INDUSTRY 50 TOP

The 50 Most Significant Precast Concrete Projects

Precast/Prestressed Concrete Institutes members select the 50 projects that have most impacted the design and construction industries

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n enormous number of projects have been created by imaginative and pioneering designers who looked to precast concrete to meet the challenges they faced. Innovative projects as diverse as stadiums, bridges, parking structures, offices, schools, housing and industrial buildings have been produced. These designers have not only expanded the ways in which precast concrete was used, but have also devised new techniques embraced by the entire design community. To celebrate the 50th anniversary of the Precast/Prestressed Concrete Institute, the organization has selected the 50 most significant projects using precast concrete components. The selections came from nearly 400 candidates nominated over a number of years by precast concrete producers, engineering firms and designers. That list was cut to approximately six dozen. The final selection by a panel of designers, engineers and others in the building community proved difficult due to the substantial number of projects that truly offer breathtaking design and innovation. Presented on these pages are the best of the best, the 50 most significant projects in North America to feature precast concrete components, listed in chronological order by completion date. They represent the tip of the iceberg in terms of creativity, effectiveness and aesthetically pleasing designs created in the past 50-plus years. Special thanks to Norman L. Scott of The Consulting Engineers Group and his committee for their work in selecting the 50 projects presented in this special report.

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1950
Walnut Lane Bridge
PHILADELPHIA
Walnut Lane Bridge, the first prestressed concrete bridge in the United States, impressed designers and engineers nationwide and encouraged more innovations. The bridges beams, including a 160-foot-long main span and two 74-foot end spans, used 5,400-psi concrete, making this first project one of the earliest structures ever to use high performance concrete.

1955
Lake Pontchartrain Causeway
NEW ORLEANS
At the time of its construction, this project was the longest vehicular bridge in the world, spanning nearly 24 miles. It represents the first large-scale use of precast, prestressed concrete for highway bridges in the country. It showed that large and very heavy sections, the width and span of the full roadway, could be precast, pretensioned, delivered and erected very quickly and cost effectively. The project, which also featured precast concrete cylindrical piles and pile caps, was completed in only 18 months at a cost of $24 million.

Garden State Parkway

NEW JERSEY
Twelve bridges along this highway were designed using pretensioned Ibeams, making it the first project to use a standardized beam for multiple bridges. The design saved considerable time and money. The Bureau of Public Roads already had proposed I-beam standards, but offered too many versions to be a practical approach. The New Jersey pretensioned design also had no end blocks, the first such project to have this feature, which provided more flexibility. Almost immediately after this project was completed, other toll authorities used the same standardized concept to achieve cost savings and faster speed. These projects include the Florida Turnpike and the Northern Illinois Tollroad, which also used a no-end block design for an incredible 216 similar bridges.

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1958
Denver Hilton
DENVER
This project represented the first large-scale use of architectural precast panels as cladding on a building. The project was a major factor in the development of the precast concrete curtainwall industry. Following this project and the Pan-Am Building (listed in 1961), architects across North America started to use architectural precast on important buildings.

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1954

1959
Oneida Lake Bridge
ONEIDA LAKE, N.Y.
Although the girders on this bridge were site-cast and post-tensioned, the structure represents the first use of linear segmental design in America. With its 320-foot length from pier to pier, it was the longest precast prestressed bridge in the country at the time of its construction. It features 24 147-foot girders weighing 250 tons each, which cantilever 72 feet over shore-side piers, along with 10 222-ton drop-in girders that were 231 feet long.

1960
Candlestick Park
SAN FRANCISCO
This famous sports venue was one of the first major stadiums in the country to make significant use of precast, prestressed concrete. Stadium seating consisted of precast, prestressed concrete L sections. The stadiums roof, which served as a wind baffle and wind shield, also was made of precast concrete components, consisting of prestressed double tees sitting on C-shaped precast frames. The design for these tees typically consisted of standard double tees modified by almost entirely eliminating the cantilevered overhangs until they resemble a channel section. The modified tees and channels include an upturned lip for drainage. The stadium was renovated in 1973, when an upper deck also consisting of precast seating sections was added. Erecting this level was challenging, as all crane work had to be accomplished from outside the existing stadium structure.

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Cheney Stadium
TACOMA, WASH.
The home to the Tacoma Rainiers AAA baseball team, this stadium has been in continuous use since its construction more than 40 years ago. The project features an all-precast concrete structure with a cantilevered roof that eliminated all sightline-disturbing columns in the seating areas. After its construction, it received national recognition for its design and fast construction schedule.

1960
McKenzie River Bridge
WESTERN OREGON
Although New Yorks Oneida Lake Bridge, built in 1959, was built a little earlier, this linear segmental bridge used typical pretensioned girders and a connection method that would be mimicked by bridges throughout North America. The 180-foot length consists of three 60-foot beams with the 90-foot center span achieved by using a 60-foot beam suspended from 15-foot cantilevers on each end. Only straight strands were used in the anchor beams, while both straight and draped strands were used in the center portion.

Port of Seattle Pier 28

SEATTLE AND PUGET SOUND, WASH.
The popularity of containerized cargo ships created a need for piers capable of handling heavier wheel loads and vessels with deeper drafts. To achieve this, the Port of Seattles engineering staff developed the concept of a high-capacity prestressed pile and a precast deck panel. Refinement of this system resulted in what today is called the Puget Sound System.

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Prestressed Railroad Ties

TAMPA, FLA. AND DURHAM, N.C.
The Association of American Railroads created a design for pretensioned concrete railroad ties that went into a track near Tampa, Fla., and Durham, N.C. Ultimately, this design proved unsuccessful, but another design by the Ben C. Gerwick Co., using a German shape, was fabricated for use in California. The tie designs that finally performed well closely resemble the Gerwick ties and are now widely used in track all over North America. Wooden ties with spikes are vulnerable to displacement under wheel loads and the force built up from temperature changes in long lengths of welded rail. The heavier precast ties with bolted fixings are better able to resist both the vertical and horizontal loading.

1961
Beverly Hilton Parking Structure
BEVERLY HILLS, CALIF.
This five-story, 400-car parking structure featured a unique precast, prestressed concrete structure for its day. Long spans eliminated columns in parking areas while lightweight aggregates minimized seismic and gravity loading. Durability was ensured by using 6,500-psi concrete. The result was an open, airy design that maximized parking layout. The facility features 8-foot-wide double tees, L spandrels, inverted tee beams and 4-story tall precast columns. Although built more than 40 years ago, it has been well maintained and retains its pleasing appearance to this day. The design was the forerunner for thousands of structures to come that have been built throughout North America using the same basic components.

Philadelphia Police Administration Building

PHILADELPHIA
This prominent institutional facility is believed to be the first building to feature precast segmental construction with architectural and structural components, including girders, beams and panels, that were post-tensioned together. Steel bar-tendons were run through preformed holes in the precast concrete members. These tendons were then tensioned and grouted to support the first-floor cantilevers and exterior wall panels. The Gulf Life Tower, built in 1969 and noted later in this list, was one of many to follow this lead.

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Pan-Am Building
NEW YORK
Constructed 59 stories tall over Grand Central Station in Manhattan, this prominent structure on New Yorks skyline was entirely clad with 11,000 precast concrete panels. They feature an exposed white quartz aggregate and were used on both the 49 tower floors and the 10 podium levels. Additional elevation modeling was offered by the installation of vertical fins that protrude 13 inches from the precast concrete faade on higher levels.

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1962
U.S. Science Pavilion
SEATTLE
Considered a standout design at the Century 21 Exposition, the worlds fair held in Seattle, this building was one of three (of a total of four) major building groups at the fair that were constructed entirely of precast, prestressed concrete. The Science Pavilion consisted of six interconnected buildings grouped in a U shape around a courtyard of pools, fountains and plantings. A key visual element was five 100-foot-tall neo-gothic vaults within the courtyard, which were designed to symbolize mans continual search for knowledge. They consisted of 71-foot-long pretensioned columns topped by open ribbed, lacy precast concrete trusses.
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1964
Chesapeake Bay Bridge
CAPE CHARLES, VA.
Constructed across the mouth of the bay in an open-ocean environment, this bridge eliminated the last water gap on U.S. Route 13 between New England and Florida. When it was completed, it was hailed by Readers Digest as one of the worlds modern engineering marvels. It was selected as One of the Seven Engineering Wonders of the World and received the Outstanding Technical Achievement award from the American Consulting Engineers Council as well as the Outstanding Civil Engineering Achievement award from the American Society of Civil Engineers. As recently as 2002, it was named one of the Landmarks in American Civil Engineering History by Civil Engineering magazine. Trestle bents were made of precast caps supported on spun precast, post-tensioned cylinder piles. More than 2,000 piles and nearly 850 precast caps were used. The superstructure features more than 250,000 linear feet of customized precast, prestressed double tee units. All of the precast components were barged to the site from the plant 180 miles away. In 1999, an additional 12 miles of two-lane precast, prestressed concrete bridge structures were added with the completion of the Parallel Crossing. The new construction features 100-foot spans with three double-tee units transversely post-tensioned side by side.

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1964
Great Atlantic & Pacific Tea Co. (A&P) Warehouse
HORSEHEADS, N.Y.
At the time of its completion, this 1.5-million-square-foot foodprocessing plant and warehouse was the worlds largest prestressed concrete building. Precast was chosen for the structural system and faade because it most economically met A&Ps full array of requirements, comprising cleanliness, fire resistance and low long-term maintenance costs. The structure is built with precast columns, prestressed double-tee roof members and supporting beams.

1965
Toronto City Hall
TORONTO, ONTARIO, CANADA
The buildings design resulted from an international competition. The facility contains four main sections: the Public Square, a circular Town Council Chamber and the two Office Towers, one on either side of the council chamber, standing 27 and 20 stories tall. These are fronted by three concrete arches spanning a large pool. The curving towers feature architectural precast panels faced with marble, and these panels acted as stay-in-place exterior formwork for a cast-in-place reinforced concrete frame. This building remains one of the most dramatic government buildings in North America.

Sky Harbor Airport

PHOENIX
One of the busiest airports in the country, processing 35 million passengers per year, this facility also is the fifth fastest-growing in the U.S. To maintain the capabilities to handle the growing Sun Belt areas needs, the airport has continued to build and has used structural and architectural precast concrete components in more than 35 separate projects.

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1966
Chancery Hall
EDMONTON, ALBERTA, CANADA
At the time, this was Canadas first major multi-story building using a precast, prestressed concrete structure. The design concept soon was duplicated with buildings in Colorado, Oklahoma, Texas, North Carolina and Florida. A building with a similar design, the 1969 Gulf Life Insurance Building in Jacksonville, Fla., also is included in this list.

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LaGuardia Airport Runway Extension

ASTORIA, QUEENS, N.Y.
Precast concrete components helped LaGuardia Airport extend its two intersecting runways into Rikers Island Channel to accommodate larger jet aircraft. Two pile-supported structures were constructed, using more than 3,000 concrete-filled, steel-pipe piles with cast-in-place concrete pile caps supporting precast, pretensioned I beams that were then post-tensioned to be continuous over the pile caps. The I-beams support inverted pretensioned double tees, which are topped with cast-in-place two-way post-tensioned concrete slabs.

1967
Habitat 67
MONTREAL, QUEBEC
Part of Expo 67, the Montreal Worlds Fair exhibition, this three-dimensional precast concrete structure was intended as a model for urban living, creating a low-cost alternative to both suburbia and tall public-housing projects. It included a number of components, including dwelling modules, pedestrian streets and elevator cores, which served as load-carrying members. The 365 precast concrete modular units, which weigh as much as 70 tons, were finished at the factory prior to installation. At the site, they were stacked in an innovative 12-story configuration and connected by post-tensioned bars and strands as well as welding to form a continuous structural system.

1969
Gulf Life Tower
JACKSONVILLE, FLA.
At the time of its construction, this 27-story office building was the tallest building in the city. The entire facility also included a multi-level luxury motel and a six-level parking structure for 1,100 cars. It was unique for its time due to its use of an all-precast, white concrete framing system made up of individual precast elements that were posttensioned together at each level and at all four sides to create a 150-foot-long beam. The beam had two 50-foot cantilevers and a 50-foot center span, which was supported on hollow white precast columns. The columns, after erection, were filled with cast-in-place concrete to tie the system together. The floor system consisted of double tees and inverted tee beams, with a cast-in-place center core completing the structural frame. 19
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1968
Department of Housing & Urban Development Headquarters
WASHINGTON, D.C.
The Robert C. Weaver Federal Building was the first modular precast government building built in the United States. At 20 stories in height, it also was one of the first mid-rise precast concrete bearing-wall buildings in the country. And at a cost of $17 per square foot, it was one of the most economical Federal buildings put under construction in this era. Its unique X (or double-Y) shape maximized the sites available space. To achieve its innovative design, it required a special structure that depended on a system of interior columns and beams along with precast concrete cladding that served as a bearing element, with its joints forming a row of exterior columns. The floors are framed with prestressed double tees.

1969
Roxse Homes
BOSTON
This 264-unit development in the citys South End renewal area featured both three-story and eight-story housing units. The structures represented one of the first uses of system building, using 8-inch bearing walls and hollowcore floor slabs. The walls were post-tensioned vertically. The nonbearing ends were enclosed using precast concrete walls, balconies or spandrel beams.

1972
Disney World Monorail
ORLANDO
The precast, prestressed elevated guideway for this famous resorts rubber-tired, electrically driven monorail trains created an aesthetically pleasing solution as well as a prototype for mass-transportation systems into the future. Simpler predecessors of this design were built at Disneyland in Los Angeles and at the Seattle Worlds Fair in 1962. The Disney World system, including an Epcot extension added in the 1980s, still functions today, providing more than 30 years of uninterrupted service.

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1970
Ala Moana Hotel
HONOLULU
This 39-story, 1,260-room hotel features a precast structure that was the first to make use of a grouted steel sleeve for splicing rebar. This design shortened the construction schedule by six months compared to what a cast-in-place system would have required, saving $1.9 million on the $36-million project just by reducing construction-loan interest and by generating revenue faster. In addition, the system created considerable material savings. The exterior moment frame consists of one-story-high precast H frames joined by splice-sleeves. Floors are prestressed beams and slabs bonded together with composite cast-in-place concrete.

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1972
TransAmerica Pyramid
SAN FRANCISCO
This 48-story, 853-foot-tall, 530,000square-foot building has become a landmark on the West Coast and one of the most famous structures in the world. The tallest building in San Francisco and northern California, it was the tallest building in the U.S. west of the Mississippi River for two years after its completion and today is the fourth tallest.

1974
Baylor Hospital Parking Structure
DALLAS
A new concept for constructing precast concrete parking structures was conceived for this project. Precast concrete walls (stack walls) were used for the first time, incorporating haunches to support the sloping ramp floor on one side and the horizontal floor on the opposite side. After this project, many parking structures were designed using this notion, with either solid walls or with punched openings commonly called lite walls.

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Cheesman East Building

DENVER
This 24-story condominium features a total precast concrete structural system and held the title of the tallest building with an all precast concrete structure for seven years after its completion. The building was designed with 8-foot-wide double-tee floor and roof beams and load-bearing precast wall panels. Precast balcony railings and stairs also were included. The panels were cast as one-story units for each of the two symmetrical sides of the building, which minimized form costs. The projects success led to more such structures in the region, notably the Cheesman Club in Denver, a 15-story luxury apartment building. It required only 10 weeks to erect that 95,000-square-foot building, with one floor completed every three working days.

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JFK Memorial Causeway Bridge

CORPUS CHRISTI, TEXAS
This precast concrete bridge over the Intercoastal Canal was the first in North America to use segmental box-beam girders. In this construction, the box sections are installed and the top surface becomes the roadway. The bridges dramatic appearance, which local news reports said made the bridge appear to be defying the law of gravity during its construction, was achieved with an 80-foot vertical clearance and a 200-foot horizontal clearance.

1975
Minneapolis Hyatt Regency Hotel
MINNEAPOLIS
This 28-story hotel was the first building to use glass-fiber reinforced concrete (GFRC) panels with steel studs for support. The innovation dramatically improved the adaptability of the material, expanding its uses. The GFRC panels featured a woodgrain appearance with white cement to create a spectacular, bright appearance. Using this approach, the thin GFRC is supported by studs that are connected directly to the buildings structural framework. The assurance of stability allowed the panels to be cast in larger sizes, with transportation logistics being the controlling factor, rather than strength or casting restrictions.

1976
ROCK ISLAND, ILL.
This three-level parking deck features four bays with 59-foot clear spans that provide column-free space for parking. The perimeter of the structure was kept level, while the central two bays slope in the same direction, permitting one-way traffic with angled parking. The outstanding factor in its design was the use of Vierendeel trusses to provide a distinctive look and structural efficiency.
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Rock Island Parking Structure

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University of Northern Iowa Stadium

CEDAR FALLS, IOWA
This project was the first low-profile, air-inflated domed stadium in the world. It features a total precast concrete structural shell and envelope, at the time the largest all-precast stadium in the world. Standard precast concrete components, including double tees, were used to create the wall and ring systems for the 450-foot-diameter stadium. Hollowcore slabs were used as floor elements, and all seating consists of precast seating units comprising treads, risers, beams and columns.

1979
Wyoming State Penitentiary
ROLLINS, WYO.
This penitentiary was the first to use three-dimensional precast concrete modules as cells and other spaces in prisons. The penitentiary includes 10 buildings totaling 400,000 square feet of space to house 472 maximum-security inmates in 236 double-cell modules. The modules measured 11 by 16 by 9 feet high and weighed 25 tons each. They contained cast-in electrical conduit, mechanical grilles and connections for security hardware and fixtures. This standardization allowed the installations to be completed at the precasters plant prior to delivery.

1980
I-181 Bridge
KINGSPORT, TENN.
These dual 2,696-foot-long bridges feature 27 spans of precast, prestressed spread box beams with a composite concrete deck. The bridge beams were designed as a simple span for the dead load of the beam and slab while offering a continuous composite span for live loads. The composite deck is composed of precast, prestressed concrete remain-in-place deck forms that were 3 inches in depth with a 4-inch reinforced concrete overlay. Significant attention came to the bridges for their elimination of all joints except at the abutments. At the time of their construction, they were the longest continuous composite bridges in the country and served as an example of the lengths that could be achieved with continuous no-open-joint designs.

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1986
Aurora Justice Facility and Municipal Center
AURORA, COLO.
The Aurora City Governments municipal center was designed as a civic campus organized around a three-acre lawn that unified the buildings. This building features a total precast concrete structural system consisting of loadbearing window wall panels and double tees.

1987
Sunshine Skyway Bridge
TAMPA BAY, FLA.
This dramatic 4-mile-long bridge across Tampa Bay features precast segmental construction that resulted in a thin silhouette that seems to float in mid air, an effect made more dramatic by a 1,200-foot central span. The main span, which has a clearance of 193 feet, was created from a single precast segmental trapezoidal box section, with a single central plane of cable stays projecting from two single pylons.

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1989
Blue Cross-Blue Shield Parking Structure
NORTH HAVEN, CONN.
This 1,400-car facility was a key component in a phased development plan that required the parking structure to blend with existing and other planned buildings on the site while offering functional efficiency. To achieve these goals, designers created a lateral-load resisting system that featured a combination of reinforced precast concrete shear walls, precast fixed-based columns and precast, prestressed girders.

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Florida Sun Coast Dome

ST. PETERSBURG, FLA.
Believed to be the first and still the only major total-precast concrete stadium in North America, this project features precast, prestressed seats, raker beams, columns, concourse double tees and beams, vomitory walls and stairs. Even the spiral pedestrian ramps are made of precast concrete. Built at a cost of $100 million, it includes more than 7,000 precast concrete components. The precast compression ring at the roof level was constructed of 90-foot-long beams sitting on 6-foot-diameter cylindrical columns up to 170 feet high. The roof consists of cable-supported fabric.

1990
United Bank Tower
COLORADO SPRINGS, COLO.
This total-precast concrete office building is an example of the beauty and economy that can be achieved by designing with precast concrete components. The $13million, 16-story facility is the tallest structure in the city and contains 249,000 square feet of space. Precast concrete components included double tees, inverted tee beams, mullions and wall panels.

1995
Life Sciences Building
SUMMIT, N.J.
A six-story, 800,000-square-foot laboratory and office facility for a pharmaceutical company, this building features an economic version of the flexible, interstitial floor scheme. This was achieved by offsetting the cost of floors between floors for MEP systems using prefabricated precast concrete components.

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1997
University of Illinois Molecular Biology Research Building
CHICAGO
This research facility on the universitys downtown Chicago campus took advantage of precast concretes plasticity of design to differentiate each function within the building. It creates a dramatic sculptural and functional design element on the interior.

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1999
Center of Science & Industry (COSI)
COLUMBUS, OHIO
This museums structure serves as one of the science lessons taught at the center, thanks to an innovative precast cladding that used the material to create clothoid curves in the new section of the facility. The $125-million, 326,000-square-foot building, which also included renovation of a high school that was connected to the new building by a glass atrium, has become a monument to the creativity that can be achieved with precast concrete. The buildings west faade is designed as an elliptical curve featuring a discontinuous clothoid curve from ground to roof. A clothoid curve is a segment of a spiral and required the precast panels to be cast to resemble the segments of an orange. The panels measured 60 feet tall and 10 feet wide. Each quadrant of precast panels was placed along segments of six curves to produce the buildings elliptical shape, with the wall panels also curving vertically into the building along segments of two other circular curves.

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2000
Lazarus Department Store
PITTSBURGH
Precast concrete played a prominent role in building this downtown department store, which contains four stories of retail space and three underground levels of parking. Highly articulated precast concrete panels with deep reveals mimic the rustication of natural stone and help the panels resemble the masonry on nearby buildings. The reveals also give the building a more human scale.

2001
Northwest Airlines Midfield Terminal Parking Structure
DETROIT
This 10-level, all precast concrete parking structure contains parking for 11,600 vehicles, making it the worlds largest parking facility ever built at one time. Containing 3.86 million square feet, it includes state-of-the-art baggagehandling equipment as well as some office space. Specifying precast concrete for the structure was estimated to have saved $15 million compared to the castin-place alternative. Total cost of the project was about $125 million.
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2002
Alameda Mid-Corridor Trench
LOS ANGELES
This $783-million project is a 10-mile-long freight rail expressway built in a 33-foot-deep, below-grade trench lying adjacent to Alameda Street. The trench is a midway section of a 20-mile-long rail corridor that links the ports of Los Angeles and Long Beach with other rail systems. The top of the trench is permanently braced with 1,500 53-foot-long, 39inch-deep precast, prestressed concrete struts. Key bridge components across the trench consist of double tees, inverted tee beams, box girders and roadway slabs. The use of precast concrete components allowed the pieces to be cast as trenching began rather than having to wait until a length was dug out to begin pouring concrete. This minimized the amount of time streets had to be closed and detours erected around the construction. During construction, excavation averaged 200 feet per day, with the precaster supplying eight struts per day.

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2002
Hearst Tower
CHARLOTTE, N.C.
The highly articulated architectural precast concrete panels on this 47-story office building help create a dramatic addition to the Charlotte skyline. The project includes both the 935,000-squarefoot building and a 1,500-car precast concrete parking structure, as well as an urban plaza and retail amenities. The precast panels were designed and produced with a variety of colors, textures and forms to provide a distinctive style while also complementing nearby architectural treasures, including its sister tower, the Interstate Johnson Land Building.
Photo: Carolina Photo Group: Cooper Carry, Inc.

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Hollywood & Highland entertainment complex

LOS ANGELES
To construct this enormous $615-million entertainment complex, complete with underground parking and the dazzling 3,650-seat Kodak Theatre (home to the Academy Awards presentation), designers used precast concrete structural components, including a precast moment-resisting frame, to build the seven levels of parking in the excavation hole and precast concrete cladding on a structural steel frame to complete the above-ground facilities.

Paramount Apartment Tower

SAN FRANCISCO
At 425 feet tall, this building remains today the tallest precast concrete building in the nations highest seismic zone (Zone 4). The $87-million project includes two floors of retail, one floor of commercial office space and 36 floors of apartments. It has expanded designers views of how to build in high-seismic zones due to the use of a new type of structural moment-resisting frame similar to techniques successfully tested in the Precast Seismic Structural Systems (PRESSS) research program.

Springs Union Free School

EAST HAMPTON, N.Y.
The addition onto this school building includes the first-ever modular precast concrete components created for the educational market. The foursided precast, steel-reinforced modules produced an 8,820-square-foot, six-classroom facility that was completed in five months. The construction speed and traditional brick appearance, which blends with the existing structure, make it a strong example for future projects.

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