Projects


 
 
PRECAST DECK PANELS- PEORIA ST. PEDESTRIAN BRIDGE
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Chicago, IL
Customer: Kiewit Infrastructure Company
Product: Specialty Structures
Installation: Summer 2015
Description: Reconstruction of the Peoria Street pedestrian bridge spanning I-190/Congress Parkway and adjacent to the rebuilding of the busy circle interchange in downtown Chicago, IL, capitalized on innovative precast concrete Accelerated Bridge Construction (ABC) techniques that allowed for high strength, thinner bridge sections and reduced delays and lane closures. The innovative, 271-linear-feet bridge, completed in the summer of 2015, includes 15,272 square feet of 8-inch precast deck panels that were set transverse to the main longitudinal I-beams in just four working days. The panels were formed with exposed vertical rebar and light pole anchor bolts so the contractor could pour a concrete parapet structurally integral with the deck. "Typically, this would have been a full depth cast-in-place deck," says Tom Heraty, VP of Sales and Engineering for Utility Concrete Products. "Utilizing precast, we were able to pour the slabs at our own pace in a controlled environment without the high cost of jobsite delays. It is also much safer to produce these slabs in a plant versus above the high-traffic I-290 expressway." Producing the precast concrete deck panels in a controlled setting with high strength, 5,000 psi concrete allowed for a thinner section than typical deck panels with less rebar clearance, but with the same or better durability and structural capacity. The precast panels were produced with a raked finish to create a rough pouring surface for the 2¼" overlay. Tapered pockets were formed into the panels allowing rebar to pass through. These pockets and the edges of the panel were treated with retarder to create a porous surface for bonding. The edges were formed with shear keys and exposed rebar to help create a continuous structural connection across joints. Panels were aligned so the pockets were set over vertical headed anchor studs from the top flange of the I-beams below. Rebar extending horizontally out of the edges had to be staggered such that it did not interfere with the overlapping bars from adjacent panels. Panels also included cast-in inserts with leveling bolts for vertical adjustability. Ductal (Lafarge), ultra-high performance concrete, was used to fill the pockets and joints to ultimately create a composite section.
 
SUBSTATION SECURITY WALL PANELS
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Product: Specialty Structures
Installation: Summer 2015
Description: Installation of security fences around the perimeter of bulk power systems has been mandated by the North American Electric Reliability Corporation (NERC) and Federal Energy Regulatory Commission (FERC) nationwide. UCP supplied a protective enclosure for a project consisting of segments that were 8'-0" long by 24'-0" tall and weighed 24,000 lbs. The wall effectively prevents against theft, vandalism, protects sensitive equipment, and ensures employee safety. Additionally, our wall provides a level of mobility and customization not seen with traditional security fences. Our product provided an additional layer of protection by effectively meeting UL 752 Level 8 Bullet Resistant specifications. While this project required a smooth steel form finish, a variety of formliner finishes and stains can be added to one or both faces with ease.
 
ISTHA DRAINAGE STRUCTURES
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Chicago, IL
Product: Drainage Structures
Installation: Summer 2015
Description: This precast headwall is located at the east end of the I-90 corridor reconstruction near O'Hare Airport. It is a tollway standard Headwall type III 4:1 slope with a 36" pipe opening. It is one of thousands of headwalls and hundreds of catch basins, junction chambers and other drainage structures that UCP is supplying for Tollway projects this year.
 
CTA SHORING BLOCKS
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Chicago, IL
Product: Specialty Structures
Installation: Summer 2015
Description: UCP supplied 4x4x4 & 4x4x3 precast concrete blocks for use on the CTA Wilson Station project currently being constructed in Chicago. The precast blocks are a part of a shoring tower system that is used to support the steel framing of both the new and existing track structure. These modular shoring towers act as support columns for the track above as the contractor continues demo to make way for installation of the new steel framing.
 
ISTHA NOISE ABATEMENT WALL
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Elk Grove, IL
Product: SoundWall
Installation: Summer 2105
Description: We fabricated this precast concrete Noise Abatement Wall on an Illinois Tollway project which is currently installing at the new ramp connecting 290 to the EB Elgin-O'Hare Expressway. What makes this soundwall unique is the use of architectural formliners to create leaf patterns in the surface of the concrete. The leaves are visible on the residential side of the wall and provide an aesthetically appealing and noise reducing solution for the residents directly behind the new ramp.
 
CONCRETE BRIDGE PANELS
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Joliet, IL
Product: Specialty Structures
Installation: Summer 2015
Description: UCP recently produced 3 concrete panels for a pedestrian bridge in Joliet, IL . The slabs were 20' 6 1/2" long, 9' 7 1/2" wide and 7 3/4" thick. They each had 2 embed steel beams with headed studs cast into the underside to span the void as well as embed angles on each edge along with rail mounts running parallel to the road . We worked closely with the contractor to ensure that the embed components of the panels were placed at the correct locations to ensure a smooth installation in the field.
 
O'HARE TAXIWAY LL FUEL LINE MODIFICATION
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O'Hare International Airport-Chicago, IL
Customer: Rossi Contractors
Product: Specialty Structures
Installation: Summer 2015
Description: The O'Hare Taxiway LL Fuel Line Modification Project included the concrete encasement of an active fuel line at O'Hare International Airport. Prior to construction, the pipes were surrounded only by earth. Originally designed as cast in place, the contractor solicited UCP for a precast concrete alternate design in order to meet the aggressive project deadline. Working closely with the contractor to assess their needs and expectations was a large contributor to the success of the project.
 
PRECAST DUCT BANK- CDOT 35TH ST. PEDESTRIAN BRIDGE
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Chicago, IL
Customer: City Lights
Product: Specialty Structures
Installation: Spring 2015
Description: UCP produced 430 feet of precast duct bank for the CDOT 35th Street Pedestrian Bridge in Chicago. The sections were 10 feet long, 1'3" wide, and 1'3" tall, had four 4" conduits running through them, and included red integral pigment. UCP was able to meet the tight deadline that this job required and our engineering team worked closely with the contractor to ensure the installation went smoothly.
 
CTA GREEN LINE PLATFORMS
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Chicago, IL
Customer: F.H. Paschen
Product: Specialty Structures
Installation: Fall 2014
Description: UCP has produced 54 precast concrete slabs for the CTA Green Line Platform in Chicago with the installing contractor F.H. Paschen. The job site photos show the transition from the south to the center platform slabs. This is a brand new platform for the CTA, and while the plans called for cast in place concrete the contractor preferred using precast slabs for ease of installation. There is still work to be done to finish this project including installing the tube enclosure around the center slabs and tactile strip.
 
ARCHITECTURAL PRECAST BRIDGE PANELS-NORTHFIELD, IL
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Northfield, IL
Customer: S&J Construction Co.
Product: Specialty Structure
Installation: Summer 2014
Description: Architectural Precast Concrete Panels affixed to the North & South side of the Willow Road Bridge spanning over the Chicago River (North Branch). These architectural precast panels are part of a complete redesign of the bridge in an effort to help beautify the surrounding area. The distinct curvature and required precision of these architectural panels presented new challenges for UCP's production team that we were able to overcome through an innovative forming design. By choosing precast for this application, the customer saved time on the jobsite and received a ready-to-install bridge facing meeting the requirement of IDOT.
 
REPLACEMENT JUNCTION CHAMBER- PERU, IL
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Peru, IL
Customer: Stott Contracting & The City of Peru
Product: Drainage Structures
Installation: Summer 2014
Description: A replacement junction chamber for a dated round structure in Peru, IL. UCP and Stott Contracting worked together with the City's engineer to devise a long term solution with this structure while updating the City's infrastructure.
 
SOUNDWALL- IDOT ALGONQUIN, IL
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Algonquin, IL
Customer: F.H. Paschen
Product: Sound Wall
Installation: Spring 2014
Description: This IDOT project near Downtown Algonquin may be our best looking wall yet. The walls and columns have a dry stack stone formliner on both sides and are accented with column caps. A custom mutli-color paint system was applied to the concrete, and an anti-graffiti coating was added as a sealant and for protection. This type of wall not only is perfect in an urban or suburban downtown setting but would also look great around any subdivision.
 
ABSORPTIVE SOUNDWALL- MONTGOMERY, IL
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Montgomery, IL
Customer: Lorig Construction
Product: Sound Wall
Installation: Winter 2014
Description: UCP recently produced a single sided absorptive Soundwall with concrete columns that was installed along Route 30 in Montgomery, IL.
 
PRECAST BRIDGE APPROACH SLABS-ISTHA I-13-4129
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Elgin, IL
Customer: Illinois Constructors
Product: Precast Bridge Approach Slabs
Installation: November 2013
Description: Precast Bridge Approach Slabs being installed at the Brier Hill Road Interchange at I90 in Elgin, Illinois, ISTHA Contract I-13-4129. Precast bridge approach slabs are a new product for the Illinois Tollway. Previously, approach slabs were poured in place, which over time would settle and separate from the bridge deck causing issues for flow of traffic. Utilizing precast bridge approach slabs saves the installing contractor time and accelerates the schedule for bridge reconstructions, provides increased durability and enhances user comfort. Due to the reputation that Utility Concrete Products has, we were selected to be the first precaster to produce precast bridge approach slabs in the state of Illinois.
 
REGIONAL DETENTION BASIN- CITY OF APPLETON
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Appleton, WI
Customer: City of Appleton, WI
Product: Underground Stormwater Detention
Installation: Summer 2013
Description: Regional detention basin for the City of Appleton, WI. This system was placed at Appleton East High School, under the north parking lot. The system is designed to be prevent water infiltration into the system, and will serve as an overflow to the main city storm sewer.
 
DES PLAINES RAILROAD- SOUNDWALL
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Des Plaines, IL
Customer: Kovilic Construction Company and the Des Plaines Railroad
Product: Sound Wall
Installation: Summer 2011
Description: Beautifully designed fluted soundwall produced by UCP and installed by Kovilic Construction Company along the Des Plaines Railroad. Des Plaines not only wanted the wall to look great, but they were also very concerned with noise, which is why we utilized absorptive noise wall with a porous cementitious material (Soundsorb) that achieves a NRC (noise reduction coefficient) of .9. As a result, the wall not only looked great, but did an amazing job of absorbing the noise of the train from the houses along the railroad tracks.
 
POST & PANEL RETAINING WALL- CTA PURPLE LINE
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Chicago, IL
Customer: CTA & Kiewit Western
Product: Retaining Wall
Installation: Fall 2011
Description: This post and panel retaining wall was installed in Chicago, IL and runs along the CTA Purple Line railroad.
 
PRECAST BRIDGE ABUTMENT- CTA PURPLE LINE VIADUCT
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Chicago, IL
Customer: CTA & Kiewit Western
Product: Specialty Structures
Installation: Fall 2011
Description: The precast bridge abutment that UCP produced for the Purple Line Viaduct in Chicago was the heaviest precast structure to ever come out of the UCP plant.
 
REPLACEMENT ROOF SLAB- WELLS ST., CHICAGO
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Chicago, IL
Customer: ComEd & Meade Electric
Product: Specialty Structures
Installation: Fall 2008
Description: The ComEd replacement roof slab was placed on top of an existing structure downtown Chicago. Using precast concrete allowed the job to be completed quickly and efficiently.
 
TORRENCE AVE. SOUNDWALL
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Chicago, IL
Customer: CDOT & Walsh
Product: Soundwall
Installation: June/July 2012
Description: Installation of soundwall from 130th & Torrence Ave. in Chicago, IL. Besides being a noisewall for the residences along Torrence Ave., CDOT chose a very aesthetically pleasing combination of textures and colors for the precast components. The precast columns were a 4 sided, red brick with a cap on the top, and the panels were a simulated wood plank with a fluted coping at the top. The result was a gorgeous wall that was functional and beautiful.
 
EPIC CAMPUS ELECTRICAL VAULT
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Installation: May 2013 Verona, WI
Customer: Epic Campus and The Morse Group
Product: Electrical Vault
Installation: May 2013
Description: 20 12x10x7 ID electrical manholes and 20 8x4x7 ID electrical manholes were installed at the Epic Campus in Verona, Wisconsin. Utility Concrete Products, LLC was able to accomodate the client's need for a quick turn around time despite these being a specialty non standard product. This is a large ongoing project that UCP has provided manholes to for several years.
 
FOX METRO WATER RECLAMATION ELECTRICAL MANHOLE
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Oswego, IL
Customer: Fox Metro Water Reclamation District & Frank Marshall Electric
Product: Octogonal Electrical Manhole
Installation: May 2013
Description: These specialty ocotogon shaped structures have been installed various times throughout the past few years at the Fox Metro Water Reclamation District in Oswego, IL. These structures bring power into the sewage treatment plant and were dampproofed at our facility before being delivered to the jobsite.
 
RED GATE BRIDGE RETAINING WALL
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St. Charles, IL
Customer: James McHugh Construction and The Municipality of St. Charles
Product: Retaining Wall
Installation: Summer - Fall 2012
Description: The Red Gate Bridge in St. Charles, IL is a new two lane bridge and pedestrian walkway which will cross the Fox River to connect Route 31 and Route 25. Utility Concrete Products, LLC worked with the General Contractor and retaining wall installer, James McHugh Construction, to come up with an engineered solution to provide a new retaining wall system that will stabilize the embankment on the bridge approach. Weekly news on the project can be found at: http://www.redgatebridge.org/news
 
I-294 ROADWAY REPLACEMENT - PRECAST PAVEMENT SLABS
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Chicago, IL
Customer: R.W. Dunteman & The Illinois Tollway
Product: Precast Pavement Slabs
Installation: Fall 2012
Description: In December of 2011, the Illinois Tollway awarded contract RR-11-5637 to replace portions of the pavement on I-294 from Bensenville Bridge to Balmoral Avenue in Cook County. The project required the use of Precast Pavement Slabs in a variety of sizes to fit the specifications of the Illinois Tollway. Due to the high quality and stringent delivery timelines required for the project, Utility Concrete Products, LLC was selected to supply the Precast Slabs. The specially designed slabs were set in place during the nighttime hours resulting in minimal lane closure and reduced traffic concerns. The slabs were installed by R.W. Dunteman of Addison Illinois.
 
VULCAN QUARRY RETAINING WALL
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McCook, IL
Customer: ECI Concrete
Installation Date: Fall 2011
Product: Stone Strong Systems
Description: Stone Strong gravity wall blocks were selected to retain the earth along a new ramp at the Vulcan quarry in McCook, IL. ECI Concrete was able to deal with the unique engineering requirements required for the application making Stone Strong the perfect fit for this particular project.
 
PRECAST CONCRETE PILE CAPS CREATE B2, UPRR FLYOVER
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Melrose Park, IL
Customer: Walsh Construction Company
Installation Date: Spring 2011
Product: Precast Concrete Pile Caps
Description: Construction of a bridge flyover connection between the Indiana Belt and Proviso Yard for the Create B2 segment 1 project and construction of phase 2 bridge over Addison Creek. Precast concrete pile caps were placed and welded on top of steel piles as the foundation for new rail.
 
SOUNDWALL - IDOT CONTRACT 60B03
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Joliet, IL
Customer: James McHugh Construction
Installation Date: Summer- Fall 2010
Product: Single-Sided Absorptive and Reflective Soundwall
Description: Installation of soundwall on I55, from Black Rd to US Rte 30. This project was comprised of segments of single-sided absorptive soundwall to reduce busy frontage road traffic noise, as well as segments of reflective.
 
SOUNDWALL - CITY OF DES PLAINES
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NOISE ABATEMENT WALL
Des Plaines, IL
Customer: Kovilic Construction Installation Date: Fall 2010
Product: Single-Sided Absorptive Soundwall
Location: Des Plaines, IL
Description: Installation of soundwall from Oakton St to Howard Ave along the east side of the Canadian National Railroad in Des Plaines, IL to relieve residents for rail noise. The railroad side of the panels was sound absorptive with a fluted finish and the residential side of the panels was reflective with a natural stone pattern finish.
 
SOUNDWALL - ISTHA CONTRACT RR-05-5428
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Northbrook, IL
Customer: Lorig Construction
Installation Date: Fall 2010
Product: Soundwall
Description: Installation of ground mounted reflective soundwall along Tri-State Tollway's Edens Spur (I94). UCP was able to produce panels with ashlar stone on both faces on a tight schedule in order to help the contractor meet their deadline.
 
PRECAST BRIDGE PANELS - WISDOT
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Milwaukee, WI
Customer: Vista Design and Construction
Installation Date: Spring 2011
Product: Precast concrete bridge panels
Description: UCP supplied precast panels for the reconstruction of the South Lion Bike & Pedestrian Bridge. The panels were placed on top of the steel structure as a base for additional concrete the was poured on top of the precast in the field.
 
BARRIER WALL - US ARMY CORPS OF ENGINEERS
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BARRIER WALL - US ARMY CORPS OF ENGINEERS / DES PLAINES RIVER BARRIER
Southwest Suburbs, IL
Customer: Old Veteran Construction, Inc.
Installation Date: Spring 2010 - Summer 2010
Product: 29,600 LF Special Precast Concrete Barriers
Location: Centennial Bike Path from Romeoville, IL to Willow Springs, IL (total of 13 miles)
Description: Precast concrete barrier were used to prevent overland travel of Asian carp between the Des Plaines River and the Chicago Sanitary and Ship Canal during flood events in order to keep the invasive species out of the Great Lakes.
 
BACKWASH TANK - GODLEY PUBLIC WATER DISTRICT
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Godley, IL
Customer: R&R Inc.
Installation Date: April 2011
Product: Backwash Reclamation Tank
Location: Godley Water Treatment Facility
Description: UCP provided an underground storage tank for Godley's Public Water Treatment Facility. The one piece vault was covered with a two-piece roof on top of which sat two risers with cast-in hatches to allow access into the tank. All concrete was poured with an integral waterproofing agent to prevent any future leakage.
 
DROP PIPE STRUCTURE - CALUMET AREA SEWER SYSTEM
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Calumet, IL
Customer: Meru Corporation
Installation Date: Summer 2011
Product: Drop Pipe Structure
Location: 133rd and Commercial Ave
Description: Precast concrete alternate to a cast-in place design, UCP was able to manufacture and ship a drop pipe structure, saving the owner time and money on this sewer replacement project. UCP was able to cast in baffle walls and steel embed plates further assisting the contractor.
 
DOGHOUSE MANHOLE - MILWAUKEE, WI
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LAKE SIDE SUBSTATION REPLACEMENT
Milwaukee, WI
UCP manufactured a WE Energies 18'-0" x 6'-0" x 6'-0" One Piece "Dog House" Manhole to install over an existing 138KV that remained at full power. The Manhole design saved the installing contractor several hours while allowing the customers of Wisconsin Electric to remain with full power.
 
COMED ELECTRIC MANHOLES - DEER RUN INDUSTRIAL PARK
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Joliet, IL
UCP did their part to help expedite one of the nation's largest private development projects. Pressure was placed on UCP to manufacture and ship over 20 electrical manholes in less than four weeks. The quick response from UCP's manufacturing and shipping team helped the CenterPoint Properties project remain on track for their estimated completion date!
Installer: Aldridge Electric
 
METERING STRUCTURE - BRAIDWOOD WWTP
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Braidwood, IL
Customer: Thieneman Construction, Inc.
Installation Date: Fall 2011
Product: 14’-0” x 12’-0” x 16’-2” ID RAS Metering Structure
Location: Braidwood Waste Water Treatment Plant
Description: UCP provided a precast concrete Return Activated Sludge and a Waste Activated Sludge Metering Vault for the expansion of Braidwood’s sewage plant. These structures are used for the increased wastewater treatment which allows the city’s system to process approximately 2 million gallons daily.
 
TUNNELS - IDOT CONTRACT 63450
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Deerfield, IL
Customer: Acura Inc.
Installation Date: Summer 2011
Product: Precast Concrete Tunnel Sections
Description: Construction of 72 feet of precast concrete tunnel built as a pedestrian underpass below existing Metra railroad tracks on Deerfield Road. The tunnel sections were designed for Cooper E80 rail loading.