Precast Solutions - Winter 2009 - (Page 6) this portion of the wall would not be visible during the high water Why Seasoned Marina Builder Promotes Precast of the summer months. Precast panels were erected in front of the existing log walls to minimize site disruption and adverse environmental effects to the lake bottom and to water quality. Wilbert Precast manufactured precast concrete docks with 96 sections up to 20 feet long each. The precast dock concrete is 3-feet 5-inches wide, with treated timber on both sides, for an overall dock width of 4 feet. Darin Swan of Wilbert Precast’s design and sales in Spokane discussed the high-flow, self-consolidating concrete mix design used in the marina project as well as some of the production challenges. “We made over 2,200 retaining wall blocks for this project,” said Swan. Wilbert Precast’s Spokane facility produced about 60 blocks and six wall panels per day as well as custom precast components for the project. The precast shoreline protection panels are designed to work as an extension of the retaining walls and serve as both breakwaters and as an aesthetically appealing entrance to the marina. In fact, the transition between the structural precast and the ”I’ve been a marina builder for over 25 years,” said Dana Martin, project superintendent of the Beyond Hope Marina development. Martin has built and supervised projects that range from floating houseboats in Seattle to an AIA-award-winning marina in Stanley, Idaho, as well as designing many other projects for marine applications. “My brother-in-law has a place on Flathead Lake in Montana, and he built a spectacular-looking seawall using a precast concrete locking block system,” he said. “I knew the kind of look the developers wanted for the Beyond Hope boat basin and I proposed the idea of using Redi-Rock walls and fixed precast concrete docks.” So he contacted Wilbert Precast to discuss the project. Precast provided the opportunity to complete the project during the winter months when the lake level is down. “We started earthwork in late December and finished the project in early June, unloading and installing about five to 10 sections per day,” Martin said. “We could not have worked during winter conditions using a cast-in-place product. The marina developers wanted to take what was essentially a run-of-the-mill resort and transition the site into a high-end marina that would fit in with future development plans for the site.” For more photos on the Beyond Hope Marina development: visit www.wilbertprecast.com/rrbeyondhope.php nonstructural wall panels is difficult to see. The rounded precast concrete docks were fabricated as a specialty item to meet the owners’ specifications for a more elegant marine facility. A one-half inch nylon insert was imbedded in the side of the docks so the wood could be attached to the concrete and not allow ingress of water that could cause potential corrosion. The dock sides support white rubber liners to protect the boats while moored. Project investors wanted to create a different and more unique appearance than that of a traditional squared-off dock, so the docks were designed with rounded-off corners. The rounded ends create a remarkably improved aesthetic for the marina and also make it easier to navigate for boaters approaching the slips. The precast docks were manufactured with steel imbeds in the bottom that are welded to the top of round pilings. The permanent steel pilings support the docks above the water year-round so the structures are protected from potential ice damage during the long, cold Idaho winters. Three people from Wilbert Precast were present at the site during the construction of the precast concrete retaining walls to ensure a quality installation. Challenges Wilbert Precast’s production facilities are located about 90 miles southeast of Hope, Idaho. The biggest challenge for the precaster was production and transport of the marina’s docks. Wilbert Precast produced the dock panels in the middle of winter when the floors of the manufacturing facility were cold. As the panels are only 6 inches thick, they required 48 hours of cure time before they gained sufficient strength so that they could be moved without the potential for stress cracks. Precast Solutions | Winter 2009 www.precastsolutions.org http://www.wilbertprecast.com/rrbeyondhope.php http://www.precastsolutions.org
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