Cell-Crete Corporation

After analysis of the 100-year-old dam structure, the US Army Corps of Engineers determined the structure was not suitable for continued use as a dam and had to be retrofit immediately. The site was at high risk for water contamination due to mining activity leaving carcinogens in the soil behind the dam. Arsenic, mercury and lead were found in high quantities in the area behind the dam, and the project was handed off to the Department of Toxic Substance Control to develop and implement a solution.

Because of the structure’s age and condition, the dam couldn’t accommodate heavy construction activity around or on top of the site. An earthen dam was chosen with lightweight cellular concrete (LCC) determined to be the best solution due to its self-compacting properties and the strengths achieved by the material as backfill. The hillside and staging area was a logistical challenge. Moving equipment in and out required a small batch plant instead of a large stockpile area required for traditional fill. Dust control was crucial and tightly managed due to the contaminated soil on the site.

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The UPRR (Union Pacific Railroad) was the owner of this project. This design-bid-build project required an 8150’ flyover structure to be built to alleviate the bottleneck created by the intersection of UPRR and BNSF (Burlington Northern & Santa Fe) Railway tracks in the area. Minimal interruption to the track, the proximity to the 10 freeway, a small construction footprint area, and soft soils found in the area, required an innovative construction to solve these issues and increase the feasibility of this complex project.

Cellular concrete offered the exact solution to this project, but this was the first time it had been used in this quantity or height. The material eliminated the need for conventional RW structures but also assisted with the overburden pressure on soft soils and reduced the impact on design in an area known for its high seismic activity due to the low density of this backfill material. Two mobile batch plants were able to produce over 2,000 CY of material each day and placed a total of 220,000 CY—the largest placement since 2007. No reported/observed performance issues or concerns have been observed to date.

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Article: Colton Crossing Victory

Cell-Crete Corporation has been contracted by Brosamer & Wall, Inc. to supply lightweight cellular concrete (LCC) backfill for the purpose of increasing roadway grade and widening this section of the highway. Cellular concrete allows for the design grade increase without excessive loading on sensitive delta soil, and saves costs on retaining the wall design.

This project was initiated in July of 2019. Starting near Grayson Creek, Cell-Crete is installing 63,000 CY (cubic units) of 27 PCF (pounds per cubic foot) of LCC over the course of two years. The first phase of this project increased the grade between and on the outside of the existing highway, developing the northbound I-680 to the westbound SR 4 ramp. Phase II traffic will reroute onto the new material while cellular concrete fills and increases elevation of the old highway lanes. This phase is focused on creating a two-lane connector ramp from the eastbound SR 4 to the southbound I-680.

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A new 48″ pipe was installed to replace the existing 42″ main line transmission. The old line needed to be abandoned using a flowable fill that was able to flow over 600’ per section in order to reduce the traffic impact and street shutdown.

The existing 42″ pipe was abandoned using 30 PCF (pounds per cubic foot) cellular concrete on a run that was over 3500′. Traffic control was set up in the center lanes, taking up only one lane of traffic in order to received bulk cement deliveries, while traffic remained open in both directions. Over 600 CY was pumped per day, and the line was completely abandoned in 2 days.

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The IKEA in Burbank is the largest IKEA west of the Mississippi. Over 350,000 square feet of beams were sprayed with fireproofing at this location.

Other companies would have spent extra time and money to mask off the deck, but Cell-Crete decided it could be done better. Instead of masking the deck, we were able to shoot the material so tightly on the beam that masking wasn’t needed, and there wasn’t any overspray. This saved time and resources, since less time was spent on masking and cleanup, while more time was spent on getting the job done.

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Cell-Crete has been contracted for the Sound Transit E-320 project in Bellevue, Washington. This project is part of an East Link Extension that will eventually connect a link light rail line from downtown Seattle to downtown Bellevue. Cellular concrete was specified in an area with soft-soil conditions and to reduce the lateral pressure on the 112th Ave. overcrossing. The project is being done in 3’–4’ lifts at approximately 600–800 CY (cubic units) filled per day with the total yardage of around 8,500 CY.

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The Second Lower Feeder, constructed in 1967 using prestressed cylinder pipes (PCCP), is an essential pipeline in the transmission of water from the treatment plant in Yorba Linda to the Palos Verdes Reservoir in Rolling Hills. In reach 4, Cell-Crete provided grout for the relined section of the pipe in order to ensure reliable water deliveries for this phase of roughly 2 miles of 78” (E) PCCP. A 75” steel liner with 1000 PSI cellular concrete material was also provided to grout the annular space between the host and carrier pipe from inside the pipeline through 2” grout ports. At the end of the year, the next reach commenced, which included adding 5.5 miles of similar grouting and reline operations.

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Precast jointed concrete pavement (PJCP) systems can quickly be installed and roadway sections could immediately be reopened, minimizing disruption. However, when the old pavement sections are cut out and the new precast pavement section is installed, the precast panel section needs to match the (e) roadway. Therefore, adjustments in the field are needed to close the gap between the panel and the subgrade that needs to be filled with a non-shrink, fast-set and high-strength bedding grout.

Cell-Crete provides a number of specialty grouts, including PJCP bedding grout. Please call us for a quote on your next project.

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The Nevada Department of Wildlife and the Nevada Department of Transportation were concerned for the safety of animals and drivers alike across I-80, an area negatively affected by animal-vehicle collisions. As a solution to this issue, the construction of a wildlife crossing structure began. Wildlife crossings have provided a safe passage for wildlife migration through man-made bridges and tunnels. Originally designed using native backfill, the animal crossing in Wells, Nevada experienced over 18″ of settlement on its northern side. Three months after it was completed, in order to stop the settlement, engineers decided to replace the top 11’ of soil fill with a lightweight backfill material.

The native fill of the wildlife crossing bridge was removed, MSE panels were disassembled and Class II cellular concrete was chosen as the lightweight backfill material to prevent any further settlement.

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Cell-Crete Fireproofing not only does the job well— we can make it look good too. In addition to being functional, if the client doesn’t want it to look like fireproofing, the material can be shaped to look like a concrete beam. This gives a more uniform look to parking structures, and fireproofing can also be added to columns and beams in outside locations where clients want their building to look cleaner.

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