< PreviousAfter lectures and demonstrations, students are given pre- cast plant and jobsite tours to deepen their understanding of the design, plant fabrication and jobsite construction pro- cesses as well as their inter-relationships. “This program is a comprehensive immersive experience where the students plan and design real-world bridge structures utilizing precast prestressed concrete members,” Koch says, “then they visit our production facility where they can see first-hand how precast is fabricated, and finally we tour a jobsite to observe and discuss the nuances of precast girder transportation and installation.” Doctor Eric Matsumoto is a Professor of Structural Engineering at Sacramento State University in the Civil Engineering department, and he matches Brent’s enthusiasm when he chimes in on the bridge studio. “It’s the first program in the country that prepares civil engineering and construction manager students in bridge design and construction to collaborate under direct industry mentor- ship. It’s a rare and very challenging task for undergraduate students to actually design a multi-span precast prestressed bridge and perform the preconstruction services. PCI West has supported us in multiple ways to provide this immersive industry experience. Our students not only achieve in the classroom, but interact with industry in the classroom, on plants tours, and through the entire mentorship process. Then they’ll get job offers, some of them directly with the precast industry, but the majority in the transportation industry based on their knowledge of precast/prestressed concrete.” PCI West’s approach to education is all about this immersive learning experience that is evident in the studios that they operate. “You only get truly educated and become the industry’s next generation by hands-on experiences,” Matsumoto says. From a yearly convention where organization members showcase their tools and equipment, to an intense 2-day multi-disciplinary design competition called Project Precast, PCI West’s reach in terms of education spans way beyond the classroom. “With the assistance of professors, PCI West sends an army of students to national and regional precast meetings, especially the PCI National Convention,” Matsumoto adds. “And this, in a sense, seals the deal for them, because they start to see the many industry members, including legends, at work in both formal technical sessions and social events, and they think “This is cool, I want to get involved.” Matsumoto also talks of midnight field trips where students observe the installation of girders on bridges. “It’s an unveiling experience for them when they get to see it up close. We’re not only educating them in a theoretical way, we’re combining their theoretical understanding with this practical industry understanding and experience.” Sacramento State University 2021 bridge girder install Photo by Eric Matsumoto | 80 FEBRUARY 2024Doug Noble, Architect and USC Professor, reflects on a particular project out in Joshua Tree which was made with precast concrete by USC students. “The project is called Carapace, like the shell of a turtle. It’s a full-size project we did out in Joshua Tree National Park, which is a little bit inland in California, just north of Palm Springs. We did this ultra-high-performance concrete, we had 36 or 37 really chal- lenging goals that we set for ourselves and we installed it last year. It has now won six major awards.” Work continues out in Joshua Tree for Doug and the team, in the form of a new project making tiny homes for rangers. “We call them pocket lodges. Tiny homes that can be prefabricated offsite out of precast concrete. These are for seasonal Park Rangers, like college students. They get 250 square feet, so a super tiny home. That project got underway about a year ago and were making progress with it.” The success of PCI West and its pioneering approach to educating the next generation is powered first and foremost by equal engagement from students, educators, and the PCI Foundation, all of whom share a passion for the precast and prestressed concrete industry and a drive to succeed within it. “PCI West brings together many disciplines that otherwise would not collaborate,” says Matsumoto, “and so it’s become a real synergy. This is a real unique aspect of what PCI West has been able to spearhead.” This unique connection between different disciplines is evident even in the small sample of PCI West members that join me today. You’ve got Eric Mat- sumoto, professor and Civil Engineer, Brent, one of the many fabricators, and Doug, representing the Architecture side of things. Each have their own unique working relationship with the foundation and with each other, with PCI West as the common ground and Lehmann leading the charge. Ruth Lehmann, as Noble describes her, is an incredible source of knowledge who takes an active role in the activities and proj- ects of PCI West’s members. “And she is there for everything no matter what we’re doing or how far she has to travel,” he says, backing up Matsumoto’s and Koch’s statements about the indispensable support that comes from PCI West. Before providing some final reflections on PCI West, Mat- sumoto tells me that he could talk all day about the sto- ries of success, collaboration, and inspiration that he has experienced throughout his involvement with the non-profit organization. “There’s a spark there,” he says. “They provide resources, they provide connections between students and industry, because there’s a big shortage of bridge engineers, especially ones who are trained and who have knowledge coming into the office. I recently spoke with AASHTO, the American Association for State Highway Transportation Officials, which is the transportation representatives for the whole country. One of the high-level Department of Transportation bridge engineers said that the whole indus- try needs more students like what we’re developing. And he asked, is there a way we can extend what you’re doing at Sacramento State University to a national model? It’s a major discussion about the next generation, and PCI West has supported our grant to get the funding for it.” It seems there is industry-wide appetite for PCI West’s education model to grow and expand, in the interest of educating the next generation and inspiring a bright future for the precast and prestressed concrete industry. USC CARAPACE program Photo by Douglas Noble USC CARAPACE program Photos by Douglas Noble and Simon Chiu | 81 APEIRON CONSTRUCTIONWRITTEN BY MEGHAN BARTON T he precast concrete industry stands as a cornerstone in modern construction, revolutionizing not only the way structures are built, but their very design. Positioned as a key player in the precast concrete industry, Precast Unlimited boasts a comprehensive range of capabilities, serving as a singular destination for an array of projects. From utility structures to intricate architectural components, its expertise spans the spectrum of precast. What distinguishes it is a steadfast commitment to customization, with an impressive 90% of its projects tailored to unique specifications. Beyond the conventional role of a pre- cast provider, Precast Unlimited emerges as a versatile organization adept at adapting its services to the distinctive requirements of each project. Whether designing for the robust functionality of utility structures or the nuanced aesthetics of architectural elements, the company thrives on the challenge of delivering exceptional precast solutions across diverse applications. | 82 FEBRUARY 2024More than 25 years ago, the founders embarked on a mis- sion to establish a company that would set new standards in customized and high-quality precast products. Originally incorporated as Universal Precast, today, Precast Unlimited stands as a leader in architectural, site furnishing, utility, and structural precast solutions. The company's impressive growth can be attributed to the successful completion of thousands of projects, collaborating with architects, general contractors, municipalities, counties, state and federal clients like the VA, and with institutes of higher education. As a growing business, the company's culture is deeply rooted in quality and craftsmanship. Paul D’Amico and Gary McCall are the visionaries behind the company's inception and have played a crucial role. After gaining knowledge and experience while working with another company, D’Amico identified a market opportunity. Starting with site furnishings and fiber- glass molds, the company evolved, incorporating rapid mod- eling and CNC capabilities for custom mold creation as the team expanded. Just over a year ago, the company divided in two with the original iteration continuing as UPC Parks which offers customizable play experiences. Precast Unlimited as the sister company still offers product design, 3D mod- eling, mold manufacturing, concrete mix designs, specialty finishes, and more. Since the early 2000s, the company’s growth has been consistent, a testament to its dedication to innovation, extraordinary customization capabilities, and customer satisfaction. | 83 APEIRON CONSTRUCTIONThe team today has evolved to support these pillars of Pre- cast Unlimited’s business model. Although the ownership is now more hands-off, the workforce of 50+ is led by Brody Bowman-Vice President/Civil Engineer, Chris Hess- Director of Product Design, Peter Goff, Chase Warner, and Blake Pewitt-Project Managers, Tricia Seylar-Office Manager, Bran- don Long- Plant Manager and Josh Weyand- Estimator. In the last year Precast Unlimited has completed projects across the lower 48 states as well as in Hawaii; while UPC Parks has shipped products as far as Europe and Dubai. Precast Unlimited continues to deliver custom precast concrete utility and architectural products with in-house capabilities for modeling, mold making, and engineering. The company prides itself on its ability to take a concept, convert it into a 3D model, create the molds, and tailor a mix design to meet its customer’s unique vision. Their extensive experience in custom design and production allows the team to be agile, informed, and innovative for every new project undertaking. “We take pride in our rapid molding process, as it enables us to create complex and interesting forms that go beyond the capabilities of traditional molding. This method sets us apart in terms of customization and quality within the pre- cast industry. The advantages of our rapid molding process contribute to our innovative approach and commitment to excellence, allowing us to deliver unique and high-quality precast products,” says Goff. The evolution of Precast Unlimited cannot be measured with the typical industry metrics due to the highly customized nature of their business. Instead of measuring its growth by an increasing product line or expanding service area, the evolution of Precast Unlimited is unmistakable in its ability to learn and augment its creativity and production, building off its past projects to execute progressively impressive, unique precast solutions. “Every job is full of new possibilities with opportunities to problem solve”, says Peter Goff, Project Manager. “90% of what we do is custom work, so we have a pretty good handle on what would work and what wouldn't work. And we are willing to test and experiment to achieve great results.” Precast Unlimited’s ability to deliver creative and elevated designs is apparent in its recently completed Fillmore Turk Mini Park project in San Francisco. Completed in collabora- tion with OBS Engineering, this project was a $2.6 million, community-led, reimagining of a park originally built in 1978. Intended to be a welcoming and inclusive gathering space for the community, the park features an artful, contempo- rary installation that seamlessly integrates tables, seating, and planters. | 84 FEBRUARY 2024“This was a unique project. We worked closely with the architect to ensure the shape and form of what he designed could be executed in concrete,” says Chase Warner, Project Manager. “The most challenging part of this project was the table. It is over 12 feet long with complex curves and angular features that had to be cast monolithically. It took four weeks to manufacture the mold for just this one part. It had to be assembled and disassembled in a specific pattern to ensure the integrity of the piece. It has since been installed and we are excited to see it at the grand opening of the park.” Another testament to its ground-breaking project work can be found on the I-40 at the Arizona/California border. Precast Unlimited was tasked with elevating the design of a state welcome feature wall with a precast 3D bear model standing upright at nearly 10 feet and 7-foot letters spelling out Califor- nia. For this project, Precast Unlimited leveraged a patented mix design that mitigates the weight of a sculpture of that scale and allows for a realistic and seamless finish. “This project was huge for us in many ways,” says Goff. “The scale of the project is notable in the opportunity to highlight our proprietary mix design, the time spent on design and col- laboration, the back and forth with the client, and the amount of concrete used. The letters spelling California, alone, used over 26,000 pounds of concrete.” The future of Precast Unlimited is continued innovation and growth, driven by a steadfast commitment to excellence and adaptability. Since its inception, the company has evolved from its origins as Universal Precast to become a leader in architectural, site furnishing, utility, and structural precast solutions. The division into two entities highlights a strategic approach to cater to a diverse clientele with custom precast needs. Led by a dedicated and experienced management team, the workforce of creative and skilled craftspeople is poised for the challenges of the future. The company's focus on professional development, continu- ous evolution, and a hands-on approach to quality enhance- ment indicates a proactive stance in an ever-evolving indus- try. Precast Unlimited's ability to transform concepts into 3D models, create molds, and tailor mix designs showcases a commitment to unparalleled customization capabilities. Underpinning each project is a personal investment in the work it does. The company's global reach underscores its potential for further expansion. As it ventures into the future, Precast Unlimited's dedication to pushing the boundaries of creativ- ity, innovation, and customer satisfaction positions it as a formidable force in the precast industry. “The letters spelling California, alone, used over 26,000 pounds of concrete.” | 85 APEIRON CONSTRUCTIONWRITTEN BY MEGHAN BARTON Bobby Unser, iconic American car racing champion, once said, “Success is where preparation meets opportunity.” This sentiment can easily be illustrated in a study of the remark- able evolution of StructureCast from a company focused on ready-mix concrete to a California-based powerhouse in the precast concrete space. StructureCast specializes in the production of custom archi- tectural and structural precast concrete, serving the western US with project sites in California, Oregon, Washington, Nevada, Colorado and Arizona. Its product line spans both above ground and underground applications, with a focus on wall panels, building cladding, and architectural precast tailored for high-rise and multi-story buildings. Emphasizing structural integrity and load-bearing capacity, the company operates under a design-build model, combining manufac- turing and contracting services. Distinguished by its Cali- fornia and Nevada contractors licenses, the company has the unique ability to function as both a manufacturer and contractor. This dual role allows it to undertake the entire pro- cess, from design and engineering, through manufacturing to delivery and installation. StructureCast is committed to deliv- ering customized, high-quality precast concrete solutions for diverse construction projects. Under the leadership of Brent and Anna Dezember, the com- pany has always prioritized being at the leading edge of the industry to be prepared for whatever opportunities arise. The husband-and-wife team founded Golden Empire Concrete in the early 1980s. This ready-mix company maintained a non-union structure in a growing market making it a target firm, attractive for acquisition. Although the Dezembers weren’t listing Golden Empire Concrete for sale, when the opportunity arose, they decided it was an offer they couldn’t refuse. This opened the door to launch a new endeavor and take advantage of the prospect of creating new success in a different stream of the concrete market. They seized the opportunity and purchased a small precast company with an inventory of forms which manufactured utility products such as septic tanks and stormwater management struc- tures. Just as with the ready-mix concrete market, Brent and Anna found success in the precast industry. Seizing the opportunity, they took advantage of their foothold in the industry, reimaged the company’s structure and deliv- erables and diversified the company’s into four product lines: architectural cladding, underground utility structures, precast fencing systems, and sustainable prefab modular buildings. StructureCast was born. | 86 FEBRUARY 2024| 87 APEIRON CONSTRUCTIONPROVEN. PRECAST. SOLUTIONS. Euclid Chemical is a leading supplier to the precast concrete industry offering a full line of engineered concrete admixtures, fiber reinforcement, integral color, and construction products. We bring innovative and sustainable technologies to the marketplace with industry-leading service and support. The Euclid Chemical Company Cleveland, OH 800-321-7628 www.euclidchemical.com A Proud Partner of StructureCast • High Performance Admixtures • Macro & Micro Fiber Reinforcement • Integral Color • Form Liners • Form Release Agents • Waterproofing Products • Joint Sealants • Patching & Repair Mortars Today, StructureCast is a booming precast concrete heavy- weight dominating the market with a workforce of 85, a strong leadership team of 15, and in-house engineering capabilities; something that can be hard to find. “Having our own experienced engineering team is really a competitive advantage,” says Anna Dezember. “This helps us maintain a high degree of control in our projects and offer value-added, design-build experience to our customers.” The other distinctive asset that is a source of pride for the team at StructureCast are the qualifications and certifications of members at every tier of the organization. “We are commit- ted here at StructureCast to qualification and certification at the highest levels, from our engineers and project managers to our production team and quality control laboratory,” says Anna. “This is very important in our industry. This sets us apart from many of our competitors. We work hard to achieve these certi- fications, and even harder to maintain them. We have received accolades and national awards in safety, quality control, and design. We have the creativity to deliver a design-build project. We have the experienced in-house engineering team to back it up. We have PCI I, II & II Certified Production and QC/QA teams to back it up. Our production facility is also PCI, NPCA, Caltrans and ISNetworld certified. And we have the leadership to back it up with our key managers having an average of over 20 years of precast experience.” | 88 FEBRUARY 2024Thank you to our loyal client StructureCast. Our success is founded in yours! Strategic Solutions For Your Success 10561 Barkley St. • Suite 200 • Overland Park, KS 66212 (913) 378-1050 Commercial Insurance Risk Management Education & Training Loss Control Claims Management Surety Bonding Benefits & Wellness Personal Insurance Protection Wealth Management Business Perpetuation Planning StructureCast’s esteem within the industry comes not only from its ability to deliver, but also from its robust industry associations. The company is a forerunner in developing and championing UHPC (ultra-high-performance concrete) and is one of a select-few precast companies approved to manu- facture products with Ductal® in California. Although there are other companies offering prefabricated modular buildings in California, StructureCast takes a unique approach. Not only does it offer a turnkey, functional, and affordable end result building, but a completely customizable and customer-focused experience. “Our difference is that we engage from the beginning with design-build, with the owner, with the municipality, and general contractor to deliver a more project specific outcome,” says Anna. “We perform like a GC for the production of our units. We partner with the best sup- pliers for outfitting. We do our own installations. Our method allows for customer engagement from conceptualization to completion.” StructureCast is a regional licensee for Easi-Set, a nationally established company, whose offerings include sustainable, modular buildings. The modular building con- cept has been an important contributor to StructureCast’s success by bolstering its operations, diversifying its offerings with a shorter life cycle product, and preparing for market fluctuations by underpinning sustainability for the company. Preparation has also paved the way for some unique collab- orations for StructureCast. Most notably is the company’s commitment to community engagement by forming signifi- cant relationships with universities and other institutions of higher learning, for instance engaging with architects and engineers at the University of California Irvine (UCI) and the University of Southern California (USC). “We are always looking to the future. Because we perform design-build, we want to be at the leading edge of precast concrete con- struction and what is happening in design, and construc- tion, and building. And the best place to cultivate that is to collaborate with universities, to understand and contribute to what they are putting into their curriculum. We want to know how we can partner with them to connect with gradu- ate students. We want to learn from them and also to share our knowledge so that they come out of school excited to design with precast concrete,” says Anna. For StructureCast this looks like symposiums, lectures, and speaking engage- ments, participation in competitions and projects, and even coursework development. | 89 APEIRON CONSTRUCTIONNext >