Orleans County successfully completed administra-tion of a federal aid project funded by the FederalHighway Bridge Program, New York State Marchiselli,and Orleans County funds to replace a structurally de-ficient bridge. The project was designed to provide areplacement structure that will require limited mainte-nance throughout its life, thereby providing economicvalue to the County. Challenges overcome through theplanning, design, and construction process include:

• Preparation and justification of the preferred alterna-tive

• Private utility coordination and relocation

• Environmental permitting and wetland delineation

• Project delay due to lack of federal funding

• Stringent construction schedule due to a constructionseason stream restriction

• A “No Effect” SHPO concurrence within an archeo-logical sensitive area, and

• Right of way acquisition

PCANY NEWSLETTERPCANY MONTHLY

PRECAST CONCRETE ASSOCIATION OF NEW YORK, INC. February 2011 Volume 23, No. 2

Focus of This Issue: Box Culverts and Three-Sided Members

(See “Knowlesville Road Bridge Replacement” continued on page 2)

Precast Arch Selected for Knowlesville Road BridgeReplacement

As the owner of the structure, the Orleans CountyHighway Department guided the project from inceptionthrough construction. NYSDOT Region IV was involvedto provide guidance for following state and federalstandards in accordance with the Procedures forLocally Administered Federal Aid Projects. The projectwas planned and designed by Clark Patterson Lee andconstructed by Ramsey Constructors.

The project involved the replacement of a two-spansteel jack arch superstructure founded on concreteabutments and piers with a precast concrete Bebo Arch

structure supported on new reinforced concrete foot-ings.

The new structure was located to maintain the samehorizontal and approximately the same vertical high-way alignments. The structure has a clear span of77.8’, a height of 21.8’, and out-to-out width (travellanes, shoulders, and headwalls) of 33.99’. Precastheadwalls and wingwalls were constructed along thearch fascia and at the four corners of the structure toretain roadway embankment fill.

Original Structure built in 1930 Replacement Structure

During the planning phase of the project a scope sum-mary memorandum was prepared detailing alternativeswhich were considered for remediation of the existing

structure including rehabilitating the existing bridge, re-placing the bridge with a single span multi-girder struc-ture, and replacing the bridge with an arch type structure.

PRECAST CONCRETE ASSOCIATION OF NEW YORK February 2011 MONTHLY NEWSLETTER Page 2

Knowlesville Road Bridge Replacement (continued from page 1)

Maneuvering Arch leg into footing keyway Placing first arch units

Placement of last two arch unit sections Waterproofing Membrane System in Place Over Arch

The arch replacement alternative involved completelyreplacing the existing structure with a reinforced con-crete arch-type structure on reinforced concrete footingsbearing on bedrock. Due to the topography of the siteconsisting of a relatively large span and rise, the geom-etry of a buried arch type structure was anticipated to fitwell.

Widely known as a structurally sound and efficientshape, a buried arch structure was considered also be-

cause of the aesthetic appearance in an area utilized forrecreational activities during the summer months. In ad-dition, a buried structure is generally known as a virtuallymaintenance free structure. The arch structure was de-tailed as a twin leaf precast concrete structure with as-sociated precast concrete headwalls and wingwalls tominimize on site construction duration. The final con-struction cost of $1,360,000 was 98% of the preliminarydesign engineer’s cost estimate.

This type of twin leaf precast structure and associ-ated tall precast mechanically earth stabilized styleheadwalls and wingwalls have been utilized in a rela-tively low number of transportation projects throughoutthe state. The precast walls minimized the amount ofon-site formwork needed and enabled placement of thewalls and the commencement of backfill operationswithout a curing process. The relatively new system

based on a long history of arch type structures pre-sented challenges for Ramsey to overcome, includingworking through inclement weather, adverse site condi-tions, and unfamiliarity with construction methods.Despite these challenges, along with a stream restric-tion during the prime construction season, work wasperformed effectively and the project was completed onschedule. (continued on page 3)

PRECAST CONCRETE ASSOCIATION OF NEW YORK February 2011 MONTHLY NEWSLETTER Page 3

Installation of first headwall unit East Facia Bracing

Select structural fill over geogrid reinforcement Finished Structure

Installing Last Headwall Unit

Project TeamChris Sichak of Clark Patterson Lee was the proj-

ect manager for the project design and construction in-spection services. Ron Centola of Clark Patterson Leeserved as the Principal-In-Charge. The ResidentEngineer on site during construction was Lisa Barrettof Clark Patterson Lee.

Bill Adams of Ramsey Constructors, Inc. was thecontractor’s project manager while Jim Kuhn and JimFarrell of Ramsey shared duties for on-siteSuperintendent. Contech Construction Products, Inc.was the supplier of the precast structure and associ-ated precast wingwalls and headwalls. LakelandsConcrete Products, Inc. fabricated the precast con-crete elements.

This article is only a small part of the APWA 2010Awards nomination package prepared by Chris Sichakof Clark Patterson Lee, Rochester, NY. For the com-plete package, including many more photos, email himat csichak@ClarkPatterson.com, or contact PCANY.

Precast Concrete Association of New York, Inc.2829 East AvenueRochester, NY 14610Tel: 585-249-9564 • Fax: 585-381-0945Email: pcany@aol.com Web: www.pcany.org

PRODUCER MEMBERSA & R Concrete Products, New Windsor, NY, 845-562-0640Bayshore Concrete Products, Cape Charles, VA, 757-331-2300Binghamton Precast & Supply, Binghamton, NY, 607-722-0334Camp Precast Concrete Products, Milton, VT, 802-893-2407J.P. Carrara & Sons, Middlebury, VT, 802-388-6361Coastal Pipeline Products Corp., Calverton, NY, 631-369-4000Dailey Precast, Shaftsbury, VT, 802-442-4418The Fort Miller Co., Inc., Schuylerville, NY, 518-695-5000Jefferson Concrete Corp., Watertown, NY, 315-788-4171Kistner Concrete Products, East Pembroke, NY, 585-762-8216Lakelands Concrete Products, Inc., Lima, NY, 585-624-1990Newcrete Products, Division of New Enterprise Stone & Lime Co., Center

Valley, PA, 814-224-2121Northeast Prestressed Products, LLC, Cressona, PA, 570-385-2352Oldcastle Precast, South Bethlehem, NY, 518-767-2116Oldcastle Precast Inc., Middle Island, NY, 631-924-7400Oldcastle Precast Inc., DBA Rotondo Precast, Avon, CT,

860-673-3291Roman Stone Construction Co., Bay Shore, NY, 631-667-0566Sunnycrest Inc., Auburn, NY, 315-252-7214LC Whitford Materials, Co., Inc., Wellsville, NY, 585-593-2741

SEPTIC TANK PRODUCER MEMBERSBinghamton Precast & Supply, Binghamton, NY, 607-722-0334Concrete Building Supply, Champlain, NY, 518-563-0700R. Deso, Inc., Champlain, NY, 518-298-8411The Fort Miller Co., Inc., Schuylerville, NY, 518-695-5000Grimm Building Materials Co., Troy, NY, 518-272-1100Guardian Concrete Products, Schenectady, NY, 518-372-0080Jefferson Concrete Corp., Watertown, NY, 315-788-4171Keeler Vault Co., Inc., Hudson, NY, 518-851-6281Kistner Concrete Products, East Pembroke, NY, 585-762-8216C.J. Miner, Inc., 25 Route 28A, Valatie, NY 12184Oneonta Block, Oneonta, NY, 607-432-6641Sunnycrest Inc., Auburn, NY, 315-252-7214United Concrete Products, Inc., Yalesville, CTWoodard’s Concrete Products, Inc., Bullville, NY, 845-361-3471Zeiser Wilbert Vault, Elmira, NY, 607-733-0568

ASSOCIATE MEMBERSA-Lok Products, Inc., Tullytown, PA, 800-822-2565Amcrete Products, Newburgh, NY, 845-562-0010

American Spacer Technologies, Inc., Hudson, NY, 800-424-8557BASF Admixtures, Cleveland, OH, 518-232-1187Buzzi Unicem USA, Stockertown, PA, 610-746-6224Cemex, Inc., Wampum, PA, 724-535-4311Chase Specialty Coatings, Pittsburgh, PA, 412-828-1500Concrete Sealants, Inc., Royersford, PA, 610-948-7867Dimension Fabricators Inc., Scotia, NY, 518-379-1936East Jordan Iron Works, Newark, NJ 973-350-0600Eastern States Steel Corp., Upper Saddle River, NJ, 800-327-8335Engineered Wire Products, Waynesville, OH, 937-433-9753Eriksson Technologies, Inc., Tampa, FL, 813-989-3317 Essex Cement Company, Port Newark, NJ, 973-344-5903Essroc Cement, Nazareth, PA, 610-746-3109The Euclid Chemical Co., Saratoga Springs, NY, 518-376-0871Federal White Cement Inc., Emmaus, PA, 610-966-9481Forta Corporation, Grove City, PA, 800-245-0306Grace Construction Products, Wynantskill, NY, 518-361-4335Helser Industries, Tualatin, OR, 503-692-6909Holcim (US) Inc., Saratoga Springs, NY, 518-376-0871Jepco Sales, Royersford, PA, 610-948-7867JVI, Inc., Lincolnwood, IL, 800-742-8127Keystone Cement Company, Exton, PA, 610-837-2100 Lafarge North America, Concord, Ontario, 888-523-2743 x 5034Lehigh Cement Company, Glens Falls, NY, 518-792-1137 x 303The M&P Lab, Schenectady, NY, 518-382-0082Meadow Burke, Billerica, MA Northeast Solite Corp., Saugerties, NY, 845-246-2646A L Patterson, Fairless Hills, PA, 800-332-7090Polylok, Inc./Zabel, Wallingford, CT, 800-765-9565Quinn Consulting, Bladensburg, MDRiefler Construction Products, Blasdell, NY, 716-332-6283St. Mary’s Cement Company, Cleveland, OH, 216-579-1911Sika Corporation, Lyndhurst, NJ, 302-218-4987Spillman Co., Columbus OH, 614-444-2184Splice Sleeve North America, Irvine, CA, 949-861-8393Superior Precast Consulting, Inc., Ardmore, PA, 610-715-1969Syracuse Casting Sales Co., Cicero, NY, 315-699-2601Trelleborg Pipe Seals Milford, Inc., Milford, NH, 800-626-2180Tuf-Tite, Inc., Lake Zurich, IL, 847-550-1011

PROFESSIONAL MEMBERSAbate Associates Engineers & Surveyors, Buffalo, NY,

716-632-2300Advance Testing, Campbell Hall, NY, 845-496-1600AECOM, Latham, NY, 518-951-2200Atlantic Testing Laboratories, Clifton Park, NY, 518-383-9144Barton & Loguidice, PC, Syracuse, NY, 315-457-5200A.S. Bell Engineering, PC, Slingerlands, NY, 518-357-0313Bergmann Associates, Inc., Rochester, NY, 585-232-5135Bernier, Carr & Associates, Watertown, NY, 315-782-8130A L Blades & Sons, Inc., Hornell, NY, 607-324-3636

C & S Engineers, Inc., Syracuse, NY, 518-455-2000CDM, Syracuse, NY, 315-434-3200Clark Patterson Lee, Rochester, NY, 585-454-7600Clough Harbour & Assoc. LLP, Albany, NY, 518-453-3961Collins Engineering Inc., Albany, NY, 518-436-0392Delta Engineers PC, Endwell, NY, 607-231-6612Dewberry, New York, NY, 212-685-0900Didonato Associates PE, PC, Buffalo, NY, 716-656-1900Edwards & Kelcey Engrs. Inc., Saratoga Springs, NY, 518-584-9733Erdman Anthony, Rochester, NY, 585-240-2666Eriksson Technologies, Inc., Tampa, FL, 813-989-3317 Fisher Associates PE, LS, PC, Rochester, NY, 585-334-1310Greenman-Pedersen, Inc., Buffalo, NY, 716-633-4844Hunt Engr Arch Surveyors PC, Horseheads, NY, 607-358-1000D.R. Johnson & Associates, LLC, Dover, NJ, 973-328-2354Keystone Associates, LLC, Binghamton, NY, 607-722-1100LaBella Associates, PC, Rochester, NY, 585-454-6110Lamont Engineers, PC, Cobleskill, NY, 518-234-4028Maser Consulting, Chestnut Ridge, NY, 845-352-0411McFarland-Johnson, Inc., Binghamton, NY, 607-723-9421O’Neill Consulting, Spring Lake, NJ, 732-974-0129Popli Consulting Engineers, Penfield, NY, 585-388-2060Ryan-Biggs Assoc., P.C., Troy, NY, 518-272-6266A H Sample, Inc., Ottsville, PA, 610-847-8945R Samsel Engineers, Henrietta, NY, 585-334-5549Shumaker Consulting Engineering & Land Surveying, PC, Binghamton, NY,

607-798-8081Simpson Gumpertz & Heger, Inc., Waltham, MA, 781-907-9000SJB Services, Inc., Hamburg, NY, 716-649-8110Slocum, DeAngelus & Associates, PC, Latham, NY, 518-763-6000Steuben County DPW, Bath, NY, 607-664-2479Transtech Systems, Schenectady, NY, 518-372-4067TVGA Consultants, Buffalo, NY, 716-655-8842VHB, 100 Great Oaks Blvd., Suite 109, Albany, NY 12203, 518-452-0300Watson Engineering, PC, Owego, NY, 607-223-4900Watts Architecture & Engineering, PC, Buffalo, NY, 716-206-1500WSP-Sells, Briarcliff Manor, NY, 914-747-1120Wilbur Smith Associates, Latham, NY, 518-783-1887

OFFICERS, DIRECTORS AND STAFFPresident: David Wan, Oldcastle PrecastVice-President: Joseph Amoia, A & R ConcreteSecretary: Mike Weigand, J.P.Carrara & SonsTreasurer: Todd Clarke, Lakelands Concrete ProductsImmediate Past President: Tom Montalbine, Roman Stone ConstructionAssociate Member Director: Wally Swiger, A-LokProfessional Member Director: Doug Vandeusen, Lamont EngineersSeptic Tank Group Director: Ed Pennypacker, Jepco SalesNECSA Director: Ric Sullivan, Lehigh Northeast Cement Co.Executive Director: Carl Buchman, PCANY, 585-249-9564

PRECAST CONCRETE ASSOCIATION OF NEW YORK February 2011 MONTHLY NEWSLETTER Page 4

Member News A Hearty Welcome to new Associate Member Dimension Fabricators, Scotia, NY, Joel Patrie,

Production Manager, and to New Professional Member Clark Patterson Lee, of Rochester, NY, ChrisSichak, P.E., Senior Associate.

And Congratulations to two Passero Associates for passing their Professional Engineer Exams, andsubsequent licensing: Jess Sudol and Lauren Monaghan.

A.L. Patterson, Inc. is pleased to announce Mr. Skip Francies has joined their company as Presidentof the newly formed ALP Precast Division.

Spillman Company announces a new brochure on Custom Forms and another on new PlasticSpacers, plus the reintroduction of 17 models of locking Plaswheels. Find them at www.spillmanform.com