Multiple severe storms and harsh weather in 2004resulted in flooding and other weather-related damageto the site where County Route 34 crosses HollowBrook (Culvert 72/0.36) in the Town of New Lebanon in Columbia County, NY. As a result, the FederalEmergency Management Agency (FEMA) declared theCounty an eligible disaster area under Disaster No.FEMA 1654 DR NY.

The culvert carrying CR 34 over the Hollow Brookpreviously consisted of two distinct types of construc-tion that were interconnected with one another. The

downstream portion of the culvert, which was immedi-ately beneath the roadway, consisted of a concrete su-perstructure and concrete abutments constructed bythe County in 1946. The upstream half of the culvertwas a dry-laid stone masonry arch and headwall whichcarried a previous roadway alignment of CR 34. Thisstone arch and headwall took the place of wingwalls onthe upstream end of the concrete culvert and as suchthe two distinct portions of the culvert were integral witheach other for conveying stream flow and retaining theroadway embankments.

The referenced flooding caused washout and col-lapse of approximately half of the stone masonry archand headwall on the upstream end of the culvert. Thiscollapse of the stone arch structure resulted in slopefailure of a portion of the 6-meter high roadway em-bankment, putting the safety and stability of the road-way in jeopardy. Barton & Loguidice, P.C. (B&L) wasretained to investigate the site and develop an engi-neering design report and remediation plan. Throughcoordination with Federal Emergency ManagementAgency (FEMA) and the New York State EmergencyManagement Office (SEMO), the Columbia CountyDPW secured emergency funding (federal and state)and proceeded with the design and construction of areplacement structure.

(continued on page 5)

PCANY NEWSLETTERPCANY MONTHLY

PRECAST CONCRETE ASSOCIATION OF NEW YORK, INC. February 2010 Volume 21, No. 2

Focus of This Issue: Box Culverts, Three Sided

Laid-up Stone Arch Portion of Culvert

Replacement of Storm Damaged Culvert in Columbia County

Partially Collapsed Stone Arch

Installation of Rigid Frame Units

Wilbur Smith Associates provided construction in-spection and contract administration services to theGreene County Highway Department for the replace-ment of the New Baltimore Road Bridge overHannacrois Creek in the town of New Baltimore,

Greene County, NY. This project was advanced as alocally administered federal aid project, designated toreceive funding through the American Recovery andReinvestment Act (ARRA).

PRECAST CONCRETE ASSOCIATION OF NEW YORK February 2010 MONTHLY NEWSLETTER Page 2

ARRA Funding Aides Replacement of New Baltimore Road Bridge

First Arch Half Being Placed Three Barrels Set

Setting Headwalls Finished Bridge

The existing 77-foot-span, prestressed concretebox-beam/steel-beam bridge, supported on concreteabutments, was completely removed and replaced witha new precast concrete BEBO arch bridge with precastconcrete wingwalls and headwalls, designed byCreighton Manning Engineering. The new span length

is 59’-11” and the new bridge width is 30’-10”, which in-cludes two, 10’ lanes and 4’ shoulders and concreteparapets. The exposed concrete surfaces received anarchitectural treatment to maintain the aesthetics thatGreene County required.

The precast arch system was chosen based on eco-nomics, aesthetics, and limited future maintenance re-quirements. Precast shop inspection was provided byAtlantic Testing Laboratories. The construction costwas $1.118M. Construction started in July 2009 and

was completed in December 2009. All work was com-pleted on time and within budget by the contractor,Bette & Cring LLC.

Our thanks to John Saia, Jr. of Wilbur SmithAssociates for this article and photographs. q

Once again, Kistner supplied 10” thick precast archsegments to span 24’-0” between the restored footings.Each oversize piece had to be shipped on edge; theywere then picked up and rolled to a vertical position,and next slid into place under the old arch, on HDPEplastic strips. The pieces were secured by two rows of1” dia. stainless steel threaded rods. Installation of the10 arch sections (and 2 fascia sections for one side)started at 10:00 am and was finished at 5:45 pm. Next,grout was pumped into the interstitial space through

grout ports supplied in the new precast arch sections,to structurally support the failing corrugated metal pipearch sections.

This State bridge replacement project was designedby the NYSDOT Structures group. Contractor for thework was CATO Construction Inc., and KistnerConcrete Products Inc. supplied the work from theirLockport plant.

Thanks to Mike Kistner for the story and photos.

The old corrugated metal pipe arch bridge on Route104 in Jeddo, NY was in urgent need of repair or re-placement. If the old bridge were to be removed andreplaced, the traveling public would have been sub-jected to a long and very inconvenient detour. A mem-ber of the NYSDOT – Structures design staff remem-bered reading a PCANY article from October 1994 en-titled “Precast Concrete Gives New Life to Old Arch

Bridge” The story began “Precast concrete load bear-ing arch segments have given new life to an old stonearch bridge on Route 67 over the Cayadutta Creek inFulton County, NY” and ended with “Engineer andowner of the project is the New York State Departmentof Transportation. Kistner Concrete Products fabri-cated the segments at their plant in Lockport, NY.”Well, why not do the same thing on this Jeddo bridge?

New Bridge Installed Without Traffic Interruption On HeavilyUsed Truck Route

PRECAST CONCRETE ASSOCIATION OF NEW YORK February 2010 MONTHLY NEWSLETTER Page 3

“Precast Concrete Gives New Life to Old Arch Bridge” 1994Newsletter

Precast Concrete Gives New Life to Another Old ArchBridge 10-6-09

Preparing to slide in new arch segments Almost complete, with no traffic interruptions q

As the owner of the structure, the Monroe CountyDepartment of Transportation (MCDOT) directed theproject from inception through construction. MCDOTcontracted with Dewberry-Goodkind, Inc. to performthe design engineering and construction support serv-ices associated with the project which began in May of2008. The design schedule allowed for MCDOT’s de-sire to begin construction on July 20, 2009 with ascheduled completion date of October 30, 2009.

The Town of Clarkson Highway Department per-formed many of the general construction tasks such asthe removal of the existing structures, grading for theplacement of the new precast concrete culvert, backfillof the new culvert, installation of a closed drainagesystem, excavation of the roadway approaches,paving operations, and general grading of the projectsite. In essence the Town of Clarkson HighwayDepartment was the general contractor for the project.C.P. Ward, Inc. performed the portion of the project en-tailing placement of the new precast culvert and cast-in-place concrete pours, which was bid out to contrac-tors as a lump sum bid.

The project was progressed by the Town crewsworking a schedule consisting of four 10-hour days andone 4-hour day. All ten box culvert sections and 7 wingwall elements were installed in one day. Occasionally

crews worked overtime hours to complete tasks thatnecessitated extra time to complete. As a part of theproject team, the Town was responsible for maintainingcontact with MCDOT regarding design questions andconstruction coordination regarding materials andneeded specialized equipment or subcontractors.

PRECAST CONCRETE ASSOCIATION OF NEW YORK February 2010 MONTHLY NEWSLETTER Page 4

Clarkson Parma Town Line Road Culvert ReplacementThe project involved the replacement of two existing

5’ x 5’ reinforced concrete box culverts, constructed in1924 with a single precast four-sided reinforced con-crete culvert structure along a curved alignment. Thenew structure has a clear span of 12’, a height of 6’, anout-to-out width (travel lanes, shoulders, and head-walls) of 35’-4”, and a lay length of approximately 69’.The precast concrete culvert was chosen as the mosteconomical solution, as compared with a prestressedslab/integral abutment bridge option. The precast cul-

vert option allowed for installation on a curved align-ment to more efficiently carry the stream channel.

Wingwalls were placed where needed to retain em-bankment fill. The wingwall at the southwest corner ofthe structure was cast-in-place to reduce associatedcosts with relocating overhead utility lines. The remain-der of the wingwalls were precast and connected to theculvert structure via closure pours. The top slab of theculvert was detailed such that it will prevent ponding ofsubgrade drainage on the structure.

Excavation for placement of new culvert Placement of first two sections of culvert

Note the curve developed as the box sections were placed

(continued on page 5)

PRECAST CONCRETE ASSOCIATION OF NEW YORK February 2010 MONTHLY NEWSLETTER Page 5

The overall progress of the project was managed byTom Frys of MCDOT. Chris Sichak of Dewberry wasthe project manager for the project design and con-struction support process. In addition to the coordina-tion required between town crews and MCDOT, coordi-nation was required with C.P. Ward for construction ofthe new structure. Andrew Bouquin of C.P. Ward wasresponsible for the installation of the new precast con-crete structure along with cast-in-place wingwall, head-wall, and closure pours. Kistner Concrete Products,Inc. was responsible for fabricating the precast culvertand associated precast wingwalls. The project teamworked successfully together to deliver a completedproduct which enabled the roadway to be opened onOctober 16, 2009 with no safety incidents or lost-timeinjuries.

Special thanks to Chris Sichak, PE, StructuralProject Manager at Dewberry, for this story and thephotos.

Clarkson Parma Town Line Road Culvert Replacement (continued)

Placement of northeast wingwall

Phase 2 cofferdam system at culvert outlet Finished culvert inlet (looking north) q

Replacement of Storm Damaged Culvertin Columbia County (continued)

The replacement structure utilized a combination ofpre-cast and cast-in-place concrete construction. Thestructure consisted of six precast concrete, three-sidedrigid frame units, each with an 18-foot span and a 10-foot rise. The rigid frame units were founded on cast-in-place concrete footings that were stepped to accom-modate the change in rock elevations at the projectsite.

Project credits include: Owner – Columbia CountyDPW; Emergency Funding Agencies – FEMA & SEMO;Engineer – Barton & Loguidice, P.C.; Contractor – A.Colarusso & Son, Inc.; Precast Manufacturer –Rotondo Precast, Avon, CT.

And thanks to Jeremy Bourdeau for submitting thisarticle and photos. Completed Structure, Hollow Brook Bridge q

PRECAST CONCRETE ASSOCIATION OF NEW YORK February 2010 MONTHLY NEWSLETTER Page 6

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-

0334J.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, 585-593-2741SEPTIC TANK PRODUCER MEMBERSBinghamton Precast & Supply, Binghamton, NY, 607-722-

0334Concrete Building Supply, Champlain, NY, 518-563-0700Cresset Chemical Co., Weston, OH, 419-669-2041R. 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-

8216Oneonta 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, 845-562-0010American 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, 610-948-7867Cresset Chemical Co., Weston, OH, 419-669-2041East Jordan Iron Works, Newark, NJ 973-350-0600Eastern States Steel Corp., Upper Saddle River, NJ,

800-327-8335Engineered Wire Products, Waynesville, OH, 937-433-9753Essex 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, 518-376-0871Iron Horse Transport Inc, Smithtown, NY, 646-529-0336Jepco Sales, Royersford, PA, 610-948-7867JVI, Inc., Pittsfield, MA, 413-442-4147Keystone 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 303Meadow Burke, Billerica, MAMixer Systems, Pewaukee, WI, 860-798-7248Northeast Solite Corp., Saugerties, NY, 845-246-2646NPC, Inc., Milford, NH, 800-626-2180A L Patterson, Fairless Hills, PA, 800-332-7090Polylok, Inc/Zabel, Wallingford, CT, 800-765-9565Quinn Consulting, Bladensburg, MDSt. Mary’s Cement Company, Cleveland, Ohio, 216-579-1911Sika Corporation, Lyndhurst, NJ, 302-218-4987Spillman Co., Columbus OH, 614-444-2184Splice Sleeve North America, Irvine, CA, 949-861-8393Stephenson Equipment, Inc., Syracuse, NY, 315-432-0779Superior Precast Consulting, Inc., Ardmore, PA, 610-715-1969Syracuse Casting Sales Co., Cicero, NY, 315-699-2601Tuf-Tite, Inc., Lake Zurich, IL, 847-550-1011PROFESSIONAL MEMBERSAbate Associates Engineers & Surveyors, Buffalo, NY,

716-632-2300Advance Testing, Campbell Hall, NY, 845-496-1600Atlantic 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, 585-232-5135A L Blades & Sons, Inc., Hornell, NY, 607-324-3636

C & S Engineers, Inc., Syracuse, NY, 518-455-2000CDM, Syracuse, NY, 315-434-3200Clough Harbour & Assoc. LLP, Albany, NY, 518-453-3961Collins Engineering Inc., Albany, NY, 518-436-0392Delta Engineers PC, Binghamton, NY, 607-231-6612Dewberry, New York, NY, 212-685-0900Didonato Associates PE,PC, Buffalo, NY, 716-656-1900Earth Tech|AECOM, Latham, NY, 518-951-2200Edwards & Kelcey Engrs. Inc., Saratoga Springs, NY,

518-584-9733Erdman Anthony, Rochester, NY, 585-240-2666Fisher Associates PE, LS, PC, Rochester, NY, 585-334-1310FRA/T Y Lin International, Henrietta, NY, 585-359-0280Greenman-Pedersen, Inc., Buffalo, NY, 716-633-4844Hunt Engr Arch Surveyors PC, Horseheads, NY, 607-358-

1000Keystone Associates, LLC, Binghamton, NY, 607-722-1100LaBella Associates, PC, Rochester, NY, 585-454-6110Lamont Engineers, PC, Cobleskill, NY, 518-234-4028Maser Consulting, West Nyack, NY, 845-727-1160McFarland-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, Elma, NY, 716-655-8842Watson 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, 518-783-1887OFFICERS, 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

An excerpt from

“Accelerated Bridge Construction – Designing for Contractors”

by Jim McMinimee and Mary Lou Ralls – an article in STRUCTURE Magazine, Sept. 2009Accelerated Bridge Construction (ABC) has taken off in the United States in recent years. This is primarily

due to two interrelated factors: (1) The need to replace deteriorated bridges, and (2) The need to maintain traf-fic flow during peak traffic hours.

The Utah DOT has completed 127 bridges using different ABC methods, and is transitioning to ABC as stan-dard practice by 2010. The ABC methods include everything from prefabricated elements such as decks, to mov-ing entire structures using self-propelled modular transporters (SPMTs). UDOT began its ABC implementationwith the reconstruction of I-15, in time for the 2002 Winter Olympics. Partial-depth, precast, prestressed con-crete deck panels and other ABC methods were used on the project to speed construction.

UDOT’s ABC implementation has relied on industry collaboration to be successful. Obtaining contractor inputin the early stages of ABC projects leads to more cost-effective, long-lasting bridges with early completions. Byposting in-depth ABC details on the website, UDOT is opening its doors to contractors and showing them thatthis is the new way of doing business in Utah. Contractors are encouraged to access UDOT ABC manuals, draw-ings, specification language, and details from past projects.