the building.”
— Sean Dixon,
High Concrete Group
14
2021 PCI DESIGN AWARDS
FDNY FIREHOUSE RESCUE #2
BROOKLYN, NEW YORK
The New York City Fire Department (“FDNY”) Rescue Company 2 in Brooklyn,
N.Y., needed a new facility where they could train their elite forces in how to
respond to a variety of crisis conditions. The specialized fire and rescue workers
would use the building to simulate a wide range of emergency conditions, which
often requires creating or using voids in the structure to release heat and smoke
and find means of escape.
This meant designers would have to be extremely thoughtful in how they could
create an adaptable three-story structure within a safe, highly resilient envelope.
The architect conducted an early study of the tools used by emergency workers,
which informed the design from the beginning and helped the architect imagine
the structure as a training tool. Through that analysis, the team determined that a
total–precast concrete solution was the best choice because it provided robust and
durable material that would be ideal to withstand the wear and tear of the training
scenarios.
“In addition, being fire-resistant was critical in the use for training of the compa-
ny that is utilizing the building,” says Sean Dixon, vice president of construction for
High Concrete Group.
The precast concrete producer’s early involvement in the planning process
helped the designers achieve the right mixture proportions and alignment of hol-
low-core, double tees, and single tees for the flooring, which was key to ensuring
the right distance of the stem of the tees throughout the building. It also helped
them align where and how much terracotta could be placed as accent elements to
the precast concrete.
SAFE HAVEN
The three-story building is organized around two large interior voids and enclosed
by precast concrete insulated sandwich wall panels that are strategically punc-
tured by windows and openings. The interior voids and façade openings enable the
rescue teams to practice common urban emergency situations, like high angle bal-
cony rescues and entering a smoke-filled manhole, while boldly highlighting the
building’s function as a crucial piece of civic infrastructure.
“Custom precast concrete panels provided a modern look while achieving en-
hanced durability,” Dixon says. “And with an R-value of R-16, the insulated sandwich
PROJECT TEAM:
OWNER: Fire Department of New York Facilities Management, Long Island City, N.Y.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER: High Concrete Group, Denver, Pa.
ARCHITECT: Studio Gang, New York, N.Y.
ENGINEER OF RECORD: Thorton Tomasetti, Chicago, Ill.
GENERAL CONTRACTOR: ZHL Group, Brooklyn, N.Y.
PCI-CERTIFIED ERECTOR: JEMCO Erectors, Inc., Shamong, N.J.
PROJECT COST: $32 million
PROJECT SIZE: 22,000 ft²
 Photos: High Concrete Group.

wall panels help improve the thermal efficiency of the

building envelope and reduce the overall HVAC [heating,
ventilation, and air-conditioning] system needs.”
A green roof, geothermal system, and solar water-heat-
ing system also reduce energy use, lowering the building’s
carbon footprint.
Once on-site, the biggest challenge was driven by restric-
tions in shipping requirements because of the project’s lo-
cation in a busy Brooklyn neighborhood. “The number of
bridges and limitations due to the size of panels was some-
thing that needed to be considered in the design of the pan-
els,” Dixon says. The site also lacked a staging area and re-
quired that panels be erected from the street. Careful
coordination of panel delivery eased this challenge and
minimized disruption on-site.
The new facility has now become a haven for rescue
workers, providing a structurally safe building that can be
leveraged for highly complex training sessions while also
providing a comfortable and functional workplace, Dixon
says. “With its adaptable spaces, environmental approach,
and civic scale, the new rescue facility is both a neighbor-
hood fixture and important piece of infrastructure, sup-
porting a highly trained corps who safeguard those who call
the city home.”

2021
 2021
HEALTHCARE/
MEDICAL BUILDING AND
SUSTAINABLE DESIGN
AWARD HONORABLE
MENTION
KEY PROJECT ATTRIBUTES
❚ Panels feature three different
colored concrete mixture designs
along with four different finishes.
❚ A “file-to-fabrication” workflow
enabled team members to push
ideas forward and manage
budgetary parameters in
the digital file.
❚ The design-assist process cut 2%
of the precast concrete budget, and
a month from the construction
schedule compared with a
traditional design-bid-build
project.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Create a nature-inspired façade
for this healthcare facility.
❚ The project included 902
precast concrete elements.
❚ Precast concrete installation
began in May 2018 and finished
in October 2018.
“Precast concrete was selected as
the best material to represent the
design narrative at the pedestrian
and building scale, and reinforced
the overall concept.”
— Norm Presello,
Gate Precast Company
16
2021 PCI DESIGN AWARDS
TEXAS HEALTH FRISCO –
NEW BED TOWER
FRISCO, TEXAS
Most people think of hospitals as the place you go when you are sick or in-
jured. But what if these healthcare centers became destinations for wellness,
where the community could go to learn practices that would help them lead health-
ier lives? And if so, what would that structure look like? These were the questions
that inspired the design of Texas Health Frisco’s New Bed Tower in Frisco, Tex.
The owners wanted to create a center that could act as a “health facilitator” for
the community, providing better outcomes by connecting healthcare staff, fami-
lies, patients, and the model of care to the surrounding natural environment. That
vision was part of every decision made in the design of the new eight-story hospi-
tal, four-story medical building, and attached parking structure—including the use
of precast concrete to bring it to life.
“With respect to degree of difficulty, this project certainly ranks as one of the top
ten most challenging for Gate Precast Texas,” says Norm Presello, senior project
manager for Gate Precast Company.
The City’s planning and development guidelines required an exterior natural ma-
sonry material for the project, and several systems were considered, including
brick, natural cut stone, ceramic panels and, precast concrete.
The designers thought precast concrete was the best choice; however, building
officials had concerns that a precast concrete design would be perceived as a
cheap-looking material. To convince them, the designers had detailed mock-up
samples created to show how the natural concept and biophilia aesthetic could be
manifested in the surface treatments, aggregates, mixture coloring, and patterns
of the precast concrete.
After demonstrating how precast concrete could deliver the sophisticated look
and feel that the city was requesting, along with considerable time and cost sav-
ings, precast concrete was accepted for the project.
CUES FROM NATURE
The designers wanted the façade to feature natural patterns of biophilic design.
The exterior skin of the building played a crucial role in telling that overall story,
says Presello. “Precast concrete was selected as the best material to represent the
design narrative at the pedestrian and building scale, and reinforced the overall
concept.”
PROJECT TEAM:
OWNER: Texas Health Resources, Arlington, Tex.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER: Gate Precast Company, Hillsboro, Tex.
PRECAST CONCRETE SPECIALTY ENGINEER: Stehler Structural Engineering, St. Paul, Minn.
ARCHITECT: HKS, Northville, Mich.
ENGINEER OF RECORD: Thornton Tomasetti, Dallas, Tex.
GENERAL CONTRACTOR: Austin Commercial, Dallas, Tex.
PCI-CERTIFIED ERECTOR: SnS Erectors, Arlington, Tex.
PROJECT COST: $168 million
PROJECT SIZE: 450,000 ft²
 The design idea is expressed as a “rugged landscape”
reminiscent of a dry and eroded riverbed carved into the
site. Using a set of design parameters, the precast concrete
producer’s integrated design and prefabrication team cre-
ated a façade pattern that mimics striated rock with tex-
tured surfaces, grooved cells, and vertical fins.
The use of digital design tools increased communication
and transparency between the teams, enabling an iterative
design process that pushed the design concept beyond its
perceived limits. It also ensured the final designs were with-
in operational, quality, and budget parameters, and elimi-
nated any risk of rework, Presello says. “It resulted in great-
er aesthetic control for the design team, more efficient
production by the plant fabrication team, and ease of in-
stallation for the construction erector team.”
The final panels feature three different colored concrete
mixture designs along with four different finishes, provided
in a three-tiered undulating surface pattern. The 9-in. pre-
cast concrete wall sections include 2 in. of closed foam in-
sulation, allowing the precast concrete to perform as a
mass wall system to better control heat gain in the hot
summer climate. “The design pattern combined with the
Photos: Daryl Shields, HKS Inc. and Gate Precast Company.
sandwich panel edge-to-edge insulated features gives us all
a great sense of satisfaction and pride,” Presello says.
A post-project review found that the design-assist pro-
cess with the precast concrete producer saved the project
2% on the precast concrete budget and cut a month from
the construction schedule compared with a traditional de-
sign-bid-build project.
Presello believes these types of innovative design tools
will help precast concrete producers achieve new levels of
creative expression in computer numerical control fabrica-
tion techniques going forward. “We can always count on
HKS to push the limits of excellence and looked forward to
the collaboration and challenge on this project.”
2021
 2021
HIGHER EDUCATION/
UNIVERSITY BUILDING
KEY PROJECT ATTRIBUTES
❚ Long-span precast concrete frame
types used pretensioning, hard-bar
post-tensioning, and unbonded
strand post-tensioning supple-
mented by conventional mild-steel
reinforcement.
❚ The aquatics center features
custom precast concrete bents
spanning 110 ft across and spaced
at 22 ft 4 in. on center.
❚ Critical erection procedures,
shoring, and bracing were required
to stabilize the foundation and
structure during construction.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Build a 245,000-ft² recreation
center featuring a pool, courts,
studios, and other active spaces.
❚ The project included 301 precast
concrete elements.
❚ Precast concrete erection was
completed in five months.
“The structure had to span long
distances over a swimming pool
and basketball court while still
providing adequate support to
control the vibration from human
foot traffic and activities
within the building.”
— Todd Haley,
Unistress Corporation
18
2021 PCI DESIGN AWARDS
BOSTON COLLEGE
RECREATION CENTER
CHESTNUT HILL, MASSACHUSETTS
Boston College’s new precast concrete recreation center is helping to redefine
the academic institution’s culture of fitness and recreation. The 245,000-ft²
facility houses a fitness center, rock-climbing wall, jogging track, aquatics center,
sport courts, yoga studios, and more. It will provide students with a one-stop des-
tination for all of their fitness needs.
To create the space, designers needed a material that could support vast, open
recreation areas on multiple floors and withstand the constant drum of running
feet, dribbling balls, and other high-intensity sports. Precast concrete was the ob-
vious choice.
“The structure had to span long distances over a swimming pool and basketball
court while still providing adequate support to control the vibration from human
foot traffic and activities within the building,” explains Todd Haley, associate proj-
ect manager for Unistress Corporation. “The additional benefit of precast concrete
on this project was the ability to satisfy all of the structural requirements for the
recreation center while still providing a product that allowed us to achieve the aes-
thetic needs of such a high-profile complex.”
UNCRACKED CONCRETE
The structure includes two long-span precast concrete frame types that deliver a
unique combination of pretensioning, hard-bar post-tensioning, and unbonded
strand post-tensioning. It is supplemented by conventional mild-steel reinforce-
ment to deliver a column-free space. In addition to gravity loads, the frames pro-
vide lateral force-resisting systems to satisfy seismic performance criteria.
The large-span frames each feature five precast concrete components to meet
the functional and aesthetic requirements. To ensure the highest level of control,
the project was accomplished with a staged construction analysis, where each
stage required consideration of prestressing and shoring to avoid cracks in the con-
crete and to support subsequent construction stages.
Restrictions on structural depth with long clear spans were constrained by the
need to design for stiffness “tuned” the structure’s vibration response. To maintain
a comfortable environment for all, the precast concrete framing could not be al-
lowed to crack, and the joints had to be designed to remain in compression under
all potential loading. At any stage, if compression limit criteria could not be met,
PROJECT TEAM:
OWNER: Boston College, Chestnut Hill, Mass.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER: Unistress Corporation, Pittsfield, Mass.
PRECAST CONCRETE SPECIALTY ENGINEER: Blue Ridge Design, Inc., Winchester, Va.
ARCHITECT AND ENGINEER OF RECORD: CannonDesign, Boston, Mass.
GENERAL CONTRACTOR: Skanska USA Building, Boston, Mass.
PCI-CERTIFIED ERECTOR: Prime Steel Erecting, Inc., North Billerica, Mass.
PROJECT COST: $127.4 million
PROJECT SIZE: 245,000 ft²

the design required adjustment of member dimensions or
anchorage configurations and the analysis was repeated.
“This unique situation resulted in pre- and post-tension-
ing not typically seen in a precast product and a complex
reinforcement design that had to fit in a relatively small
footprint of the precast columns and bents,” Haley says.
The decision to use precast concrete also aided in con-
struction through the winter months, explains Scott Long
of Prime Steel Erection. “Forming, pouring, and win-
ter-heating for cast-in-place construction versus precast
erection would have had negative impacts on schedule and
appearance.”
Photos:
Cannon Design,
Anton Grassl
Photography, and
Unistress Corporation.
To ensure successful erection, designers worked with the
erection crew to review plans for bracing and stability, as
well as the sequencing of all grouted and welded connec-
tions. Large shoring towers were put in place to support
bents and the double-tee roof while welding and post-ten-
sioning of members were completed. The towers were not
removed until the concrete topping slab was installed on
top of the double-tee framing.
“It was a very challenging project where we had to think
outside the box,” Long says. “But the final product came
out great, which is very rewarding.”
2021
 2021
HOTEL/MOTEL
BUILDING
KEY PROJECT ATTRIBUTES
❚ The choice of precast concrete
saved the owner $700,000 and the
project was completed four
months early.
❚ The precast concrete system can
withstand storm surges, high
winds, and salty sea air.
❚ Use of precast concrete allowed
thinner walls and floors systems,
maximizing ocean frontage.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Build two three-story structures
with 41 beachfront guest rooms
and suites.
❚ The project included 43,713 ft² of
hollow-core and solid slabs and
72,434 ft² of spandrels and
wall panels.
❚ Total–precast concrete erection
was completed in just nine weeks.
“Precast concrete
gave us a material that would
provide superior acoustical,
thermal, moisture, and
fire-protection benefits.”
— Michael Ramsey,
Architectural Design
& Planning Group
20
2021 PCI DESIGN AWARDS
THE PEYTON HOUSE AND
OCEAN HOUSE, PONTE VEDRA
INN & CLUB
PONTE VEDRA BEACH, FLORIDA
The Ponte Vedra Inn & Club has been a landmark destination on Ponte Vedra
Beach for nearly 100 years. But the owners wanted to update the setting with a
modern-day addition to the AAA Five Diamond–rated resort.
The plan was to add two new three-story structures with 41 beachfront guest
rooms and suites, each of which would have a sweeping view of the ocean. The
owners wanted a façade that matched the resort’s historic brick, as community
expectations and acceptance of the finished product were critical to the project’s
success.
The challenge: the designers had to complete both structures before the next
tourist season, while keeping nearby facilities operational throughout construction.
Those demands caused the architect to replace their original plan to use a com-
bination of cast-in-place, concrete masonry, brick, and precast concrete with an
all–precast concrete solution. “Precast concrete was the only material that ad-
dressed all of the challenges of this project,” says Michael Ramsey, president of
Architectural Design & Planning Group.
Along with helping to meet the aggressive schedule, using precast concrete
made it easier to erect the buildings on the constricted beachfront site, which had
limited access for materials and labor. And it provided a resilient structure that
exceeded all wind-load requirements and could withstand the salt, humidity,
storm surges, and high winds that buffet these oceanside properties.
“Precast concrete gave us a material that would provide superior acoustical,
thermal, moisture, and fire-protection benefits,” Ramsey says. “And it allowed for
precision construction in a very challenging and competitive construction labor
market.”
NINE WEEKS VERSUS ONE YEAR
Construction of the buildings began in January 2019, and erection went quickly.
Precast concrete work on the north building was completed in five weeks and on
the south building in six weeks. By overlapping the two projects, the entire precast
concrete erection time took nine weeks total, compared with the estimated
PROJECT TEAM:
OWNER: Ponte Vedra Inn & Club, Ponte Vedra, Fla.
PCI-CERTIFIED PRECAST CONCRETE PRODUCERS: Gate Precast Company, Jacksonville, Fla.,
and Gate Precast Company, Kissimmee, Fla.
ARCHITECT: Architectural Design & Planning Group, Raleigh, N.C.
ENGINEER OF RECORD: ONM&J Structural Engineers, Ponte Vedra, Fla.
PRECAST CONCRETE SPECIALTY ENGINEER: LEAP Associates International, Temple Terrace, Fla.
GENERAL CONTRACTOR: Danis, Jacksonville, Fla.
PCI-CERTIFIED ERECTOR: Specialty Concrete Services, Inc., Umatilla, Fla.
PROJECT SIZE: 49,247 ft²
Photos: Gate Precast Company.
12 months that would have been required for traditional
masonry construction. “These compressed construction
schedules allowed earlier access for follow-along trades,
and ultimately earlier owner occupancy,” says Tom New-
ton, vice president of operations for Gate Precast Company.
There were challenges along the way, but the precast con-
crete producer proved the material’s resilience through an
innovative, collaborate approach to the design. That includ-
ed matching the new precast concrete buildings with the
brick on the existing cast-in-place structures in the complex,
while simultaneously reducing cost and erection times.
Ramsey admits that originally he didn’t think precast
concrete was a viable solution due to the complex layout
and the owners’ desire for a brick exterior matching the rest
of the resort. But he was wrong, he says. “Precast concrete
proved to be the perfect material and satisfied all of the
design criteria without significant compromise in our aes-
thetic intent.”
“Total–precast concrete is a viable and potentially
cost-saving option for any large residential project,” New-
ton adds. “Total–precast concrete construction reduces the
overall construction duration, resulting in earlier owner oc-
cupancy, and dramatically reduces the number of on-site
trades and personnel.”
2021
 2021
MULTI-FAMILY
BUILDING COWINNER
KEY PROJECT ATTRIBUTES
❚ The decision to build an entirely
precast concrete solution resulted
in vibrant revitalization on a
restricted budget.
❚ The project earned two Green
Globe awards for exemplary
sustainable design.
❚ Using a single precast concrete
system and provider for the
structure and enclosure led to
cost and time savings.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Build a cost-efficient, mixed-use,
seven-story building on Chicago’s
Near North Side.
❚ The project included 1600 precast
concrete pieces.
❚ Erection was completed
in 16 weeks.
“As part of the adaptation,
ownership expressed an interest in
using the material honestly
and not disguising it.”
— Michael Henning,
Pappageorge Haymes Partners
22
2021 PCI DESIGN AWARDS
CLYBOURN 1200
CHICAGO, ILLINOIS
Chicago’s Near North Side was once home to Cabrini Green, a vast housing
project that was notorious for violence and neglect. In 2000, the Chicago
Housing Authority began demolishing those towers and replacing them with more
modern, durable, and family-friendly homes.
The latest addition to this transformation is Clybourn 1200, a 157,000-ft² mixed-
use, mixed-income redevelopment project that leverages precast concrete to pro-
vide a resilient, sustainable living and working space for the entire community.
The project includes a combination of retail, parking, and residential options
within a tight triangular site located in a busy section of the city. The building exte-
rior material also had to be cost-effective, durable, and low-maintenance.
The designers had originally considered a brick and metal design, but precast
concrete quickly emerged as the better choice. “The use of precast concrete start-
ed as a cost-savings strategy,” says Michael Henning, associate with Pappageorge
Haymes Partners.
Once the decision was made to use precast concrete, his team reimagined the
original design. “As part of the adaptation, ownership expressed an interest in us-
ing the material honestly and not disguising it,” Henning says. That led to the evo-
lution of the aesthetic.
LIKE AN OPEN BOOK
The new design uses precast concrete to create a book-shaped massing for the
seven-story building featuring an acute angle to fit the nontraditional infill site.
The “spine” of the book, which is located at the narrowest point on the lot, includes
full-height glazing with a steel and glass canopy providing a backdrop.
The exterior panels and columns use different planes of relief with features that
are either light acid-washed or sandblasted and, with the exception of selected
accent areas that are stained dark, the surface is untreated. Window units punctu-
ated with bright contrasting color and alternating orientation from floor to floor
play up movement in the elevation and reduce the building mass. The glassy, open
base, accented by contrasting colored precast concrete piers and banding accents,
provides an active and engaging street presence.
PROJECT TEAM:
OWNER: Brinshore Development, Northbrook, Ill., and
the Michaels Organization, Chicago, Ill.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER: ATMI Precast, Aurora, Ill.
PRECAST CONCRETE SPECIALTY ENGINEER: Precast Engineering Company, Brookfield, Wis.
ARCHITECT: Pappageorge Haymes Partners, Chicago, Ill.
ENGINEER OF RECORD: Matrix Engineering Corporation, Chicago, Ill.
GENERAL CONTRACTOR: McShane Construction Company, Rosemont, Ill.
PROJECT COST: $35 million
PROJECT SIZE: 157,000 ft²
 Henning’s team chose a single precast concrete system
and provider for the structure and enclosure to achieve cost
and time efficiencies with a durable and attractive solution.
They gained many benefits by combining structural and ar-
chitectural elements, adds Mike Walsh of ATMI. “We were
able to fabricate architectural components that act as the
exterior load-bearing frame for the building.”
Because the building footprint is pushed to the lot lines
along two sides, the project team faced significant staging
and erection constraints, and they had to come up with an
innovative access system for parking. To accommodate ac-
cess to the parking structure, the precast concrete produc-
er designed a precast concrete ramping system that ex-
tends beyond the footprint, allowing the architect to
maintain the parking stall count. Photos: Pappageorge Haymes Partners.
To minimize traffic disruption during construction, they
positioned a single large crane inside the V-shaped site to
set the entire building. “On-site, the simultaneous assem-
bly of structure and enclosure kept costs down with a tight,
controlled schedule,” Henning says.
“It does not look like a precast concrete structure at the
first glance,” Walsh adds. “The colors are very vibrant and
accented with depth of structure, and you have to look hard
to see the subtle differences.”
2021
 2021
MIXED-USE BUILDING
AND HARRY H. EDWARDS
INDUSTRY ADVANCEMENT
AWARD HONORABLE
MENTION
KEY PROJECT ATTRIBUTES
❚ Use of 3-D printed molds and
Revit software expedited
panel production.
❚ Nearly 2500 windows were
installed at the precast concrete
plant, cutting eight months from
the schedule.
❚ The molds could support
more than 200 pours
without reconditioning.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Create a façade with maximum
waterfront views for a 42-story
residential building and 22-story
commercial tower.
❚ The project included 1593 precast
concrete panels.
❚ Erection occurred from August
2018 through February 2020.
“It offers a unique opportunity to
prioritize energy efficiency through
the complementary energy
profiles of different uses.”
— Steve Schweitzer,
Gate Precast Company
24
2021 PCI DESIGN AWARDS
ONE SOUTH FIRST
BROOKLYN, NEW YORK
One South First in Brooklyn, N.Y., is a new mixed-use building that promises
to redefine waterfront living. Overlooking the East River, the 42-story residential
tower and 22-story commercial tower have transformed the property, which was
once home to an old sugar factory. The new owners saw the potential for luxury liv-
ing on the site, and they wanted a façade that would maximize the waterfront views.
The architect envisioned a contemporary façade that was inspired by sugar’s
crystalline structure as a way to connect the new building with the industrial histo-
ry of the site.
“That brought us to the idea of dealing with sugar,” says Pam Campbell, partner
at CookFox and designer of the project. “We were interested in creating a façade
that would really be animated, but reminiscent of the reflection and form of sugar
crystals.”
They used precast concrete to bring that idea to life.
The precast concrete façade features repetition of angled white precast concrete
using interlocking panels with deep facets to create a play of light and shadow that
animates the rigorous forms. Designed to self-shade, each elevation is formed to
respond to its specific solar orientation and optimized to reduce energy use for
cooling. “It offers a unique opportunity to prioritize energy efficiency through the
complementary energy profiles of different uses,” says Steve Schweitzer, vice pres-
ident of operations for Gate Precast Company.
The window openings were deep-set and the sides were faceted back at different
angles to catch the light and show the sparkle of the glitter sand used in the
acid-etched white concrete. The front faces of the panels were polished to give a
smooth, reflective surface to complement the acid-washed surface. The layout of
the molds in the panel were varied throughout the building to give an appearance
of randomness.
TWO HUNDRED POURS PER MOLD
Along with helping designers achieve their aesthetic goals, using precast concrete
for this façade delivered considerable time and cost savings.
To create the façade, the precast concrete producer used three-dimensional (3-D)
printed molds in a process known as additive manufacturing. The 3-D printed
forms made it possible to rapidly produce a large number of panels with window
openings.
PROJECT TEAM:
OWNER AND GENERAL CONTRACTOR: Two Trees Management Co. LLC, Brooklyn, N.Y.
PCI-CERTIFIED PRECAST CONCRETE PRODUCERS: Gate Precast Company, Winchester, Ky., and
Gate Precast Company, Oxford, N.C.
PRECAST CONCRETE SPECIALTY ENGINEER: Gate Precast Company, Jacksonville, Ark.
ARCHITECT: CookFox, New York, N.Y.
ENGINEER OF RECORD: Rosenwasser/Grossman Consulting Engineers, New York, N.Y.
PCI-CERTIFIED ERECTOR: E. E. Marr Erectors, Baltimore, Md.
PROJECT SIZE: 462,000 ft²
 Photos: Gate Precast Company and Kumar.

Traditionally, a mold for this type of project would re-

quire between 40 and 60 man-hours, notes Schweitzer. But
with the automated 3-D printing, that time was cut to just
14 hours. Each mold could support more than 200 pours,
whereas traditional wood molds typically require recondi-
tioning after 16 to 18 uses. This allowed the production
teams to run consecutive days without downtime during
the fabrication of the façade.
Throughout the project, the design-assist team worked
collectively using Revit software to plan and track various
stages in the building’s lifecycle. They created “intelligent
families” within the software to enable rapid advancement
and collaboration between the teams.
The Revit model served as the cornerstone for the ad-
vance production workflow, Schweitzer says. “Without the
ability to make real-time modifications in the architect’s
office and then share those changes with the fabrication
team instantly, the process of design and detailing would
have taken several more months to complete, thus delay-
ing production and delivery on-site.”
To further expedite erection, nearly 2500 windows were
installed at the precast concrete plant, which saved at least
eight months on the schedule and allowed the interiors
program to start sooner. “The inclusion of the window sys-
tem installation at the precast concrete producer’s produc-
tion facilities proved to be invaluable to the owner and con-
struction team,” Schweitzer says.
Special considerations for the attachment methods during
the design stage enabled a rapid installation time of around
30 minutes per window. “As the precast panels were erected
on-site, the building envelope was virtually complete,” he
adds. “This not only saved significant time on the construc-
tion schedule, but also provided a clean, weather-protected,
and safe work area for the other trades that followed.”

2021
 2021
OFFICE BUILDING
KEY PROJECT ATTRIBUTES
❚ Coordination of shared cranes
ensured multiple subcontractors
could sequence their work.
❚ Six-inch rib extrusions on
spandrels created depth in
the façade pattern.
❚ 75% of the precast concrete
was polished.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Replace an aging steel office
space and parking lot with a
vibrant 10-story building, buried
parking structure, and pocket park.
❚ The project included 483 precast
concrete elements.
❚ Precast concrete production and
erection was completed in
10 months.
“We chose precast concrete as the
spandrel panel primarily to allow
the design team the opportunity
to mold the panels to the desired
shape and for the flexibility in
color and finish.”
— Chuck Gannaway,
Hastings
26
2021 PCI DESIGN AWARDS
PEABODY PLAZA
NASHVILLE, TENNESSEE
On a sunny day, Peabody Plaza looks more like a painting than a structure.
The 290,000-ft² office building’s façade uses an artistic combination of patterned
precast concrete panels, brick, and glass, to create an ever-changing reflection of
the surrounding city.
The new building and adjoining park replaced a 250-space parking lot on a bluff
overlooking the Cumberland River, giving the community greater access to the
views and nature surrounding the site.
Initially, designers planned to use a glass curtainwall system for the project, but
instead shifted to a window wall supported by a precast concrete framework. “We
chose precast concrete as the spandrel panel primarily to allow the design team
the opportunity to mold the panels to the desired shape and for the flexibility in
color and finish,” explains Chuck Gannaway, principal at Hastings.
Precast concrete also brought “affordability, durability, and interesting finish col-
ors and textures,” notes Chris Cruze, project manager for Gate Precast Company.
A GOOD RIBBING
The façade design is a nod to the adjacent historic trolley barns. The concept re-
quired precast concrete spandrels and columns covered with a 6-in. trapezoidal
projection that runs the length of each piece and aligns to the adjacent spandrels,
column covers, or both. The shapes extend to all-glass corners at both the south-
east and northwest corners to denote major entry locations. The main floor of the
building on the southeast corner has structural columns wrapped in polished pre-
cast concrete.
The depth of the projections was accentuated by lightly acid-etching the rib
component, leaving its finish lighter and homogenous, while deeply polishing the
larger adjacent back body faces. The polishing reveals a Tennessee black granite
aggregate to create a darker, more reflective contrasting face.
The tight jobsite resulted in limited staging areas, causing alternating loads to
be stored in different locations. “Our shipping departments excelled in overcoming
these challenges, which allowed for a continuous flow of product to the project
site, allowing the installer to complete the installation in an expeditious manner,”
Cruze says. To add further efficiencies, the precast concrete producer produced the
architectural precast concrete panels at two of its prefabrication facilities, which
involved very detailed communication and timing between both facilities’ shipping
departments and the erector.
PROJECT TEAM:
OWNER: Eakin Partners, Nashville, Tenn.
PCI-CERTIFIED PRECAST CONCRETE PRODUCERS: Gate Precast Company, Ashland City, Tenn.,
and Gate Precast Company, Winchester, Ky.
PRECAST CONCRETE SPECIALTY ENGINEER: J&M Structural Engineers, Kissimmee, Fla.
ARCHITECT: Hastings, Nashville, Tenn.
ENGINEER OF RECORD: EMC Structural Engineers, Nashville, Tenn.
GENERAL CONTRACTOR: Brasfield & Gorrie, Nashville, Tenn.
PCI-CERTIFIED ERECTOR: Precision Stone Setting Company, Hiram, Ga.
PROJECT COST: $2.1 million
PROJECT SIZE: 41,840 ft²
 Once on-site, the various project teams worked collabo-
ratively, sharing cranes and coordinating their work to en-
sure multiple subcontractors’ sequences could be per-
formed in sync. “The installation of the precast concrete
was completed by wrapping the building finishing one floor
at a time, due to the challenge of using on-site tower cranes
during a second shift,” Cruze says.
The finished project features the ten-story building,
along with a 37,500-ft² pocket park and promenade that
establishes a pedestrian connection between the metro
city’s downtown and a multiuse trail.
“We love the shape of the precast and the resultant Photos: Kendall McCaughtery © Hall + Merrick
Photographers and Gate Precast Company.
shadows that it casts in different light and at different
times of the day,” Gannaway says. “The ability to see and
touch these finishes up close at the column covers displays
the refinement of the product.”

2021
 2021
ALL–PRECAST CONCRETE
PARKING STRUCTURE
KEY PROJECT ATTRIBUTES
❚ Three-dimensional curved
spandrels reflect Pennsylvania’s
rolling hills.
❚ Designers used Rhino and
Tekla tools to meet exact
weight requirements.
❚ The 8-ft overhang cantilever
entrance was created in two pours
to accommodate its massive depth.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Build a 1235-space, four-story,
all–precast concrete parking
structure with room for expansion.
❚ The project included 771 total
pieces of precast concrete.
❚ Erection was completed
in four months.
“Precast concrete was our best
option among the materials we
proposed for the façade of this
project. It was the most economi-
cal solution that provided flexibility
to meet the various design
challenges we would face.”
— Dohyoung Kim,
Lamar Johnson Collaborative
28
2021 PCI DESIGN AWARDS
PENN STATE HERSHEY MEDICAL
CENTER PARKING GARAGE
HERSHEY, PENNSYLVANIA
When owners of the Penn State Hershey Medical Center decided to add a
four-story, 1235-space parking structure to their rapidly expanding medical
center campus, they wanted it to be eye-catching. “It would be set within the
context of an architecturally significant campus, so it had to complement and en-
hance the materiality already established,” says Amy Luchun, principal at Lamar
Johnson Collaborative.
But at the same time, it had to fit within the cost, schedule, and technical re-
quirements of the project. The architects used precast concrete to tackle all of
these goals.
“Precast concrete was our best option among the materials we proposed for the
façade of this project,” says Dohyoung Kim, associate at Lamar Johnson Collabora-
tive. “It was the most economical solution that provided flexibility to meet the
various design challenges we would face.”
Finding inspiration in the landscape, the designers took advantage of the fluidity
and versatility of precast concrete to create a three-dimensional (3-D) design that
mimics the rolling hills and flowing rivers of Pennsylvania’s topography. The total–
precast concrete design features a series of 3-D wave spandrels that flow across
the sides of the parking structure in four levels. On each level, the panels merge
together at central points, then cascade away to create a natural flow in both the
design and the way light and air moves throughout the building.
Three 8-ft cantilevered concrete overhangs at the stair tower entrances were
incorporated to allow more light to fill the structure, creating a safe and pleasant
user experience. The overhangs offer a canopy to protect patrons from rain and
snow, while adhering to the flowing design aesthetic.
NO FINS REQUIRED
To achieve the waved design while staying within budget goals, the design team
found ways to maximize forms, while keeping engineering stability in check and
minimizing design changes. Significant cost savings were achieved by reducing the
number of unique molds from 72 to 8, and by increasing the bay size using larger
double tees.
PROJECT TEAM:
OWNER: Penn State Health, Hershey, Pa.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER: High Concrete Group, Denver, Pa.
ARCHITECT: Lamar Johnson Collaborative, Chicago, Ill.
ENGINEER OF RECORD: Hope Furrer Associates, State College, Pa.
GENERAL CONTRACTOR: Clayco, St. Louis, Mo.
PCI-CERTIFIED ERECTOR: High Structural Erectors, Lancaster, Pa.
PROJECT COST: $32.4 million
PROJECT SIZE: 411,000 ft²
 Photos: High Concrete Group.
However, these changes resulted in concerns about the
weight of the massive panels. The precast concrete produc-
er had to stay within a 100,000-lb limit, which they did by
using a Grasshopper script in Rhino and Tekla tools to con-
stantly monitor the weight of the panels. In some cases,
they hollowed out certain panels to reduce weight and to
make space for internal systems.
“The natural features of precast concrete allowed us to
control size, weight, and center of gravity to meet challeng-
ing requirements for transportation and for lifting and
swinging the pieces into place,” Kim says. Within the park-
ing structure, glass-wall stairwells reflect light through the
space, casting shadows off the spandrels that complement
the landscape seen through the open spaces. The addition
of wood soffits built into the precast concrete canopy en-
trance further reflects nature in the surroundings.
Luchun notes that the designers initially thought they
would have to adhere metal panels and fins to the façade to
bring the design to life, but found that precast concrete al-
lowed them to meet all of their design goals while provid-
ing the structural purpose of a parking structure. “The
eye-catching waving spandrels are now the first element to
greet visitors who drive onto the health campus,” she says.
The project was completed in January 2020, and, as an
unexpected benefit, the parking structure was used as a
drive-through COVID-19 testing site, she adds. “With the
larger bays and well-lit area, it was a perfect location that
also provided a safe space to tend to their community.”
2021
 2021
FAÇADE-ONLY
PARKING STRUCTURE
KEY PROJECT ATTRIBUTES
❚ Precast concrete helped designers
deliver intricate details with a
cost-effective and resilient
material.
❚ Rapid installation met the
owner’s strict construction
deadlines.
❚ The precast concrete producer
was able to exactly replicate the
neoclassical design that is common
across the campus.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Create a detailed neoclassical
façade for this seven-story
parking structure.
❚ The project included 517 pieces of
precast concrete.
❚ Erection of the precast concrete
façade was completed in
four months.
“The University of Alabama prides
itself on the architectural beauty
and history of its largely
neoclassical campus.”
— Neil King,
Evan Terry Associates
30
2021 PCI DESIGN AWARDS
UNIVERSITY OF ALABAMA
PARKING DECK
TUSCALOOSA, ALABAMA
The new seven-story parking structure at the University of Alabama looks
more like a state-of-the-art library than a place to park your car. The neoclas-
sical architecture and brick-and-limestone design were specifically chosen to mimic
the century-old buildings that cover the university’s campus, and to give the struc-
ture a feeling of strength and permanence.
“The University of Alabama prides itself on the architectural beauty and history
of its largely neoclassical campus,” says Neil King, president and chief operating
officer of Evan Terry Associates.
From the outset, designers wanted the building to blend with that neoclassical
style but knew it wouldn’t be easy. King notes that this architectural style features
many ornate elements, including balustrades, cornices, parapets, and entabla-
tures, which require strict adherence to proportion and scale. In the past, these
architectural elements were hand-carved from limestone and similar materials,
but that approach would be unaffordable in today’s world.
“To that end, we were able to take advantage of the precision, consistency, and
economy of precast to exactly replicate classical details rendered to proper classi-
cal proportions,” King says. Choosing precast concrete allowed them to achieve
the strict design goals with a cost-effective, extremely durable, and low-mainte-
nance product.
EXCEEDING EXPECTATIONS
The structural frame of the parking structure is cast-in-place concrete. That frame
was then hung with precast concrete panels to form the highly detailed building
envelope. The precast concrete producer used thin-brick veneer to exactly replicate
the brick appearance on the upper floors, and sandblasted panels with limestone
accents on the lower levels.
Each mold was designed to replicate the classical details, while adhering to
proper classical proportions. Both the brick wall panel molds and sandblasted pan-
el molds included multiple window spacings, which required additional molds and
modifications.
PROJECT TEAM:
OWNER: MBA, Inc., Birmingham, Ala.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER: Gate Precast Company, Monroeville, Ala.
PRECAST CONCRETE SPECIALTY ENGINEER: Gate Precast Company, Springboro, Ohio
ARCHITECT: Evan Terry Associates, Birmingham, Ala.
GENERAL CONTRACTOR: Bailey Harris Construction, Auburn, Ala.
PCI-CERTIFIED ERECTOR: SE Precast Erectors, Roswell, Ga.
PROJECT SIZE: 511,800 ft²
 Along with meeting the design goals, using precast con-
crete helped the project team meet the strict delivery sched-
ule, which was built around the school’s academic calendar.
“The inherent efficiency and rapid installation of precast
concrete was vital in helping us to meet, or even exceed, the
university’s expectations,” King says. The precast concrete
erection process was completed in four months, ending in July
before the start of the school year. It marks the completion of
phase one of this multiphase project to provide on-campus
living space, food service, and parking for university students,
King says. “The owner loved the rapid and timely completion Photos: Gate Precast Company.

of the project, and how well this new parking deck blends
seamlessly with the university’s design aesthetic.”

2021
 2021
HYBRID PARKING
STRUCTURE
KEY PROJECT ATTRIBUTES
❚ Fast-track erection of the parking
structure concurrent with other
site activities shortened the
project schedule.
❚ The use of precast concrete
helped the project earn LEED
gold certification.
❚ Value engineering delivered
roughly $8 million in savings.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Build a seven-story, 700-car
hybrid precast concrete
parking structure.
❚ The project included 733 precast
concrete elements.
❚ Erection was completed on a
fast-track schedule.
“Partnering with the precast
concrete producer upfront through
real-time design and BIM resulted
in the elimination of redundancies
and the reduction of conflicts in
drawings and change orders.”
— Steve Callahan Jr.,
Callahan Construction
32
2021 PCI DESIGN AWARDS
ASSEMBLY ROW BLOCK 6
PARKING GARAGE
SOMERVILLE, MASSACHUSETTS
The new seven-story Assembly Row parking structure in Somerville does
more than offer weary shoppers a place to leave their cars. The building replac-
es a formerly contaminated industrial site, providing an anchor structure that will
play a key role in transforming the city center into an urban destination, connecting
community, commerce, and mass transit.
The structure was part of a larger project to build the city’s tallest building and
connect it to adjoining residential structures. While the complete structure took
three years to construct, the project owners wanted to fast-track the precast con-
crete parking structure, and they needed an experienced precast concrete design
and construction team to help make it happen.
They partnered with Unistress, whose team worked closely with the project
owner to streamline the design process and rein in costs. “Partnering with the pre-
cast concrete producer upfront through real-time design and BIM [building infor-
mation modeling] resulted in the elimination of redundancies and the reduction of
conflicts in drawings and change orders,” says Steve Callahan Jr., vice president of
business development for Callahan Construction.
Through the close collaboration, the teams identified value-engineering oppor-
tunities worth roughly $8 million during the preconstruction phase alone. “We
were able to resolve many complex engineering and façade issues early in the de-
sign phase, generating significant cost and schedule savings,” says Perri Petricca,
chief executive office of Unistress Corporation.
CONCRETE AND STEEL
The precast concrete parking structure incorporated a unique hybrid design using
steel bracing frames on the exterior and steel columns bearing on shared shear
walls to support a residential tower above the structure. The hybrid design required
early coordination with the architect, engineer, and precast concrete producer to
work out expansion joints, ductile connections, precast concrete product layout,
and block-out locations.
The project required steel columns from the 10-story residential tower to needle
down and through the structure, which is skewed and offset from the precast con-
crete parking structure below. They needed the precast concrete parking structure
elements to brace the steel needle columns, but to not transfer gravity loads,
PROJECT TEAM:
OWNER: Federal Realty Investment Trust, Somerville, Mass.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER: Unistress Corporation, Pittsfield, Mass.
PRECAST CONCRETE SPECIALTY ENGINEER: TRC Worldwide Engineering, Inc., Allentown, Pa.
ARCHITECT: Stantec Architecture, Boston, Mass.
ENGINEER OF RECORD: Odeh Engineers, Inc., Providence, R.I.
GENERAL CONTRACTOR: Callahan Construction, Bridgewater, Mass.
PCI-CERTIFIED ERECTOR: Prime Steel Erecting, Inc., North Billerica, Mass.
PROJECT COST: $143 million
PROJECT SIZE: 110 million ft²
explains Daniel Batt of Odeh Engineers. “Working with pre-
cast concrete producers on this project and having them
join in the design team as a design-assist partner from the
schematic design phase allowed us to do this detailed coor-
dination during the design phase,” he says.
To accommodate the skewed layout of the adjoining res-
idential tower, the precast concrete producer integrated
diagonal steel bracing through block-out tees in the precast
concrete floors and walls, and worked closely with the
PCI-certified erector to coordinate the steel elements and
connection details. The designer and precast concrete pro-
ducers worked together to develop unique ductile connec-
tions to ensure successful integration of the precast con-
crete parking structure and steel residential towers. “The
coordination between the steel and the precast concrete
eased the transition of construction phases beyond the
erection of the precast,” says Scott Long of Prime Steel
Erecting.
The design also resulted in high shear loads from the res-
idential tower that had to transfer into the precast con-
crete parking structure shear walls. That required sophisti-
cated detailing and coordination between the precast
concrete, steel, and cast-in-place concrete elements. The
close collaboration between all of the teams on this project
resulted in a resilient structure that gave the designers the
flexibility to begin leasing residential units and opening re-
tail spaces sooner than anticipated. Photos: Odeh Engineers Inc.
“It was extremely gratifying to be part of a team that rec-
ognized the value of precast concrete and the benefits of
partnering up front to resolve constructability issues and
maximize opportunities for value engineering,” Petricca says.
2021
 2021
RELIGIOUS STRUCTURE
KEY PROJECT ATTRIBUTES
❚ Revit software allowed the
designer and precast concrete
producer to do coordination
checks in real time.
❚ Using load-bearing precast
concrete cut $350,000
from the budget.
❚ The precast concrete producer
created a hand-laid brick
appearance by placing fired
bricks into liners with various
joint thicknesses.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Build a Catholic church to host
more than 1200 parishioners.
❚ The project included 227
precast concrete pieces.
❚ Precast concrete erection was
completed in four months.
“Gate Precast’s design assistance
was critical to achieving the
owner’s lofty design goals: an
aged limestone and brick motif
and the inclusion of several
gothic-style archways.”
— David Hebert,
Grace Hebert Curtis Architects
34
2021 PCI DESIGN AWARDS
ST. GEORGE CATHOLIC CHURCH
BATON ROUGE, LOUISIANA
When the leaders of St. George Catholic Church in Baton Rouge decided to
build a new church, they envisioned an elegant yet simple design that would
be a welcoming center for parishioners in the community.
With that vision in mind, the architects created a structure that features a col-
lage of transcendental Christian motifs, veiled within the fabric of historic gothic
architecture. “The design intent for the church was for it to look and feel as though
it was built hundreds of years ago, representative of the history of the community
it serves,” says David Hebert, principal and architect for Grace Hebert Curtis Archi-
tects.
The efficient and creative use of precast concrete played a vital role in achieving
that aesthetic.
Hebert’s team engaged the precast concrete producer early in the design phase to
explore the best techniques and paneling options to achieve the desired look. The
precast concrete producer worked in a design-assist role and then as supplier of the
architectural precast concrete after the project was awarded to the contractor.
“Gate Precast’s design assistance was critical to achieving the owner’s lofty de-
sign goals: an aged limestone and brick motif and the inclusion of several goth-
ic-style archways,” Hebert says.
LOAD-BEARING ARCHES
The architect and precast concrete producer both used Revit software, which en-
abled them to easily sync their work and conduct coordination checks in real time
and was key to addressing many of the complex challenges on the project. “It was
the perfect way for us to get everyone on the same page,” Hebert says.
To achieve the stone aesthetic, the precast concrete producer used a proprietary
casting method that resulted in different shades in the façade as well as random-
ness within the panels. The inlaid brick pattern was achieved by placing old fired
bricks from overseas into liners with various joint thicknesses to appear as though
they were hand-laid. The brick veneer precast concrete panels along the base pe-
rimeter of the building serve not only as an aesthetic cladding, but also as the lat-
eral stability of the structure.
The church also features gothic precast concrete archways to add a transitional
look, though these elements required careful design consideration. Each of the
arches, which have varying supporting structure ranging from steel to glue-lami-
nated lumber, required examination of the various load paths and connection
PROJECT TEAM:
OWNER: St. George Catholic Church, Baton Rouge, La.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER: Gate Precast Company, Monroeville, Ala.
PRECAST CONCRETE SPECIALTY ENGINEER: Gate Precast Company, Jacksonville, Ark.
ARCHITECT: Grace Hebert Curtis Architects, Baton Rouge, La.
ENGINEER OF RECORD: Fox-Nesbit Engineering, Baton Rouge, La.
GENERAL CONTRACTOR: Womack Construction, Baton Rouge, La.
PCI-CERTIFIED ERECTOR: Ranger Steel Erectors, Inc., West Monroe, La.
PROJECT COST: $15.6 million
PROJECT SIZE: 24,500 ft²
 Photos: www.toddlandryphotography.com
and Milton J. Womack, Inc.

schemes required to resolve dead loads and address the lat-

eral forces due to wind. In response, the precast concrete
producer created panels that would resolve forces from
both the structural diaphragm and, in selected cases, the
forces from the precast concrete arches.
Precast concrete banding, projections, and brick sections
had to be aligned from panel to panel, which required an
extensive amount of coordination between the precast
concrete producer’s detailers, carpenters, and production church to further achieve the look of stone and eliminate
teams. Templates were often used during the mold-build- large caulk joints. They also made a decision late in the de-
ing process and after the panels had been cast to verify sign process to switch all of the precast concrete to
alignment. load-bearing panels that could support the curved roof
Some of the more extravagant bell tower column panels structure, Hebert notes. “This change resulted in a net sav-
with “wings” required multiple pours over two to three days. ings of $350,000 by eliminating perimeter columns and all
Arched brick-inlay entrance panels at the bell tower had to of the curved steel beams.”
be perfectly cast to ensure they matched the brick arched In the end, both the architect and owner were pleased.
panels back to back to provide a seamless transition. “The experience was fantastic,” Hebert says. “The panels
Through close collaboration, the teams were able to re- went up almost flawlessly.”
duce panel joints to ½ in. at most areas at the front of the
2021
 2021
RETAIL BUILDING
KEY PROJECT ATTRIBUTES
❚ Precast concrete design approved
by New York’s Historic Landmark
Commission to replicate an original
white marble façade.
❚ Three-dimensional modeling gave
the project teams the detailed view
they needed to align connections
to the existing steel structure.
❚ The precast concrete producer
produced a “marbled” effect on the
cast stone to exactly match the
existing marble.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Retrofit the lower façade on the
historic Nordstrom flagship store in
Manhattan using precast concrete
to mimic original Vermont
white marble.
❚ The project included 85 precast
concrete elements.
❚ Erection was completed over
three summer months.
“The design intent was always to
restore as much of the original
Beaux Arts details as possible, and
the key to doing so was materiality.”
— Bridgette Hyde,
CallisonRTKL
36
2021 PCI DESIGN AWARDS
NORDSTROM NYC FLAGSHIP
NEW YORK, NEW YORK
Being asked to update a certified historic landmark can bring added pressure
to any project. But it is also a great opportunity for companies to demonstrate the
versatility of their people and their design choices. This was the case for the team
in charge of renovating Nordstrom’s flagship store in New York City.
Originally built in 1912 by architects Carrère and Hastings, the Beaux-Arts-style
building was the architects’ first true skyscraper at 20 stories. The building’s use of
Vermont white marble under an ornate copper cornice was meant to reflect the
splendor of the automobile era. But in 1959, the street-level façade was replaced
with flat, gray granite slabs and aluminum curtain walls, destroying the iconic aes-
thetic.
CallisonRTKL was hired to redesign the façade and bring it back to its original
glory, but sourcing and replacing that quantity of white marble was prohibitively
expensive.
“We needed to balance our fiscal responsibility to the client’s budget and con-
struction schedule with our emotional responsibility to this historic landmark,”
says Bridgette Hyde, lead designer with CallisonRTKL. “The design intent was al-
ways to restore as much of the original Beaux Arts details as possible, and the key
to doing so was materiality.”
So the team partnered with Gate Precast Company to create a custom precast
concrete panel that would elicit a modern take on the grand façade, while keeping
the project on schedule and budget.
To convince the New York City Landmarks Preservation Commission that it could
work, Gate fabricated full-size precast concrete mock-ups of the cornice profiles
and base with a partial physical submittal. They also experimented with tech-
niques to produce a marbled effect on the cast stone. The quality of those models
helped the project team secure the commission’s approval to move forward with
precast concrete.
SANDED BY HAND
Due to the building’s age, there were no detailed drawings that the team could use
to ensure a precise precast concrete fit, which was a challenge. “We could not go
off of assumptions nor afford a delay in the field,” says Chris Cruze, project manag-
er at Gate Precast.
To achieve the required precision, his team had to expose the steel structure to
see what needed to be adapted, then work with the engineering team to create
PROJECT TEAM:
OWNER: Nordstrom, Seattle, Wash.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER AND PRECAST CONCRETE SPECIALTY ENGINEER:
Gate Precast Company, Ashland City, Tenn.
ARCHITECT: CallisonRTKL, Seattle, Wash.
ENGINEER OF RECORD: Coffman Engineers, Seattle, Wash.
GENERAL CONTRACTOR: J.T. Magen & Company, New York, N.Y.
 Photos: Gate Precast Company.

custom precast concrete connections. “Our drafting team

modeled the desired façade and worked on making the pre-
cast façade fit with the building by dodging steel, brick, and
thinning panels up where needed,” he says.
The architects used three-dimensional modeling to give
everyone in the team a detailed view to piece together the
façade with a paneling method that would connect to the
existing steel structure.
Master mold builders used the models to create the intri-
cate details to achieve the desired look. The precast con-
crete molds consisted of multiple height steps and radii.
The form buildup was built to add as much detail as the
carpenters could achieve, stacking several layers of wood of
various shapes and sizes to within around ⅛ in. Different
mold-finishing techniques were used to obtain the desired
detail and crispness of the finished product. Then the ma-
jority of the sanding was done by hand to accommodate all
of the tight steps and radii.
By the time the finished panels were on-site, the erection
team had everything they needed to meet the exacting re-
quirements of the historic façade. “The speed at which the
façade was constructed is an important part of the proj-
ect’s success,” Hyde says.
It’s another great example of how the versatility of pre-
cast concrete helps project owners address the cost, time,
and aesthetic challenges that so many projects face. “The
efficiency and resiliency of the precast concrete material
allowed for the creation of a façade that brings back the
historical past and will last for years in Manhattan’s harsh
urban environment,” says Paul Hjorten, project manager
for CallisonRTKL.

2021
 2021
SCHOOL BUILDING (K-12)
KEY PROJECT ATTRIBUTES
❚ Twelve-inch wall panels and
48-in.-deep double tees can
withstand an EF5 tornado.
❚ Lightweight precast concrete
double tees allowed roof spans
greater than 100 ft.
❚ It is now one of the largest storm
shelters in North Texas.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Build a 23,000-ft2 storm
shelter to hold 1000 people.
❚ The project included 70
precast concrete elements.
❚ Erection was completed
in just five days.
“Lightweight precast concrete
double tees provided a solution
that allowed for greater than
100-foot roof spans, minimized
structure depth, and provided
space for the installation of
mechanical equipment.”
— Nick Heinlen,
Dunaway Associates
38
2021 PCI DESIGN AWARDS
SMITHFIELD MIDDLE SCHOOL –
GYMNASIUM ADDITION
NORTH RICHLAND HILLS, TEXAS
In Texas, hurricanes and dangerous storms are a constant threat. To mitigate
these risks and keep the community’s most vulnerable citizens safe, Smithfield Mid-
dle School in North Richland Hills wanted to build a larger storm shelter that would
provide a safe space for students, faculty, and the community.
Thanks to a bond package passed in 2018, all independent school district campus-
es in the area received funding to build shelters, and the designers of this shelter
knew early on that precast concrete was the best choice.
“Immense wind and debris loads associated with storm shelters create unique
structural design challenges,” notes Nick Heinlen, project engineer for Dunaway As-
sociates. “Selecting a structural system requires a balance of many factors, espe-
cially for a gymnasium where uninterrupted clear space is critical.” Precast concrete
would give them the highly resilient structure they needed within the prescribed
budget, and it would create minimal site disruption while the school was occupied.
ONE HUNDRED-FOOT ROOF SPANS
To meet wind and debris load requirements, the designers used long-span (103 ft
9 in.) roof double tees to support superimposed live loads of 100 lb/ft² for debris
loading. They also added a 260 lb/ft live load for a roll-up dividing curtain located
at midspan of the double tee. Dead and collateral loads consisting of 4-in. topping
at 150 lb/ft³ were spread throughout the roof.
The combination of 12-in.-thick wall panels and 48-in.-deep double tees makes
this storm shelter capable of withstand an EF5 tornado (the highest rating on the
Enhanced Fujita scale of tornado intensity). “Lightweight precast concrete double
tees provided a solution that allowed for greater than 100-foot roof spans, mini-
mized structure depth, and provided space for the installation of mechanical
equipment,” Heinlen says.
PROJECT TEAM:
OWNER: Birdville Independent School District, Haltom City, Tex.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER AND PRECAST CONCRETE SPECIALTY ENGINEER:
Coreslab Structures (OKLA), Oklahoma City, Okla.
ARCHITECT: VLK Architects, Fort Worth, Tex.
ENGINEER OF RECORD: Dunaway Associates, Fort Worth, Tex.
GENERAL CONTRACTOR: Key Construction Texas, Fort Worth, Tex.
PROJECT COST: $8.78 million
PROJECT SIZE: 23,000 ft²
 Photos: Eric Childs, Key Construction.

To reduce disruption on the active school campus, the

panels and double tees were erected over a single weekend,
which allowed the waterproofing, masonry, and roofing
work to commence much faster than standard storm shel-
ter construction. The close collaboration between the pre-
cast concrete producer and engineer and thoughtful com-
mitment to the short schedule enabled this 70-piece
precast concrete structure to be erected in just five days.
It is now one of North Texas’s largest storm shelters, says
Robert Cortez, superintendent of Key Construction. “Our
team is extremely proud of the end result and having been
a part of such an important component to the safety of fu-
ture generations and the city of North Richland Hills.”

2021
 2021
STADIUM AND
ARENA STRUCTURE
KEY PROJECT ATTRIBUTES
❚ Thin-brick inlays mimic the
appearance of hand-laid brick
at a fraction of the cost.
❚ A distressed travertine look was
achieved by incorporating three
finishes in 1-in. increments
within the panels.
❚ The retractable roof rolls onto a
steel frame with decorative
thin-brick precast concrete arches.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Build a 1.7 million-ft² baseball
field for the Texas Rangers.
❚ The project included approxi-
mately 114,000 ft² of finished
precast concrete.
❚ Precast concrete erection was
completed from October 2018
through April 2019.
“The precast concrete brick-clad
columns and arches now read as
one singular element, thanks to
the collaborative efforts of the
design and construction teams.”
— John Arehart,
Enterprise Precast Concrete
40
2021 PCI DESIGN AWARDS
GLOBE LIFE FIELD, HOME
OF THE TEXAS RANGERS
ARLINGTON, TEXAS
The Texas Rangers are a 60-year-old Major League Baseball team that needed
a new home. In 2016, the team announced they would build a brand new stadium
through a public/private partnership between the City of Arlington and the Rang-
ers. The new 1.7 million-ft² 41,000-seat ballpark would provide a permanent site
for home games, as well as a multipurpose sports and entertainment venue for the
community.
Designers originally wanted to use hand-laid brick for the north façade. Howev-
er, the contractor emphasized early on that 100% hand-laid brick would not be
possible with the construction schedule.
As an alternative, they split up the brickwork, using precast concrete on the ex-
terior of the façade and hand-laid on the interior. They selected a thin-brick version
of the same full brick that was being used throughout the ballpark and cast them
into the precast concrete column wrap units, which were eventually lifted into
place and hung from the steel structure.
“From the start of design, Fred Ortiz [of HKS] challenged us to ‘think outside the
box’ on the finishes for the exterior of the non-brick-clad areas,” says John Arehart,
vice president of the architectural division for Enterprise Precast Concrete.
The design team ultimately selected a distressed finish that simulates aged
travertine by incorporating three finishes at varying widths and depths within a
15 × 30 ft panel. “The level of exterior texture gave the façade a travertine look, but
in more monolithic, large, random blocks,” says Fred Ortiz, director of sports and
principal at HKS. “Instead of being consistent, it was consistently inconsistent, and
that worked for the betterment of the project.”
Because the masonry in the north arcade was part of the same arch element,
the precast concrete producer had to work closely with the masonry company
and the contractor to ensure that similar masonry color and coursing comple-
mented the hand-laid brick on the interior face of the arches for a cohesive aes-
thetic. “The precast concrete brick-clad columns and arches now read as one
singular element, thanks to the collaborative efforts of the design and construc-
tion teams,” Arehart says.
PROJECT TEAM:
OWNER: Texas Rangers, the City of Arlington, and Globe Life, Arlington, Tex.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER AND PRECAST CONCRETE SPECIALTY ENGINEER:
Enterprise Precast Concrete, Omaha, Neb.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER: Gate Precast Company, Hillsboro, Tex.
ARCHITECT: HKS, Dallas, Tex.
ENGINEER OF RECORD: Walter P. Moore, Dallas, Tex.
GENERAL CONTRACTOR: Manhattan Construction, Dallas, Tex.
PCI-CERTIFIED ERECTOR: Precast Erectors LLC, Hurst, Tex.
PROJECT COST: $1.2 billion
PROJECT SIZE: 1.7 million ft2
 Photos: Enterprise Precast Concrete and Jacia Phillips | Arch Photo KC.

RETRACTABLE ROOF
One of the most important features in the design is a mas-
sive retractable roof that can be opened and closed based
on the weather. In the old stadium, extreme heat or rain
were often cited as reasons why attendance was lower than
in other baseball stadiums. The retractable roof, which rolls
onto a steel frame with decorative thin-brick precast con-
crete arches, solved this issue, Arehart says. “The roof in-
troduces a fully climate-controlled atmosphere, a first of
its kind in a Major League Baseball facility.”
To meet the tight schedule, which was set to accommo-
date the 2020 baseball season, the project team was able
to speed erection through the shared use of cranes and hav-
ing the precast concrete set overnight to avoid conflicts
with other trades. A second PCI-certified producer was
brought in to provide 1650 structural components in the
stadium, including risers, raker beams, columns, beams,
and interior structural walls. Cooperation and collabora-
tion between the two different precast concrete producers,
who are typically competitors in this market, was essential
to the project’s success.
As a result, the project was delivered on time, and was
tapped to host the 2020 World Series, but because of the
pandemic, the fans haven’t yet had a chance to experience
the beauty of this new ballpark. “Sitting in the empty stands
… is a strange experience,” Ortiz says. “You hear so many
more nuances of the game, like voices, and the clear crack
of the bat. But we are all ready for baseball to be back.”

2021
 2021
THEATER STRUCTURE
KEY PROJECT ATTRIBUTES
❚ Precast concrete panels were
used as permanent formwork to
support structural concrete during
installation.
❚ Countless unique connection
brackets allowed installers to
adjust each panel from behind to
correct global positioning.
❚ A consistent radius allowed
molds to be reused many times
with only minor adjustment of
edge forms and blockouts.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Renovate a historic museum and
add a massive spherical precast
concrete addition.
❚ The project included 727 total
panels cast on 30 base molds.
❚ Precast concrete erection
took 26 months.
“Precast concrete allowed for
better and more cost-effective
finish quality and tighter
tolerances and geometry control
to ensure a perfect sphere.”
— Daniel Hammerman,
Renzo Piano Building Workshop
42
2021 PCI DESIGN AWARDS
ACADEMY MUSEUM
OF MOTION PICTURES
LOS ANGELES, CALIFORNIA
The new Academy Museum of Motion Pictures in Los Angeles was created to
celebrate the art and science of movies—past, present, and future. And what
better way to do that than to create a structure that looks like it could have rolled
off the set of a Star Wars movie?
The project involved the exterior restoration and interior gut renovation of a
230,000-ft² historic landmark structure, with the addition of a 60,000-ft² spheri-
cal glass and concrete structure to house the 1000-seat David Geffen theater. The
150-ft-diameter precast concrete sphere appears to float above ground, offering a
whimsical counterbalance to the more sedate renovated historic structure.
The sphere was originally conceived as a cast-in-place concrete shell, but as the
design evolved, it became clear that cast-in-place was not the right solution.
“Spherical formwork would have been prohibitively expensive for carpenters to
fabricate and assemble on-site,” says Daniel Hammerman, architect for Renzo Pia-
no Building Workshop. “Precast concrete allowed for better and more cost-effec-
tive finish quality and tighter tolerances and geometry control to ensure a perfect
sphere.”
Because the sphere features a consistent radius, the project required only 30
base molds, which could be reused many times with only minor adjustments of
edge forms and blockouts. The use of precast concrete also allowed the large,
column-free space, providing unobstructed sightlines for the theater in the round,
as well as providing the physical mass necessary for acoustic isolation of the
high-performance theater.
Initially, designers were concerned that precast concrete would not be able to
deliver the desired variation in the finish. “Precast concrete tends to prize a consis-
tent, uniform look of factory-made cladding panels,” says Hammerman. However,
the precast concrete producer generated multiple samples and mock-ups to ulti-
mately define the best technique to achieve the intended finish appearance. The
final design used a standard gray cement and a single aggregate to produce all of
the panels.
Rather than using a typical sandblasted finish, which erases all the flaws but also
the character, they opted for an “as-cast” finish to impart a luminous surface qual-
ity. “The gentle sheen on the soffit panels above the plaza brings fantastic daylight
and reflections underneath the mass of the sphere, helping create a wonderfully
welcoming public plaza,” Hammerman says.
PROJECT TEAM:
OWNER: Academy Museum Foundation, Los Angeles, Calif.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER: Willis Construction Co., Inc.,
San Juan Bautista, Calif.
ARCHITECTS: Gensler, Los Angeles, Calif., and
Renzo Piano Building Workshop, Genoa, Italy
ENGINEER OF RECORD: Buro Happold, Los Angeles, Calif.
GENERAL CONTRACTOR: Matt Construction, Santa Fe Springs, Calif.
PROJECT COST: $388 million
PROJECT SIZE: 290,000 ft²
 Photos: Willis Construction Inc.

PRECAST CONCRETE AS FORMWORK

“One of the most innovative features of the project was the
use of precast concrete panels as permanent formwork to
support the structural concrete during placement opera-
tions,” says Mark Hildebrand of Willis Construction. That
meant the precast concrete architectural spandrels had to
be installed on a steel structure before the dome could be
built. Extensive supports and birdcage scaffolding held the
structure in place until the final piece of glass was installed,
locking it together like the keystone of an arch. The design-
er’s signature spider stairways, which feature finely detailed
railings and treads, wrap around the outside of the sphere.
The outer envelope is sculpted to reflect light downward,
while a highly articulated and transparent dome glazing sys-
tem partially wraps the upper half of the sphere, casting a
changing pattern of shadows that animate the concrete
façade. A terrace and exhibition space is perched on top of the
sphere, offering panoramic views from under a glass dome.
“Without the client’s support in working through the
challenges of using precast as permanent formwork, the
completion of this project would not have been possible,”
says Richard Stoner, senior associate at Gensler. Celebrat-
ing history and imagining new possibilities, the museum
now features more than 50,000 ft² of gallery space, two
theaters, outdoor plazas, rooftop terraces, education labs,
offices, conservation facilities, a restaurant, and shop. “We
were very fortunate that the Academy Museum allowed
the design team, general contractor and precast concrete
contractor to think outside the box … to achieve a stunning
object from the outside that will be an icon in Los Angeles
for many years to come.”

2021
 2021
CUSTOM SOLUTION
KEY PROJECT ATTRIBUTES
❚ The finishes combine embedded
thin brick and white concrete with
an acid-etched finish to match the
historic look of the racetrack.
❚ Back-to-back precast concrete
spandrels were cast separately and
welded together in the plant to
achieve a unified, two-sided
appearance.
❚ Crane work couldn’t begin until
after 10:00 a.m. to avoid spooking
the horses, requiring a just-in-time
approach to panel delivery.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Build a colonnade and gate at the
historic Churchill Downs Racetrack.
❚ The project included 950 precast
concrete elements.
❚ Both phases of construction were
completed in winter and early
spring around meet events.
“The biggest challenge we faced
was creating an authentic design
for such an iconic racetrack and
historical grounds that would
include complex classical detailing
in a cost-effective, feasible
installation.”
— Kelly Kerns,
Populous
44
2021 PCI DESIGN AWARDS
CHURCHILL DOWNS
COLONNADE AND INFIELD GATE
LOUISVILLE, KENTUCKY
Churchill Downs is one of the most iconic sports venues in the country. Thou-
sands of guests pour through its gates every year to watch the Kentucky Derby and
other world-famous horse races.
In 2017, the owners decided they wanted to add a colonnade wall to the famous
park, to increase security and create better pedestrian flow in and out of the race-
track. The new colonnade and gate would have to match the signature architecture
of the site, with its historic details and grand scale.
“The biggest challenge we faced was creating an authentic design for such an
iconic racetrack and historical grounds that would include complex classical de-
tailing in a cost-effective, feasible installation,” says Kelly Kerns, senior principal at
Populous.
He notes that while the primary facility is dominated by white brick, the site has
incorporated many materials and detailing in later additions, including an exterior
insulation and finish system, wood, and brick. “The variety of materials presented
a challenge to our design team, and we quickly realized that precast concrete with
inlaid brick provided the optimum solution,” Kerns says.
Choosing precast concrete also accommodated the project’s tight time frame,
says Steve Schweitzer, vice president of operations for Gate Precast. “The schedule
for this project revolved around million-dollar horses and the racetrack’s meet
schedules,” he says. “Since this racetrack is only open for racing 75 days out of the
year, all on-site construction had to be completed between the meets.”
The construction crews also had to abide by strict sound requirements while
they were on-site. “During construction, noise had to be controlled while the hors-
es were training, which meant no loud cranes until after 10:00 a.m.,” Schweitzer
notes. To accommodate that restriction, his team scheduled a small crew to pro-
vide just-in-time delivery and installation of the pieces to meet the tight deadline.
TWO-FACED
The project was completed in two phases to ensure all construction could be com-
pleted in the winter and early spring months. Design and bidding for each phase
was completed before the Fall Meet at the racetrack so that construction could
begin promptly at the end of November.
PROJECT TEAM:
OWNER: Churchill Downs Racetrack, Louisville, Ky.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER AND PRECAST CONCRETE SPECIALTY ENGINEER:
Gate Precast Company, Winchester, Ky.
ARCHITECT: Populous, Kansas City, Mo.
ENGINEER OF RECORD: Walter P. Moore, Houston, Tex.
GENERAL CONTRACTOR: Calhoun Construction Services, Louisville, Ky.
PCI-CERTIFIED ERECTOR: Ben Hur Construction Co., Fairfield, Ohio
PROJECT SIZE: 75,000 ft²
 Photos: Gate Precast Company.

The design features four-sided brick-inlay columns with

back-to-back precast concrete spandrels at the main en-
trances. Because it would be a perimeter wall, the precast
concrete would be visible on both sides, requiring two-sid-
ed finished surfaces.
The spandrels were cast separately and welded together
in the plant before delivery and installation. And in the Ser-
vice Area, the backs of the spandrels feature an acid-washed
finish to simulate the front side of the spandrels. The col-
umns were self-supporting, standing on cast-in-place piers
with the spandrels resting in pockets in the precast con-
crete columns.
“While the design takes full advantage of the efficiency
of repetitive precast concrete bays, the formwork design
and detailing required close collaboration between the de-
sign and construction team,” Kerns says. Working together,
they took advantage of the flexibility of precast concrete to
incorporate numerous design variations that responded to
varied site conditions, elevations, and geometries. This re-
sulted in a bespoke design that looks and feels like it has
been in place for decades.
“Precast concrete’s ability to incorporate matching thin
bricks with concrete trim elements mimicking natural
stone was a key accomplishment in this project,” Sch-
weitzer says. “The ability to seamlessly add new elements
with classic designs while utilizing products with enhanced
durability and security were major factors in its success.”
2021
2021 TRANSPORTATION
PCI DESIGN AWARDS
48 Replacement Old Easton
Road Bridge Over Pine Run
BRIDGE WITH A MAIN SPAN UP TO 75 FEET (23 M)

50 CR 661/ Blackhall Road Over Rum Creek

BRIDGE WITH A MAIN SPAN FROM 76-149 FEET (23 TO 45 M)

52 Rockingham I-91 Bridges

24N And 24S – IM 091-1(66)
BRIDGE WITH A MAIN SPAN MORE THAN 150 FEET (46 M)

54 Lake Pontchartrain Causeway

Safety Bay Improvements
REHABILITATED BRIDGE

56 Sound Transit E360 Guideway Bridge

NON-HIGHWAY BRIDGE

58 Port of Corpus Christi

North Bank Cargo Dock 16
TRANSPORTATION SPECIAL SOLUTION
 TRANSPORTATION
PCI DESIGN AWARDS
JURY
SENIOR STRUCTURAL ENGINEER,
Reggie Holt
FEDERAL HIGHWAY ADMINISTRATION, WASHINGTON, D.C.
Reggie Holt is a senior bridge engineer and concrete bridge specialist at the Federal Highway
Administration (FHWA) Office of Bridges and Structures in Washington, D.C. He is responsible for
national policy and guidance on bridge design and analysis.

Prior to joining the FHWA, Holt was a senior project manager with T.Y. Lin International. He is a
registered professional engineer and has a bachelor’s and master’s degrees in civil engineering
from the University of Maryland.

Bijan Khaleghi
STATE BRIDGE DESIGN ENGINEER, WASHINGTON STATE
DEPARTMENT OF TRANSPORTATION OLYMPIA, WASH.
Bijan Khaleghi is a state bridge design engineer with the Washington State Department of Trans-
portation and adjunct faculty member at Saint Martin’s University, where he is a lecturer on
civil engineering.

Khaleghi is a member of AASHTO Technical Committees T-8 Movable Bridges, T-10 Concrete,
and T-20 Roadway Tunnels. He is a member of the PCI and ASBI bridge committees and chairs
the PCI Seismic Design subcommittee. His committee work also includes the Transportation
Research Board (AFF30 Concrete and AFF50 Seismic) and the World Road Association, PIARC.
He is the recipient of IBC, PCI, ASCE, SEI, and T.Y. Lin awards.

Khaleghi received his master’s degree and doctorat in engineering from the National Institute of
Applied Sciences in France.

TECHNICAL DIRECTOR OF STRUCTURAL ENGINEERING

Glenn Myers
FOR BRIDGES AND PORTS, ATKINS, FORT LAUDERDALE, FLA.
Glenn Myers is Atkins’s principal technical professional for structural engineering of bridges and
maritime structures. He has 42 years of experience, 35 of which have been with Atkins. His work
centers on the design of highway and railroad structures, as well as underground tunnels, aerial
guideways, and stations for heavy rail, light rail, trolleys and automated people mover-systems.
He has also worked on aviation facilities, ports and marinas, and building structures.

Myers’s unique blend of experience in structures and architecture, combined with his knowledge
of the construction industry, has resulted in the design of award-winning structures recognized
for their aesthetic value, constructability, and economy. He is a registered professional engineer
and a former Florida-certified general contractor.

Myers chaired the PCI Committee on Bridges and the Girder Stability sub committee, and is a
member of the Transportation Activities Council. He has a bachelor of science degree in architec-
tural engineering and a master of science degree in civil engineering from the University of Miami.

2021
 2021
BRIDGE WITH A MAIN SPAN
UP TO 75 FEET (23 M)
KEY PROJECT ATTRIBUTES
❚ Seven precast concrete box
beams were installed in two days.
❚ New bridge abutments were
installed behind existing ones to
avoid extra permits.
❚ The original stone abutments and
wingwalls now function as scour
protection.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Demolish and replace a 50-ft
10-in. two-lane bridge.
❚ The project included seven
precast concrete box beams.
❚ The project was completed
ahead of schedule.
“The prestressed concrete beams
were also easy to fabricate and
easy to install. This reduced labor
costs and construction time.”
— William Castle,
W.J. Castle, P.E. & Associates.
48
2021 PCI DESIGN AWARDS
REPLACEMENT OLD EASTON
ROAD BRIDGE OVER PINE RUN
PLUMSTEAD TOWNSHIP, PENNSYLVANIA
In 2019, Old Easton Road Bridge in Plumstead Township had to be replaced.
Its past several inspections showed increasing scour issues and deterioration of the
main load-carrying members, indicating it was becoming structurally deficient.
The township wanted to replace the original two-lane bridge with a more robust
design, but they were limited by permit requirements and other restrictions that
prevented widening the roadway. The township also had a limited budget, which
further constrained the design team, says William Castle, founder and president of
W.J. Castle, P.E. & Associates.
“The biggest challenge was to design the bridge within the township’s limited
budget and timeframe,” Castle says. “This included construction considerations,
such as maintaining the existing under-clearance, and saving what we could on the
old bridge, while ensuring the design was able to handle the required load ratings.”
The original bridge was a single-span concrete T-beam structure founded on
stone masonry abutments. The age, foundation type, and bottom of footing ele-
vations were unknown, and no original drawings or records of the bridge were
available.
It left many questions unanswered, but Castle had worked with precast concrete
on many previous projects and he knew it would help his team to address all of
these challenges.
A 1700s LOOK IN A MODERN DESIGN
The design team came up with a solution that allowed the new bridge to remain in
the exact footprint of the previous structure and to blend seamlessly with the sur-
roundings. It included tinted stone facing on the fascia and wingwalls, precast con-
crete box beams, and painted bridge railings, to make the new bridge feel like it had
been there for centuries.
“They gave extensive thought and care to the character of the area with a
1700s-era mill that is now an elegant restaurant in the shadow of the bridge,” says
Alan Bleam, director of the Plumstead Township Public Works.
The existing stone abutments and wingwalls were left in place with the top por-
tion removed. New abutments were installed behind the existing abutments to
PROJECT TEAM:
OWNER: Plumstead Township Public Works, Plumsteadville, Pa.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER: Northeast Prestressed Products, LLC,
Cressona, Pa.
ENGINEER OF RECORD: W.J. Castle, P.E. & Associates, Hainesport, N.J.
GENERAL CONTRACTOR: DOLI Construction, Chalfont, Pa.
PROJECT COST: $1.95 million
PROJECT LENGTH: 50 ft 10 in.
 Photos: Richard Parisi.

support the adjacent precast concrete box-beam super-

structure. To accommodate the existing gas main and leave
room for future utilities, two open bays were incorporated
in the design. Reinforced concrete moment slabs were in-
stalled on top of the partially cut wingwalls, and stone fac-
ing was then added to the parapets and exterior face of the
bridge to create the desired aesthetic.
This approach reduced the earthwork required, which
made permitting easier to obtain, and preserved the exist-
ing hydraulic opening. The remaining stone abutments and
wingwalls now act as scour protection for the new bridge.
“The design provided cost and time savings to the resi-
dents of Plumstead by allowing us to forego the need for PA
DEP [Pennsylvania Department of Environmental Protec-
tion] permits to work in the waters of the commonwealth,”
Bleam says. “This was [achieved] by designing and install-
ing the new bridge abutments ‘behind’ the existing ones.”
“The prestressed concrete beams were also easy to fabri-
cate and easy to install,” adds Castle. He notes that all sev-
en box beams were installed over two working days. “This
reduced labor costs and construction time.”
The project was successfully completed in July 2020,
ahead of schedule and on budget, thanks to the innovative
design strategies and thoughtful implementation of pre-
cast concrete, Castle concludes. “The client is extremely
happy that the township now has a new bridge that is going
to last for many years.”

2021
 2021
BRIDGE WITH A MAIN
SPAN FROM 76-149 FEET
(23 TO 45 M)
KEY PROJECT ATTRIBUTES
❚ ABC construction cut road closure
time from 9 months to 60 days.
❚ The bridge deck was cast on-site
over AASHTO precast concrete
bulb-tee beams.
❚ Casting the deck on-site
eliminated profile management
issues due to differential cambers
in decked bulb tees.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Build a 195-ft bridge over
Rum Creek in Georgia.
❚ The project included 15 AASHTO
precast concrete bulb-tee beams.
❚ The project was completed
in two months.
“It was an innovative use of
precast concrete that allowed us
to reduce the duration of the
road closure and impact to the
public from months to weeks”
— Kevin Kahle,
CHA Consulting
50
2021 PCI DESIGN AWARDS
CR 661/BLACKHALL
ROAD OVER RUM CREEK
HENRY COUNTY, GEORGIA
Like many bridges built in the 1960s, the original Blackhall Road bridge over
Rum Creek in Georgia didn’t meet modern design standards. It was narrow,
with a substandard vertical curve, and showing signs of wear. The Georgia Depart-
ment of Transportation (GDOT) wanted a bigger and better bridge that would
meet the community’s needs with minimal disruption to the flow of traffic.
That’s where problems arose. The original plan was to close the road for nine
months while a replacement was built. However, that generated a local uproar in
the community, causing the project team to rethink their design and reduce the
closure time to just two months. They came up with a hybrid precast concrete
solution using accelerated bridge construction (ABC) techniques to create the new
195-ft two-lane bridge with 2-ft travel lanes and 8-ft shoulders.
HYBRID DESIGN SOLUTION TO SITE CONSTRAINT ISSUES
Because the jobsite is tight due to a nearby dam and homes, the design team came
up with a plan to use American Association of State Highway and Transportation
Officials (AASHTO) precast concrete bulb-tee beams as the base of the bridge,
then to cast the bridge deck on top of them at designated staging areas on-site.
“It was the first project in Georgia to use a hybrid concept of using precast con-
crete beams and precasting the deck in an on-site lay-down area while maintaining
the traffic on the existing bridge,” says Dexter Whaley, bridge design ABC liaison for
GDOT.
By casting the deck in place at the project site, the common problem of profile
management created by differential cambers in precast concrete decked bulb tees
was eliminated. False bents that matched the vertical profile and cross slope of the
proposed bridge superstructure were fabricated to make construction work.
This method allowed the bridge superstructure to be constructed before closing
the road. “It was an innovative use of precast concrete that allowed us to reduce
the duration of the road closure and impact to the public from months to weeks,”
says Kevin Kahle of CHA Consulting.
Once the roadway was closed, the existing bridge was demolished and the new
permanent bridge foundations and substructures were constructed. After the sub-
structure was completed, the deck girders were transported and erected on the
permanent bridge substructures using an 800-ton-capacity crane. Steel dia-
phragms were used as both temporary bracing for the initial deck pour in the stag-
PROJECT TEAM:
OWNER: Georgia Department of Transportation, Atlanta, Ga.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER: Standard Concrete Products, Savannah, Ga.
ENGINEER OF RECORD: CHA Consulting, Atlanta, Ga.
GENERAL CONTRACTOR: C.W. Matthews, Marietta, Ga.
PROJECT COST: $5 million
PROJECT LENGTH: 195 ft
ing yard, then they were reinstalled and the bridge edge
beams and end-walls were formed and cast with 24-hour
concrete. Wood formwork and foam were used to create
block outs for the 9-in. closure pour between the precast
concrete decked beam unit.
When the deck was fully cured, the skim pour was
chipped out and the foam and wood forms were removed.
The skim pour created cross-slope continuity across the
deck that would not require additional grinding to achieve a
consistent deck surface between each decked beam unit.
In the final phase of construction, 9-in. closure strips
were poured using ultra-high-performance concrete, and
the deck was ground to remove minor undulations. After
grooving and completion of the roadway approaches, the
road was reopened to traffic on schedule, after a closure of
only 60 days.
“The use of precast concrete for this project demonstrat- Photos: CHA Consulting Inc. and CW Matthews Contracting Co.
ed how it is possible to use the standard AASHTO precast
concrete beams that were readily available from the Geor-
gia fabricators to develop an accelerated bridge construc-
tion solution that allowed the bridge to be completed in
under 60 days,” says Jim Aitken of CHA. “This solution did
not require any specialty contractors or equipment, and
other than the use of a few special details and the ul-
tra-high-performance concrete closure pours, it was con-
structed like any other bridge in the GDOT inventory with
the same durability and maintenance expectations.”

2021
 2021
BRIDGE WITH A MAIN
SPAN MORE THAN
150 FEET (46 M)
KEY PROJECT ATTRIBUTES
❚ Precast concrete girders
weigh up to 186,920 lb.
❚ The girders have a lifecycle of
more than 100 years—25 years
more than the standard service life
of bridges in this region.
❚ The PCI-certified producer used
specialized trucks with steerable
trailers to transport the massive
girders on Vermont’s
winding roads.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Build two 863-ft precast concrete
bridges over the Williams
River in Vermont.
❚ The project included 70 precast
concrete girder segments ranging
from 96 to 147.5 ft.
❚ Girder installation was completed
in six weeks for the northbound
bridge, and 10 weeks for the
southbound bridge.
“Precast, prestressed concrete
provides great long-term durability
as well as reduced maintenance
efforts over its lifetime versus a
steel superstructure.”
— Carolyn Cota,
Vermont Agency
of Transportation
52
2021 PCI DESIGN AWARDS
ROCKINGHAM I-91 BRIDGES
24N AND 24S – IM 091-1(66)
ROCKINGHAM, VERMONT
In Rockingham, Vt., there were two bridges over the Williams River that were
falling into disrepair. They were built in the 1960s and were not designed to with-
stand the increasing flow of traffic in the region. An engineering study around 2015
determined that the most cost-effective solution was to replace both bridges.
When the owners put out a call to engineers for proposals, HDR’s team consider
five possible design options, laying out the benefits and challenges of each. They
ultimately chose an innovative precast concrete design using pretensioned bulb-
tee beam segments that are post-tensioned together.
“A high-level cost analysis of each option showed that the four-span, spliced
precast concrete girder alternative was the least costly, and best met their means
and methods,” says Thomas French, senior project manager and office leader for
HDR. He notes that the girders are designed for a 100-year life span, exceeding the
typical 75-year standard service life for bridges in the area. The design includes us-
ing high-performance 9000-psi concrete, and stainless steel for any projecting
steel.
The project owner agreed that precast concrete was the best choice. “Precast,
prestressed concrete provides great long-term durability as well as reduced main-
tenance efforts over its lifetime versus a steel superstructure,” says Carolyn Cota,
project manager for the Vermont Agency of Transportation (VTrans). The spliced
precast concrete girder option brought many ancillary benefits to the project. It
allowed a reduction in superstructure depth and weight, will require minimal
maintenance, and has a smaller “coefficient of expansion,” reducing the need for
multiple large bridge joints.
This is a major issue for bridges in the region, says project engineer David Peter-
son. “VTrans has found that failing bridge joints are one of the largest factors in
reducing the life of a bridge and increasing the need to perform maintenance and
repairs, especially in colder climates where road salt is heavily used during the win-
ter,” he says.
A LONG AND WINDING ROAD
The winning design features two distinct bridges with individual substructures and
continuous girders. The new bridges are wider than the existing structure, with two
12-ft travel lanes, a 4-ft left side shoulder, and a 10-ft breakdown lane. Both bridges
24N and 24S have abutments and pier substructures supported by footings on
piles, with the exception of one pier on the southbound bridge bearing on bedrock.
PROJECT TEAM:
OWNER: Vermont Agency of Transportation, Barre, Vt.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER: J. P. Carrara & Sons, Inc., Middlebury, Vt.
ENGINEER OF RECORD: HDR, Manchester, N.H.
GENERAL CONTRACTOR: Reed & Reed, Woolwich, Maine
PROJECT COST: $45 million
PROJECT LENGTH: 863 ft

The main prestressed concrete beam segments range in
weight from 144,920 lb to as much as 186,920 lb. “The final
design was based on J. P. Carrara’s capacity to fabricate and
ship the elements to the jobsite,” French says. The girders
maxed out the lifting capacity at the Middlebury, Vt., plant,
and Carrara used professional drivers and trucks with steer-
able trailers to safely transport the girders along the wind-
ing roads that led to the jobsite.
Once demolition was complete, the bridges were con-
structed in two phases with one bridge built at a time.
Highway crossovers were used so that one lane of traffic in
each direction was maintained on the existing bridge while
the new bridge was constructed adjacently, preventing the
need for total road closure.
Photos: J. P. Carrara & Sons Inc.
Due to the large size of the girders, cranes with 440-ton
capacity were required to install them. The contractor built
a temporary trestle across the river that had enough capac-
ity to hold the weight of the cranes as well as the picks.
The resulting bridges were completed on schedule in the
fall of 2020, and the owners are thrilled with the results.
“The continuity between the superstructure and sub-
structure provides an aesthetically pleasing bridge,” Peter-
son says. “Vermont is a small state, so when we are giving
the opportunity to provide a unique bridge for the public,
we take pride in making that happen.”
2021
 2021
REHABILITATED BRIDGE
KEY PROJECT ATTRIBUTES
❚ Thirty pullover lanes were
assembled and installed on two
overwater bridges with almost
no lane closures.
❚ Assembly-line construction on
the jobsite accelerated progress.
❚ Self-propelled modular trans-
porters were used for deck
span installation.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Build 30 safety bays on two
bridges over Lake Pontchartrain.
❚ The project included more than
900 precast concrete elements.
❚ Precast concrete erection
began in February 2019 and was
completed in April 2020.
“Using prefabricated components
allowed for all major elements
to be constructed off-site in a
controlled setting and then
transported and assembled
on the bridge.”
— Carlton Dufrechou,
Greater New Orleans
Expressway Commission
54
2021 PCI DESIGN AWARDS
LAKE PONTCHARTRAIN
CAUSEWAY SAFETY BAY
IMPROVEMENTS
NEW ORLEANS, LOUISIANA
The Lake Pontchartrain Causeway features two bridges that span nearly 24
miles over water. The bridges, which were built in 1956 and 1969, are among the
longest overwater bridges built in their time. And because they don’t have shoul-
ders, when accidents occur, traffic on the bridges comes to a halt. As traffic in the
region grew, the bridges were seeing 8 to 12 breakdowns daily, and 180 crashes per
year, many of them rear-end collisions, says Christopher White, senior bridge engi-
neer for Volkert. To improve safety and traffic flow, the owners wanted to add safe-
ty bay shoulders up and down both bridges to support stranded vehicles.
The use of precast concrete and accelerated bridge construction (ABC) was key
to the safe and successful delivery of this project.
“The original causeway bridge was built entirely out of precast components and
was the first project ever to employ mass production and assembly-line techniques
in fabricating and assembling a bridge,” White says. “Its use of prefabricated bridge
elements and systems and ABC was decades ahead of its time.”
In 2018, the owners embarked upon the upgrade to add 1008-ft pullover lanes at
multiple locations in both directions. “The goal from the get-go was to add the
most emergency stopping area for the least cost and with the least impacts to
commuters,” says Carlton Dufrechou, general manager of the Greater New Orle-
ans Expressway Commission.
The bridges support 40,000 vehicle crossings every day, which meant lane clo-
sures during construction were not feasible. So the project team chose an all–
precast concrete solution, which included precast concrete cylinder piles, pile
caps, and composite girder/slab deck units with barrier rails. “Using prefabricated
components allowed for all major elements to be constructed off-site in a con-
trolled setting and then transported and assembled on the bridge,” Dufrechou
says. “This saved time, money, and almost entirely eliminated delays to our 40,000
daily commuters.”
ASSEMBLY-LINE CONSTRUCTION
To speed construction, the contractor set up long-line fabrication beds along the
waterfront. Each line could accommodate components for one complete 1008-ft
safety bay, consisting of 12 spans for the northbound structure and 18 spans for the
southbound structure.
PROJECT TEAM:
OWNER: Greater New Orleans Expressway Commission, Metairie, La.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER: Gulf Coast Prestress Partners, Ltd.,
Pass Christian, Miss.
ENGINEER OF RECORD: Volkert, Inc., Houston, Tex.
GENERAL CONTRACTOR: Boh Bros. Construction Co. LLC, New Orleans, La.
PROJECT COST: $57.5 million
PROJECT SIZE: 175,894 ft²
 Photos: BOH Bros. Construction Co. LLC.

Once one span was installed, the barge moved to the

next span and that deck unit was transported into place.
This process was then repeated for each span until the en-
tire bay had been erected. Each bay was loaded in reverse
order so that the final span loaded would be the first one
erected at the bridge site.
Using the assembly-line method allowed the contractor
to keep dedicated crews for each step continuously working
somewhere along one of the lines. When the first line was
ready for loadout, the pieces were transferred to a barge and
the second line moved into assembly. Then the first bed was
turned over to begin repeating the process for the next bay.
The long-line method also facilitated deck alignment at
the bridge site. Assembly pedestals allowed vertical adjust-
ments, using shims to ensure the constructed spans would
best fit the geometry of the adjacent existing deck spans
over water. This was critical due to the misalignment of
spans that had occurred due to storms and minor vessel
collisions with pier bents over time.
All of this was performed with no lane closures on the
southbound structure, and only a limited number of night
lane closures on the northbound structure. Throughout
construction, the existing bridge rails remained in place to
ensure safety for the traveling public and the workers.
“The bridge is ‘living proof’ that precast concrete is resil-
ient,” White says. “So it only made sense that precast con-
crete would be used for this first major upgrade to the
causeway in half a century.”

2021
 2021
NON-HIGHWAY BRIDGE
KEY PROJECT ATTRIBUTES
❚ Two 182-ft girders were made
continuous to allow the removal of
a post-tensioned straddle bent.
❚ Optimized design eliminated the
need for five 9-ft shafts.
❚ Prestressed concrete stay-in-
place deck forms were used on the
guideway structure to increase
construction speed.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Build a 4569-ft bridge to
support light-rail extension.
❚ The project included 128
precast concrete pieces.
❚ The project was completed
in August 2020.
“Using precast simplified designs
sped up project delivery, increased
quality of materials, and reduced
the impact of construction
on the neighborhood.”
— Catherine Hovell,
T. Y. Lin International
56
2021 PCI DESIGN AWARDS
SOUND TRANSIT E360
GUIDEWAY BRIDGE
BELLEVUE, WASHINGTON
The city of Bellevue is making significant investments in public transporta-
tion to make it easier for citizens to traverse the region. That includes extend-
ing its local light-rail system to connect two major metropolitan city centers. This
process included the design-build of the E360 guideway bridge, a 0.86-mile struc-
ture adjacent to the highly-traveled Washington State Department of Transporta-
tion State Route 520.
“With a design-build delivery, construction cost and schedule are always top prior-
ity, or else we would not have won the original bid,” says Catherine Hovell, of T. Y. Lin
International. Her team’s winning design also had to ensure the design was com-
patible with future expansion goals to accommodate the adjacent roadways.
They chose a precast concrete design early in the process to address these con-
straints. “Using precast simplified designs sped up project delivery, increased qual-
ity of materials, and reduced the impact of construction on the neighborhood,” she
says. “For a project like this, located next to a major freeway and employment hub,
these benefits were significant towards positive public opinions on the project.”
CONTINUOUS SPANS
The final design features 31 spans ranging from 125 to 182 ft, and four parallel wide-
flange girders, ranging in depth from 74 to 100 in. Typical spans are 95-in. girders
spanning 140 ft.
During the design phase, the plan was optimized to minimize the number of
foundations required, which allowed the design team to eliminate five 9-ft shafts
from the original design. A 65-ft post-tensioned straddle bent was also eliminated
by using the two 182-ft spans made continuous over a fixed pier. “This adjustment
opened space under the guideway for a new highway off-ramp to be constructed in
the future,” Hovell says.
Of the 128 prestressed concrete girders fabricated, 80 were the same size and
length, with only minor changes in prestressing strand design, which helped accel-
erate delivery and minimize trades on-site. Consistent girder and pier designs were
used to increase fabrication quality and further expedite construction.
That speed, quality, and efficiency was seen as a major benefit to the project,
according to Eza Agoes, deputy project director for Downtown Redmond Link Ex-
tension (R200). “E360 ’s use of precast bridge concrete panels eliminated the use
of time-consuming, labor-intensive formwork that would otherwise be needed to
deliver a cast-in-place concrete deck for the bridge superstructure construction,”
PROJECT TEAM:
OWNER: Sound Transit, Seattle, Wash.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER: Concrete Technology Corporation,
Tacoma, Wash.
ENGINEER OF RECORD: T. Y. Lin International, Olympia, Wash.
GENERAL CONTRACTOR: Kiewit-Hoffman East Link Constructors, Federal Way, Wash.
PROJECT COST: $225 million
PROJECT LENGTH: 4569 ft
 Photos: T.Y. Lin International.

Agoes says. “Additionally, the precast concrete panels were

placed faster on-site, minimizing the number of traffic clo-
sures needed for the bridge deck construction.”
To further increase construction speed, precast, pre-
stressed concrete stay-in-place deck forms were used on
the guideway structure. The structure was laid out in a
manner that will allow construction of a future slip ramp
between the columns. “The construction speed and mini-
mal disruption would not have been possible without the
use of long-span prestressed concrete girders,” Hovell says.
Using precast concrete also created a safer jobsite, Agoes
adds. “It allowed considerable work to be done off-site,
reducing safety exposures to construction workers and the
public around the construction site.”

2021
 2021
TRANSPORTATION
SPECIAL SOLUTION
KEY PROJECT ATTRIBUTES
❚ The choice of a precast concrete
design accelerated construction
and reduced costs.
❚ It will require less maintenance
than a steel structure.
❚ Tight quality control procedures
at the plant enabled the team to
meet strict mixture design
specifications.
PROJECT AND PRECAST
CONCRETE SCOPE
❚ Build a 40,500-ft² cargo
dock and ramp.
❚ The project included nearly 400
precast concrete elements.
❚ Precast concrete erection was
completed in five months.
“Precast concrete construction also
minimized the need for expensive
overwater formwork, which would
have been required for
cast-in-place construction.”
— Louis Klusmeyer,
Port of Corpus Christi Authority
58
2021 PCI DESIGN AWARDS
PORT OF CORPUS CHRISTI
NORTH BANK CARGO DOCK 16
CORPUS CHRISTI, TEXAS
In 2018 the Port of Corpus Christi Authority put out a request for proposals to
design and build a new 40,500-ft² cargo dock and ramp for the port’s North
Bank. The dock had to be durable enough to support a steady stream of cargo from
the Handymax and Panamax vessels arriving in the port.
“One of the challenges on this project was to develop the most cost-effective
solution,” says Louis Klusmeyer, the port’s chief of design for engineering services
at the time of the project.
The design they chose featured a precast, prestressed concrete pile-supported
ship dock, consisting of precast concrete beams, precast, prestressed concrete
slabs, and a cast-in-place topping slab.
The use of precast concrete piles, pile caps, and deck panels met the financial
goals, with added financial benefits achieved through rapid erection of the struc-
ture. That reduced the need for costly floating cranes and associated labor costs,
Klusmeyer says. “Precast concrete construction also minimized the need for ex-
pensive overwater formwork, which would have been required for cast-in-place
construction.”
FLEXIBILITY FOR THE FUTURE
Once the design was approved, the biggest challenge for the precast concrete pro-
ducer was meeting stringent concrete mixture design specifications, which would
have been very difficult to accomplish without the use of plant-cast precast con-
crete. It required tight quality control procedures, which the precast concrete pro-
ducer was able to meet by following close specification requirements set by the
design team.
Once on-site, the precast concrete elements were erected in just five months.
The precast concrete slabs delivered the necessary strength and functionality,
while serving as an in-place forming system over water, which enhanced the proj-
ect schedule while improving worker safety.
“The precast concrete deck concept not only simplified the installation of top-
sides, including the ship unloader rails, but also provided enough flexibility for fu-
ture liquid bulk operations,” says Carlos E. Ospina, former vice president of Berger-
ABAM and current vice president of WSP USA. “Innovative design ideas and close
communication with the design-builder owner and suppliers were paramount for
the success of the project.”
PROJECT TEAM:
OWNER: Port of Corpus Christi, Corpus Christi, Tex.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER: Heldenfels Enterprises, Inc., San Marcos, Tex.
PRECAST CONCRETE SPECIALTY ENGINEER: Eriksson Technologies, Temple Terrace, Fla.
ENGINEER OF RECORD: BergerABAM, Houston, Tex.
GENERAL CONTRACTOR: Orion Construction, Deer Park, Tex.
PROJECT COST: $17.5 million
PROJECT SIZE: 40,140 ft²
 The final design now provides a highly efficient structure
that will meet the needs of the port and its clients for years
to come. With ample space, lots of storage, and a highly
durable, extremely low-maintenance structure, the termi-
nal is now open for business, accommodating cargo ships
coming from around the globe.
Photos: Orion Construction LP.
“The additional benefits of precast beyond the cost sav-
ings is the greater durability and longer time until first re-
pair that precast concrete exhibits over a steel structure,”
Klusmeyer says. “This was important to reduce the long-
term maintenance costs of the facility to the owner.”

2021
 HONORABLE MENTIONS
Government and Public Building
NATHAN DEAL
JUDICIAL CENTER
ATLANTA, GEORGIA
KEY PROJECT ATTRIBUTES
❚ Use of precast concrete delivered a limestone
aesthetic in a cost-effective, energy-efficient
package.
❚ Panels had to be sized to accommodate
long-span crane placement on a tight jobsite.
❚ Spray foam insulation on precast concrete panels
helped deliver R-values exceeding code minimums.
PROJECT AND PRECAST CONCRETE SCOPE
❚ Deliver a precast concrete façade to mimic
limestone architecture for a state government
building.
❚ The project included 972 precast concrete pieces.
❚ Precast concrete erection was completed in less
than one year.
Photo: © Brian C. Robbins.
60
2021 PCI DESIGN AWARDS
The new seven-story Nathan Deal Judicial Center in Atlanta, Ga., was
designed to reflect its status as a state government building and to com-
plement the classical architecture of the nearby Capitol Hill district.
Early design ideas included cladding the building in marble to match oth-
er state government buildings in the district, or using limestone cladding to
correspond with the Georgia State Capitol. However, the design team ulti-
mately chose to use precast concrete because it could deliver the desired
stone look in a durable, cost effective, and energy-efficient package. Addi-
tionally, a precast concrete structure would also be faster and easier than
the alternatives to erect on the tight jobsite.
SIZING PANELS FOR LONG-SPAN PLACEMENT
Early design-assist workshops helped the design team fast-track project
coordination; fine-tune the precast concrete wall panel sizes for efficient
shipping, crane lift, and installation; and control the location of panel
joints to support the overall façade’s design.
The combination of spray foam insulation on the back of the precast
concrete panels and traditional stud wall framing with batt insulation at
the building perimeter provided excellent R-values (R-30) for wall assem-
bly, significantly exceeding code minimums. Working in tandem with
high-performance glazing, the exterior envelope contributes to lower ener-
gy costs and greater occupant comfort, while eliminating road noises from
adjacent highways.
To mimic the limestone on the adjacent Capitol Building, the precast
concrete producer developed a perfect color match using a blend of local
materials combined with a quality cement and dye combination. The faces
of the panels are acid etched to look like Indiana limestone, which is nor-
mally cut from large blocks.
During construction, the siting of the building and adjacent interstate re-
taining walls restricted crane access; therefore, all panels had to be sized below
crane capacity to achieve an extended reach. The panel sizes were coordinated
with the panel articulation desired by the design team and are indiscernible.
Because the entryway panels are granite clad, they had to be broken up
several times to stay under crane load capacity. At the colonnade, the col-
umn surrounds had to be installed first, and then the spandrels were in-
stalled at the back side. The erector shimmed these spandrels off the col-
umn surrounds to keep the tube beams from rotating; after this was done,
workers were able to install the front spandrel panels to be balanced.
The result is a stunning companion building to the State Capitol, rein-
forcing this new building’s status as a central home for state government.
PROJECT TEAM:
OWNER: Georgia Building Authority, Atlanta, Ga.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER: Gate Precast Company, Monroeville, Ala.
PRECAST CONCRETE SPECIALTY ENGINEER: Gate Precast Company, Lexington, Ky.
ARCHITECT AND ENGINEER OF RECORD: Stevens & Wilkinson, Atlanta, Ga.
DESIGN ARCHITECT: Robert A.M. Stern Architects, New York, N.Y.
GENERAL CONTRACTOR: Gilbane Building Company, Atlanta, Ga.
PCI-CERTIFIED ERECTOR: Precision Stone Setting Company, Hiram, Ga.
PROJECT COST: $130 million
PROJECT SIZE: 235,225 ft²
When the Moss and Johns Residence Halls at Longwood University
were erected in 1969 and 1970, they were built out of concrete ma-
sonry with uninsulated brick cavity walls. Fifty years later, when the
10-story residence halls needed repair, the university considered demol-
ishing them but opted instead to renovate the buildings with an insu-
lated precast concrete, brick-faced panel system that could mimic the
traditional aesthetic of the historic college campus. The precast con-
crete solution saved time and money, while retaining the welcoming
appearance of these structures.

DOWN TO THE FRAME

To transform the outdated residence halls to include modern ameni-
ties, the project team had to first strip them down to the steel frame.
The entire façade was then replaced with an architectural precast con-
crete panel system supported on separate foundations that did not add
loading to the existing structural steel frame.
The design team worked directly with the precast concrete producer,
using building information modeling software to develop the final de- Higher Education/University Building

MOSS JOHNS
tailing of the building envelope. This allowed smooth development and
approval of shop drawings, so that the production of the panels could
be accelerated to meet the project schedule.
The primary design challenges for the project were achieving consis-
tent architectural details and giving the monotonous layout some ar-
ticulation and architectural interest. The designers were able to achieve
RESIDENCE HALLS
FARMVILLE, VIRGINIA
the intricate detailing while staying within the budget through the use
repetitive forms, which included thin brick embedded in precast con-
crete with limestone accents with an acid-etched finish. Off-site pre-
casting also sped up construction and reduced the number of trades on
site at the busy campus. This helped the team meet the strict goal of KEY PROJECT ATTRIBUTES
❚ Architectural precast concrete panels deliver
renovating each building within one academic year.
historic architectural detail in a cost-effective
The designers used highly repetitive forms for the precast concrete package.
façade panels to achieve consistent architectural details and align- ❚ The panel system is supported on separate
ments. Then, they placed the panels in different configurations to add foundations that do not add load to the
variety to the design. Durability and precision were achieved through existing steel frame.
factory-controlled production, which delivered the panels to the jobsite ❚ Each renovation was delivered within
one academic year.
precisely when they were needed.
The self-supporting precast concrete cladding system brought beau-
ty, structural capability, and excellent thermal performance to the PROJECT AND PRECAST CONCRETE SCOPE
campus on a demanding schedule. Each building, from demolition to ❚ Completely renovate two 10-story
residence halls.
occupancy by students, was completed within one year.
❚ The project included 740 precast
concrete architectural wall panels.
❚ The first tower was delivered in
PROJECT TEAM: August 2019, the second in August 2020.

OWNER: Longwood Housing Foundation, Farmville, Va.

PCI-CERTIFIED PRECAST CONCRETE PRODUCER: Gate Precast Company, Oxford, N.C. Photo: T. Frisbie-Fulton.
PRECAST CONCRETE SPECIALTY ENGINEER: Gate Precast Company, Brentwood, Tenn.
ARCHITECT OF RECORD: Little Diversified Architectural Consulting, Arlington, Va.
DESIGN ARCHITECT: Franck & Lohsen Architects, Washington, D.C.
ENGINEER OF RECORD: Alpha Corporation, Sterling, Va.
GENERAL CONTRACTOR: English Construction, Lynchburg, Va.
PCI-CERTIFIED ERECTOR: E. E. Marr Erectors, Baltimore, Md.
PROJECT COST: $63 million
PROJECT SIZE: 217,678 ft² 2021
 HONORABLE MENTIONS
Multi-Family Building
1550 MISSION
SAN FRANCISCO, CALIFORNIA
KEY PROJECT ATTRIBUTES
❚ Precast concrete panels are exposed on both
sides, so strict vibration control was required
during pouring.
❚ Two-color design features sharp lines between
contrasting design elements.
❚ Reinforcing steel inserts add structural strength
for panels with large windows.
PROJECT AND PRECAST CONCRETE SCOPE
❚ Create a precast concrete façade for a
40-story residential tower.
❚ The project included 845 precast
concrete panels.
❚ Precast concrete erection was completed
in one year.
Photo: © SOM/Mark Schwettmann.
62
2021 PCI DESIGN AWARDS
The new high-rise residential tower on Mission Street in San Francisco,
Calif., is bringing affordable living and retail space to an increasingly
expensive city. The 40-story residential tower provides 550 homes, includ-
ing 110 that are affordable to low-income residents. It also offers a wide range
of retail, community, and outdoor residential spaces on multiple levels.
The initial decision to use precast concrete for this project came from the
team’s desire to construct a cost-effective building that stood as the gate-
way to San Francisco’s Civic Center, in a neighborhood full of limestone,
plaster, and concrete buildings. Precast concrete also supported the team’s
desire to include large windows and areas of uninterrupted glass on the
building, and to minimize the amount of site labor and crane time in the
busy neighborhood.
BEYOND THE VEILS
The final design was inspired by the prominence, geometry, and adjacency
to the Civic Center. On the façade, two primary precast concrete surfaces
wrap opposing corners of the building with a gently curved, variegated skin,
which dramatically parts at the acute corner of the site. This gradually wid-
ening seam supports a series of residential balconies and is framed by two
luminously white precast concrete veils.
A variegated grid of narrow white precast concrete has been used to
form three sides of each window, with the fourth side created from a dark-
er, polished material that blends into the look and proportion of the win-
dows. In this way, both lightness and mass are achieved at once.
To achieve the design, cast panels had be exposed from both sides, and
the precast concrete producer had to incorporate two colors into one pan-
el with a polished concrete finish for one of the colors. Additionally, the
precast concrete producer had to minimize vibration during the pour pro-
cess or hand-seed the exposed poured side with additional aggregate to
achieve a consistent sandblasted finish on both sides of the panels. The
timing to pour the two colors was also crucial to ensure both parts of the
design would cure together as one bonded piece without bleeding. This re-
quired extra quality control for the duration of casting. Once cast, hand-
held polishing equipment was used to achieve the polished black look.
To accommodate the large windows with minimal concrete around
them, each panel had to work as one solid, cured concrete beam. There-
fore, the precast concrete producer developed a specific pour procedure for
careful placement of concrete and inserted reinforcing steel to add struc-
tural strength. The new building provides a beautiful, energy-efficient hav-
en for residents, proving once again that precast concrete can be an ideal,
cost-efficient solution for projects with high envelope performance and
aesthetic value.
PROJECT TEAM:
OWNER: Related California, San Francisco, Calif.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER: Willis Construction Co., Inc.,
San Juan Batista, Calif.
ARCHITECT: Skidmore, Owings & Merrill, San Francisco, Calif.
ENGINEER OF RECORD: DCI Engineers, Seattle, Wash.
GENERAL CONTRACTOR: Build Group, San Francisco, Calif.
PROJECT SIZE: 760,000 ft²
Immersed in the grand beauty of the Rocky Mountains, this project
combines mountain charm and luxurious living in a highly sought-after
vacation destination. This project added five additional mixed-use struc-
tures to service the current residents and the ski base area.
Erected at a challenging mountain jobsite, the buildings had strict seis-
mic design requirements and had to be delivered in tight time frames
despite unpredictable winter weather. The designer chose a total–precast
concrete solution using emulative design techniques to meet all of these
challenges. The emulative design cut 24 months from the original cast-
in-place construction timeline, while netting the owner extensive cost
savings. The design also met all seismic requirements and allowed the archi-
tect to incorporate higher ceilings without making the building taller.

FAST-TRACK ERECTION
Extensive coordination among the design, engineering, general contractor,
and precast concrete producer teams was necessary to meet the rigorous
project requirements with minimal disruption to residents and visitors
throughout the design, delivery, and construction of the buildings. The Mixed-Use Building

YELLOWSTONE
team also had to work out extremely complex framing geometry and shal-
low floor plates in the residential units to ensure stringent height require-
ments were met.
The project’s precast concrete scope had 4613 premanufactured compo-
nents, including retaining walls, hollow-core flat slabs, double tees, span-
drels, uninsulated monolithic shear/shaft walls, columns, shallow beams,
CLUB
BIG SKY, MONTANA
a short V-shaped wall, soffit beams, and bidirectional balcony slabs. In to-
tal, 16,900 yd³ of concrete were shipped in 1342 truckloads from Colorado
Springs, Colo., to the ski resort, and erected over a 12-month period. The
largest piece weighed 86,000 lb.
Precast concrete was used for 96 unique balcony elements, many with KEY PROJECT ATTRIBUTES
❚ Emulative design shortened the original
drastically different geometries. The balconies required bidirectional pre-
cast-in-place construction timeline by 24 months.
stressing of many members, followed by post-tensioning of the cantile-
❚ Almost 17,000 yd³ of concrete were shipped in
vered slab to resolve negative moments. 1342 truckloads from Colorado Springs, Colo.,
To meet the aggressive timeline, the project team facilitated a fast-track to Big Sky, Mont.
schedule over four seasons, battling extreme temperatures and several se- ❚ All structures met or exceeded International
vere freeze/thaw cycles. The off-site production of precast concrete com- Energy Conservation Code guidelines.
ponents limited the negative impact of weather on the construction cycle.
The end result of the project is a beautiful and durable solution that PROJECT AND PRECAST CONCRETE SCOPE
meets extreme seismic activity requirements. Additionally, all the struc- ❚ Build five total–precast concrete
tures met or exceeded International Energy Conservation Code guidelines, mountain-side buildings.
ensuring the community and its residents will be able to meet stringent ❚ The project included 4565 precast
concrete components.
energy-efficiency requirements.
❚ The project was completed in just 12 months.

Photo: Stresscon Corp.

PROJECT TEAM:
OWNER: Yellowstone Club, Big Sky, Mont.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER: Stresscon Corporation, Colorado Springs, Colo.
PRECAST CONCRETE SPECIALTY ENGINEER: FDG, Arvada, Colo.
ARCHITECT: Hart Howerton, San Francisco, Calif.
ENGINEER OF RECORD: Nishkian Menninger, San Francisco, Calif.
GENERAL CONTRACTOR: G.E. Johnson Construction Company, Colorado Springs, Colo.
PCI-CERTIFIED ERECTOR: EnCon Field Services, Denver, Colo.
PROJECT COST: $312 million
2021
PROJECT SIZE: 485,716 ft²
 HONORABLE MENTIONS
MENTION
This five-level precast concrete parking structure is part of an innova-
tive new health center at the University of Pennsylvania. The under-
ground structure supports half of the 17-story, 1.5-million ft² steel patient
center, which will house 500 private patient rooms, 47 operating rooms, and
a 61-room emergency department.
Constructed 67 ft underground, the parking structure includes 689 parking
spaces to serve the patient pavilion, two stair towers, a series of elevator
shafts, and two precast concrete cisterns, as well as provisions for fuel tanks,
a network, locksmith, materials management, and information technology.
The designer chose precast concrete for the project in part due to the
speed of erection it would afford the larger initiative. However, digging 67 ft
underground to build a parking deck that would eventually support half of
the 1.5 million ft² structure created several challenges.
The first was proving the precast concrete design could support the weight
of the structure. The designers were confident it would work, and in-depth
study proved them to be correct. The design solution was to emulate a cast-
in-place concrete design with precast concrete elements so that the struc-
All-Precast Concrete tural performance is equivalent to that of a conventionally designed, cast-in-
Parking Structure place, monolithic concrete structure.

THE PAVILION SIX MILLION POUNDS

PARKING DECK
PHILADELPHIA,
PENNSYLVANIA
KEY PROJECT ATTRIBUTES
❚ Designers used emulative detailing to achieve
structural performance with precast concrete
equivalent to a cast-in-place design.
❚ The use of precast concrete significantly
accelerated the construction schedule.
❚ Many of the typical columns were designed
for loads in excess of 6 million lb.
PROJECT AND PRECAST CONCRETE SCOPE
❚ Build a five-level underground parking structure
that partially supports a 17-story patient pavilion.
❚ The project included 1138 pieces of
precast concrete.
❚ Precast concrete construction was
completed in 14 months.
The new structure was designed and detailed to meet the requirements of
the applicable building code as if it were to be constructed of monolithic
cast-in-place reinforced concrete. However, the structure was divided into
structural elements of sizes and shapes that could be plant fabricated, trans-
ported, and safely and efficiently erected on site. This method is consistent
with American Concrete Institute (ACI) 550.1R-09, Guide to Emulating Cast-
in-Place Detailing for Seismic Design of Precast Concrete Structures, and is
judged by ACI to be applicable to any structural system where monolithic
structural concrete would also be appropriate.
The above-grade patient tower is supported primarily on below-grade pre-
cast concrete framing. To support the massive pavilion, many of the typical
columns had to be designed for loads in excess of 6 million lb. Typical precast
concrete columns were 33 × 66 in. using 9000-psi concrete.
The pavilion’s lateral force–resisting system is primarily composed of steel-
braced frames around the stair and elevator core. At the transition from above-
grade steel framing to below-grade precast concrete framing, the steel-braced
frames distribute loading to precast concrete shear walls beneath. Lateral
loads from the pavilion are also distributed into the below-grade floor dia-
phragms to the below-grade columns and perimeter walls.
This innovative use of precast concrete significantly accelerated the con-
struction schedule and allowed work on the massive steel patient pavilion to
begin sooner than would have been possible with cast-in-place concrete con-
struction.

PROJECT TEAM:
Photo: Hover Solutions, LLC.
OWNER: University of Pennsylvania, Philadelphia, Pa.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER: Shockey Precast, a Metromont Company, Winchester, Va.
PRECAST CONCRETE SPECIALTY ENGINEER: FDG, Arvada, Colo.
ARCHITECT: HDR, Charlotte, N.C.
ENGINEER OF RECORD: HDR, Washington, D.C.
GENERAL CONTRACTOR: LF Driscoll/Balfour Beatty Joint Venture, Bala Cynwyd, Pa.

64
2021 PCI DESIGN AWARDS
PCI-CERTIFIED ERECTOR: Jonasz Precast, Inc., Westville, N.J.
PROJECT SIZE: 1.5 million ft²
Madison, Wis., is the state capital and a bucolic college town, famous for
its architectural history, beautiful lakeside settings, and the active cam-
pus of the University of Wisconsin. One of the latest additions to the univer-
sity is the Mead Witter School of Music’s Hamel Music Center. The new center,
which includes a 650-seat concert hall, a 330-seat recital hall, and a large re-
hearsal room, is a significant component of the university’s east campus devel-
opment plan.
When planning for the new center, the designers had to take into account
the many challenges of building a world-class music center in the heart of a
busy and crowded urban setting. Those challenges led them to a precast con-
crete design solution.
Precast concrete appealed to designers because it is durable and flexible,
and because it provides unique opportunities to create a dramatic exterior ef-
fect. The precast concrete design helped maximize the footprint of the site Theater Structure

MEAD WITTER
while minimizing concerns about traffic noise and vibrations that could com-
promise the precise acoustic needs of the building’s multiple performance

SCHOOL OF MUSIC–
spaces.

BOX IN A BOX
The building design, both inside and out, was driven by the acoustic goals at the HAMEL MUSIC CENTER
heart of the project. The most striking exterior feature of the new music center MADISON, WISCONSIN
is the folded precast concrete façade of the exterior walls. The accordion de-
sign mimics a curtain frozen in time and provides the mass and form needed
for ideal acoustic isolation of the building’s interior from the noise of the busy
KEY PROJECT ATTRIBUTES
streets outside.
❚ Precast concrete panels create an acoustic
The deep folds of the “curtain” were achieved by rotating panels horizontal- shell, eliminating outside noise.
ly and tilting them forward and backward vertically. This allowed the panels to ❚ Box-in-a-box precast concrete design further
be staggered, each with one end in front of the previous panel and the other minimizes sound and vibration.
end behind the next. As a result, traditional sealant joints were concealed be- ❚ Staggered precast concrete panels emulate
tween panels. The texture was created using a combination of exposed aggre- a folded curtain in the façade.
gate material and a custom fluted profile on every other panel face.
PROJECT AND PRECAST CONCRETE SCOPE
Double-wall construction ensured no traffic noise would affect performanc-
❚ Build a two-story music and performance
es, while also allowing for opportunities to strategically incorporate natural center on a busy university campus.
daylighting at the top of the recital hall volume. Using this strategy, the design- ❚ The project included 152 precast concrete panels.
ers were able to locate the Collins Recital Hall prominently at the front of the ❚ Precast concrete erection was
facility, rather than burying it at the core. completed in four months.
The recital and rehearsal halls were designed as a box-within-a-box concept,
using 8-in.-thick precast concrete panels to minimize the impact of outside Photo: Mike Rebholz.
sounds and vibrations. The panels were strategically shaped and sloped in dif-
ferent directions, leaning in or out by 2 degrees to further deflect sound.
PROJECT TEAM:
To ease assembly, the supplier created computer-aided-design layout points
that provided the bottom profile and top corner points of the panels. This OWNER:
State of Wisconsin, University of Wisconsin-Madison
saved time by eliminating layout from the piece drawings. Lasers and 2-in.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER:
shims were used to rapidly set the panels in place. International Concrete Products, Germantown, Wis.
Along with meeting acoustic and aesthetic goals, the use of precast con- PRECAST CONCRETE SPECIALTY ENGINEER:
crete brought practical advantages to the busy jobsite. The new center is locat- CSD Structural Engineers, Milwaukee, Wis.
ed at the eastern gateway to the university, one of the most publicly visible ARCHITECT: Strang, Inc. in association with Holzman
corners of the campus. This gateway is active with traffic for most of the day, Moss Bottino, Madison, Wis.
and the use of precast concrete was essential to ensuring rapid construction ENGINEER OF RECORD: Strang, Inc., Madison, Wis.
with minimal disruption to the community. GENERAL CONTRACTOR: JP Cullen, Madison, Wis.
The project is currently pursuing LEED certification, and most of the points PROJECT COST: $55.8 million
supporting this effort reflect the project’s integration into the dense campus PROJECT SIZE: 7500 ft²
and downtown surroundings.
2021
 HONORABLE MENTIONS
Custom Solution
STORMWATER
OUTFALLS
BILOXI, MISSISSIPPI
THREE LOCATIONS
KEY PROJECT ATTRIBUTES
❚ Replace aging rainwater outfall infrastructure
with precast concrete wave-shaped walkways.
❚ Precast concrete was the only material that could
withstand the 597-lb/ft² wave pressures.
❚ Factory-applied coating prevents permanent
graffiti damage.
PROJECT AND PRECAST CONCRETE SCOPE
❚ Build three precast concrete wave outfall
structures to replace pipes on coastal beaches.
❚ The project included 90 precast concrete pieces.
❚ The first two walls were erected in one week; the
third was completed two months later.
Photo: PCI Gulf South.
66
2021 PCI DESIGN AWARDS
The beaches along the Mississippi Gulf Coast experience constant
erosion and deposition due to wave conditions. This shift is exacer-
bated by ugly and aging outfall pipes that discharge debris-filled
rain-water onto beaches.
The Mississippi Department of Marine Resources wanted to reduce the
problem by replacing a number of aging outfall pipes with more aesthet-
ically pleasing structures. However, the solution had to be able to with-
stand the 597-lb/ft² wave pressures that pound local beaches. Precast
concrete proved to be the best solution, both aesthetically and structur-
ally, for the multiphase project, as it was the only material that could
support this type of abuse.
GRAFFITI RESISTANT
In the initial phase of the project, the old drainage systems were replaced
with new piping, overflow junction boxes, and box-culvert systems to the
edge of the sand template, which encompasses the area located 230 ft
south of the existing seawall. Three architectural and structural precast
concrete wave outfalls were then constructed, combining nine existing
and future round pipes into three public walkway structures where visi-
tors can view the beauty of the Sound.
The precast concrete producer assisted in the design of gray-and-tan
wave patterns in the panels to blend with the beach color palette. The
color patterns flow with spontaneity, like the rolling waves of the Sound.
To prevent graffiti from tarnishing the design, the architect chose a facto-
ry-applied coating that will prevent any permanent graffiti damage and
keep the maintenance costs as low as possible.
The new outfalls now provide increased capacity for the existing storm
sewer system, with new oversized box-culvert drainage outlets. They also
can be used as a secondary safety measure for Highway 90 drainage
through the installation of overflow boxes that allow for constant drain-
age if primary systems fail.
The innovative precast concrete solution will help to enhance, con-
serve, and upgrade waterfront areas while improving public amenities
and the aesthetics of the beach environment for years to come.
PROJECT TEAM:
OWNER: Mississippi Department of Marine Resources, Biloxi, Miss.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER AND
PRECAST CONCRETE SPECIALTY ENGINEER: Gate Precast Company, Monroeville, Ala.
ARCHITECT: Dale Partners, Biloxi, Miss.
ENGINEER OF RECORD: Simpkins & Costelli, Gulfport, Miss.
GENERAL CONTRACTOR: Necaise Brothers Construction Company, Gulfport, Miss.
PROJECT COST: $4.35 million
The original Clarks Mills County Route 113 Bridge connecting Green-
wich, N.Y., and Easton, N.Y., was built more than 100 years ago, and
was in dire need of replacement. The structure spanning the Batten Kill
River was in poor condition, and the community needed an overpass with
wider lanes to support increased truck traffic. However, local residents
didn’t want to lose the historic charm of the original arched bridge.
To meet the community’s needs and aesthetic goals, the designers
used precast concrete to replicate the look and feel of the original bridge
in a more durable replacement bridge. The decision to use precast con-
crete also eliminated need for significant formwork over the river. This
reduced construction time significantly, minimizing the project’s impact
on travelers.
Bridge with a Main
HOMETOWN PRECAST CONCRETE PRODUCER Span From 76-149 Feet

CLARKS MILLS
The new three-span arch bridge features 84 precast concrete units, with
the heaviest piece weighing 54,000 lb. The pieces were manufactured just

COUNTY ROUTE 113

two miles from the jobsite, at the Fort Miller Co. manufacturing facility.
Due to the width of the river and limited site access from the embank-
ments, the contractor had to construct the bridge by placing cranes and
construction equipment in the river. Workers built a tall stone causeway,
diverted the heavy stream flow through three main channels using a tem-
porary barrier, and then bridged these gaps with large composite steel/
ARCH BRIDGE
GREENWICH TO EASTON,
wood crane mats. NEW YORK
Each arch span consisted of 16 precast concrete pieces per span. The
arch spans were split in halves, and the adjoining arch halves had to be
set simultaneously into their final position; by design, the arch spans
could be held in place by gravity alone. The contractor incorporated air
hoists within the rigging setup to trip the arch pieces from the transport KEY PROJECT ATTRIBUTES
❚ Precast concrete delivered a durable replacement
position to their final setting position. A final closure pour at the top of
arch bridge with a historic design.
the arch created a permanent connection in the field.
❚ Match-cast headwalls were designed to
Once the bridge was backfilled, paved, and opened to traffic, the stones accommodate limited crane access.
in the stone formliner finish on the headwalls were individually stained to
❚ All pieces were cast at a plant just two miles
create an aesthetically pleasing final product. The complete erection of from the jobsite.
the precast concrete elements took less than four weeks. The new, wider
bridge now allows better access for heavy vehicles and tractor trailers. PROJECT AND PRECAST CONCRETE SCOPE
❚ Build a three-span precast concrete arch bridge.
❚ The project included 84 precast concrete pieces.
❚ Erection was completed in less than four weeks.

PROJECT TEAM:
Photo: Brian Haynes.
OWNER: Washington County, Fort Edward, N.Y.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER: Fort Miller Co., Inc., Greenwich, N.Y.
ENGINEER OF RECORD: Greenman-Pedersen, Inc., Albany, N.Y.
GENERAL CONTRACTOR: Kubricky Construction Corp., Wilton, N.Y.
PROJECT COST: $4.3 million
PROJECT LENGTH: 282 ft

2021
 HONORABLE MENTIONS
MENTION
For years, a highway interchange in Jacksonville, Fla., created con-
stant traffic delays. Because the southbound Interstate 95 (I-95) traffic
exited to eastbound State Route 202 (SR-202) at a stoplight, vehicles would
back up for a mile or more during rush hour. City leaders finally decided the
problem had to be fixed.
In 2014, the owner awarded a design-build contract for the redesign and
construction of the interchange to eliminate the congestion. The winning
design featured four bridge structures, new ramp configurations, new high-
way alignments, and roadway widening of both highways.
The signature piece of the design is a curved, post-tensioned, precast
concrete U-girder flyover ramp bridge to carry southbound I-95 traffic to
eastbound SR-202 lanes, eliminating the traffic backup problem. The sev-
en-span, 1342-ft-long structure is curved on an 1100-ft horizontal radius
and features a superstructure composed of curved, spliced precast con-
crete U-girders that are post-tensioned for continuity.

FALSEWORK TOWERS NOT REQUIRED

Bridge with a Main Because the flyover was constructed over three major traffic crossings,
Span More Than 150 Feet only overnight lane closures were allowed, limiting the construction crew

SB I-95 TO EB
to six eight-hour windows for erection in traffic areas. To accommodate the
constant flow of traffic through the jobsite, the designers incorporated

SR-202
several innovative features into the design and construction staging, in-
cluding precast concrete hammerhead pier caps for interior piers adjacent
to traffic. These pier caps also served to support the pier girders during con-

FLYOVER BRIDGE
JACKSONVILLE, FLORIDA
KEY PROJECT ATTRIBUTES
❚ Curved post-tensioned, precast concrete U-girder
flyover ramp solves traffic congestion issue.
❚ Precast concrete hammerhead pier caps
eliminated the need for falsework towers in
traffic zones.
❚ The project was the first implementation of a
spliced, curved, post-tensioned U-girder
superstructure by the Florida Department of
Transportation.
PROJECT AND PRECAST CONCRETE SCOPE
❚ Build a curved, post-tensioned, precast concrete
U-girder flyover ramp bridge.
❚ The project included 28 precast concrete
U-girders and four precast concrete
hammerhead pier caps.
❚ The bid was won in August 2014, and the
bridge was open to traffic September 2017.
Photo: Modjeski and Masters.
struction, eliminating the need for falsework towers within the traffic zone.
To minimize form changes, both the left and right girders were designed
to be cast at the same radius. This casting method did not significantly af-
fect the design, but it allowed for vastly increased efficiency in girder pro-
duction. Once stripped from the formwork and stored at the precast con-
crete producer’s yard, the girders were mildly reinforced, and
post-tensioning tendons were installed and grouted to control concrete
stresses during shipping and erection. These tendons are also part of the
final structure design.
Before erecting the drop-in girders, all other girders in the superstructure
unit had to be erected with splices cast, lid slabs poured, and partial-length
continuity tendons stressed. This required a detailed erection sequence and
coordination among the contractor, precast concrete producer, and
post-tensioning subcontractor to minimize schedule impacts.
The successful rapid construction of this flyover bridge proves that
spliced post-tensioned, precast concrete designs can provide innovative
solutions for many bridge design challenges. The new structure will fulfill
local traffic needs for years to come.
PROJECT TEAM:
OWNER: Florida Department of Transportation, Jacksonville, Fla.
PCI-CERTIFIED PRECAST CONCRETE PRODUCER: Dura-Stress, Inc., Leesburg, Fla.
ENGINEER OF RECORD: Modjeski and Masters, Littleton, Colo.
GENERAL CONTRACTOR: SEMA Construction, Orlando, Fla.
PROJECT COST: $66.7 million
PROJECT LENGTH: 1342 ft

68
2021 PCI DESIGN AWARDS
 Photo: H&K Group.
The new State Route 191 bridge replacement project in Stroudsburg,
Pa., faced many obstacles in design and construction. The project in-
volved replacing a steel through-girder bridge that passed through one bar-
rel of an existing concrete railroad tunnel. This tunnel, which supports rail-
road tracks that could not be disturbed, needed rehabilitation, and the
bridge structure carrying the roadway over the overflow channel in one cell
of the tunnel needed to be fully replaced.
The original tunnel rehabilitation and reconstruction plan included cre-
ating a 345-ft-long reinforced concrete culvert structure inside the tunnel
and two new post-tensioned reinforced concrete approach spans. Howev-
er, the winning contractor teamed with an engineer to develop a better
plan using a precast concrete design that brought innovation to the ap-
proach structures and helped coordinate the timing and scheduling of the
multiple site activities required for the complex project.
To facilitate delivery and erection using readily available cranes and de- Transportation Special Solution
livery trucks, the new plan used segmental bridge design features and de-
tails normally reserved for long-span structures. Segmental bridge design SR 191 BRIDGE
and structural post-tensioning are not normally used by this owner; how-
ever, they recognized that an innovative solution was required to provide a REPLACEMENT INSIDE
“side opening,” and saw that using a precast concrete edge girder with
post-tensioning would address that need. The new design also used similar STITES TUNNEL
load paths to the cast-in-place model with modifications to use precast EAST STROUDSBURG,
concrete to reduce field work and accommodate the time schedule. PENNSYLVANIA
MONOLITHIC EDGE GIRDER
The design of the approach span structures had to account for the unique
KEY PROJECT ATTRIBUTES
arrangement of the overflow channel of the creek, which takes two
❚ The precast concrete deck was designed transverse to
90-degree bends under the spans. To accommodate this layout, the design the roadway to accommodate 90-degree turns in the
involves a precast concrete deck transverse to the roadway and supported tunnel.
by new integral abutments under the outside shoulder. Because the box ❚ The precast concrete edge girder was cast monolithi-
culverts were designed with the top slab spanning perpendicular to the di- cally with the deck slab to keep unit weights within
acceptable limits.
rection of traffic, standard design software could not be used; instead, a
more rigorous analysis using finite element software was used to develop ❚ Replacing cast-in-place concrete with precast
concrete reduced on-site work and shortened the
the live-load forces. schedule.
The project team wanted to take advantage of the efficiency of fabricat-
ing multiple precast concrete segments with the same forms, so each seg- PROJECT AND PRECAST CONCRETE SCOPE
ment was made a common length. Once the 78 precast concrete sections ❚ Replace a girder through one barrel of an existing
concrete railroad tunnel.
were on site, the team used two Taylor “Big Red” industrial lift trucks work-
ing side by side to move the individual box-culvert segments through the ❚ The project included 101 precast concrete elements.
tunnel and into their final position on a new abutment foundation. The re- ❚ The project began in January 2019 and was completed
in July 2020.
sulting structure will be more durable than the original plan to use existing
abutments.
The precast concrete edge girder was cast monolithically with the pre-
cast concrete deck slab to keep precast concrete unit weights within ac- PROJECT TEAM:
ceptable limits for handling and erection. The 11-to-12 girder segments were OWNER: Pennsylvania Department of
post-tensioned in the field after erection on temporary supports. The joints Transportation District 5-0, Allentown, Pa.
in the precast concrete segments and edge girder were designed to use PCI-CERTIFIED PRECAST CONCRETE PRODUCER:
Northeast Prestressed Products, LLC, Cressona, Pa.
8000-psi grout, which was readily available in the state and thereby avoid-
ENGINEER OF RECORD: Larson Design Group, Lititz, Pa.
ed the need for less readily available solutions.
Eliminating the cast-in place concrete formwork and temporary false- GENERAL CONTRACTOR: H&K Group, Douglassville, Pa.
work reduced the duration of the on-site work, which extended into cold PROJECT COST: $8.2 million
weather months, and helped with the overall project schedule. PROJECT LENGTH: 532 ft

2021
 CALL FOR ENTRIES
Entries open on May 10, 2021. Join us in our
search for excellence and submit your projects
electronically by August 10, 2021.
The improved PCI Design Awards program will
showcase the winning projects in multiple ways:
The PCI Design Awards is not just looking for design excellence,
but also for projects with outstanding use of precast concrete.
PCI looks for projects that push the envelope and advance the
precast concrete industry.

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