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J U N E 2 0 2 4 | 13 Precast Concrete P H OTO G R A P H Y BY J AC I A P H I L L I P S – A RC H P H OTO KC /CO U RT E S Y A LT US G RO U P P H OTO G R A P H Y CO U RT E S Y H EI D EL B ERG M AT ER I A L S Business in 2024 is brisk for Heidelberg Materials and Justin Arnott, Calgary-based area VP and gen- eral manager for Precast Concrete Pipe says, "While most of our market is residential development, we're noticing a push in infrastructure projects in Western Canada, especially in B.C." As a result, certain processes are gaining traction to facilitate the work, and Arnott cites the increasing instances of microtunneling in situations where tra- ditional open cut pipe laying is not feasible. Microtunneling (also known as pipe-jacking) is a non-disruptive method of installing utility tun- nels and conduits by thrusting pipes through the ground as controlled excavation is undertaken at the face. Pipes manufactured in a variety of materi- als to include concrete, clay, and steel can be jacked and standard pipe diameters generally range from 150 millimetres (mm) to 2,400 mm, or greater when required, and lengths can be in excess of one kilometre depending on pipe diameters, ground conditions, and excavation methods. Arnott says, "We've had good success with the process in B.C., with projects including the Trans Mountain Pipeline and currently the Burnaby Lake interception project. Since an increasing number of areas are being built out and regions are become urbanized, the need for microtunneling grows." For the concrete and precast concrete industry in general, another evolving innovation is the use of 3D printing to facilitate construction, and one example showcasing the potential of this technol- ogy is Kakatoosoyiists, 16 one-bedroom units being built across four buildings on the Siksika Nation about 100 kilometres east of Calgary. This is the first 3D concrete-printed housing initiative in Alberta and the largest in the country, with external walls being 3D printed with concrete using a four-foot tall robotic arm to pour the substance. Arnott says Heidelberg Materials Pipe has estab- lished an in-house 3D operation "to help solve nitpicky problems associated with the limitations of sand cast- ing, and we use it to create custom jigs. It's a fabulous aid to the bespoke work we do, and 3D has potential as a game-changer in the precast world." Heidelberg Materials has vast experience in 3D concrete printing materials, supplying dry mortars in Europe to some precast operators. In North America, the 3D opera- tions are mostly focused on single family homes and concrete furniture or landscaping elements. As for Heidelberg Materials' ongoing com- mitment to achieve and maintain sustainable standards, its Manitoba concrete pipe plant in January shifted from 30 percent production with EcoCem Plus to 100 percent, and Arnott says it's just a matter of time before the company's other plants across Canada follow suit. "We're getting the same strengths from EcoCem Plus compared to normal cement and its workability is great," he says of the blended Portland Limestone Cement that is produced by inter-grinding clinker, fly ash, lime- stone, and gypsum (and can lower the carbon footprint by more than 22 percent compared to General Use cement). John Carson, executive director at AltusGroup, Inc. says, "The precast industry in North America is very strong with many significant projects in a wide mix of markets – but the future is somewhat cloudy due to high interest rates, material infla- tion, and other factors. In general, schedules are sliding somewhat and demand is heavily dependent on regional economic activity and growth." AI con- tinues to drive data centre project development. Carson points to the recent opening of the new Knife River prestressed and precast plant in Spokane, Washington, as an example of the industry scrambling to fill the need for precast projects. One of Knife River's early accomplishments has been supplying a new electric car dealership with a pre- cast roof system as an alternative to steel roof joists; the company built the system in the space of a week and finished installation in six months, hence the use of precast. Carson, who toured the plant, says, "It's doing lots of wall and transportation projects, and the industry overall is also adding capacity through internal capital expenditures." Carson notes that in addition to manufactur- ers continuing to seek ways to improve productivity, achieve footprint reduction, and manage labour shortages, technological innovations continue to inform their work. "New fibre reinforced polymer connection systems and design methodologies like CarbonCast and the use of composite design in wall assembly makes precast a desirable selection for builders and GC's," he says. "Ultra and high-perfor- mance concrete admix technology continues to gain attention, and less cement and lighter weight ele- ments are drivers for new sustainable systems." CarbonCast High Performance Insulated Wall Panels are composed of two concrete wythes sep- arated by continuous insulation. With very low thermal conductivity, the high-strength C-GRID connectors help deliver insulation values up to R-37 depending on the thickness and type of board foam insulation used. Twin precast box culvert line installation, Bonnybrook Wastewater Treatment Facility Outfall, Calgary, AB. Oil/Grit Separator installation, Balzac, AB. CarbonCast High Performance Insulated Wall Panels, Boys Town School, Omaha, NE.

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