WWW.CELL-CRETE.COM or (800) 669-0433

CALIFORNIA (Lic #243404), OREGON, WASHINGTON, NEVADA, UTAH, IDAHO, MONTANA, ARIZONA, HAWAII, ALASKA, WESTERN CANADA

WWW.CELL-CRETE.COM or (800) 669-0433

CALIFORNIA (Lic #243404), OREGON, WASHINGTON, NEVADA, UTAH, IDAHO, MONTANA, ARIZONA, HAWAII, ALASKA, WESTERN CANADA

Re: Cellular Concrete as Engineered Fill I’m pleased to report that cellular concrete Engineered Fill has continued to grow in acceptance with proven results by both public agencies and the private sector. The increased acceptance is due to tireless product research and development by the Elastizell Corporation and the entire cellular concrete industry. The many varied and successful applications installed by the Cell-Crete Corporation provide confidence with our clients. We are seeing increasing confidence from Geotechnical engineers, agencies, consultants, contractors, owners and designers in this game-changing product. ELASTIZELL EF is specialized cellular concrete formulated specifically by the Elastizell Corporation of America for Geotechnical applications. It is often used in difficult situations where either the standard fill materials are too heavy or alternate solutions are too costly and time consuming as demonstrated through project specific value engineering. The various applications of ELASTIZELL EF are as broad as the designer’s imagination. Below are the most common applications of this material, which may weigh as low as 18 pounds per cubic foot (pcf), more commonly around 25-30 pcf. It is 10X stronger than most soil and dirt fill materials.

1. due to it high strength and low density while maintaining or increasing accompanying elevations. This is especially important with older structures when new uses are contemplated. This may save the difficult and costly strengthening of existing buildings, bridges, or specialized structures such as culverts, retaining walls and plaza fills.

2. The most common

application, where the ELASTIZEL EF thickness at the abutment may vary from less than 5 feet to often more than 20 feet. Different densities may be required in various locations of the approach fill to satisfy specific requirements.

3. . With a properly load balanced application of Elastizell EF there is no longer the cost or

delay of surcharging to stabilize deep soft soils or bay mud.

4. for rehabilitating an existing roadway or for the construction of a new road over a poor subgrade. When maintaining an existing road, the additional weight of roadway leveling patches will often further consolidate the soil leading to additional differential subsidence. For these, as well as new roadway sites over poor soils, ELASTIZELL EF provides a solid, yet lightweight roadway base, which reduces further settlements and will span most differential subgrade movement. Water in an Elastizell subgrade does not cause settlement!

5. because of its lightweight flowability, ease of placement, cementitious

properties and no need for compaction! These applications may include abandonment fills, annular fills for sliplined pipes, fills between both a pipe and a tunnel cut as well as a pipe and a cribbed excavation. Other void fill applications may be sink holes, swimming pools, voids under slabs, and voids created by washouts.

6. of ELASTIZEL EF will spread loads over larger areas as well as reduce the weight of

these supporting structures. These are important considerations over poor soils and can often replace more costly alternatives such as pilings, caissons, micropiles, surcharging, etc.

7. Once ELASTIZELL EF sets, it does not apply lateral

pressure. Depending on its shape and location, the ELASTIZELL EF may be designed to reduce or eliminate lateral soil pressures. This may result in substantial savings in the design and construction of new structures or the remodeling of existing structures.

ELASTIZELL EF may be the most timely and cost efficient solution for your geotechnical problem. Please call to discuss your application, its technical design, and the costs of a Cellular Concrete solution. Scott M. Taylor, PE, MBA Senior Estimator Vice President - EF Division Cell: 415-419-6876

CELL-CRETE (Engineered Fill)

Bay Bridge approach slabbeing replaced while traffic

is maintained on the other side.

West County Connector

San BrunoGrade

Separation

A view along the roadwayreconstruction showing

depth of cut, ELASTIZELL EF,aggregate road surface, and

temporary traffic barriers.

ROADWAY FILLS

PROBLEM

SOLUTION

DISCUSSION

ADVANTAGES

Tight constructionconditions with Heavy and Light Rail

Roadway base overexisting TransitTunnel

Specialized and certified equipmentis required for theselarge CELL-CRETE

installations.

UNDERGROUND CULVERTSTRUCTURES

PROBLEM

SOLUTION

DISCUSSION

ADVANTAGES

RESEARCHREPORT

LOAD RELIEF COMPARISON

ROADWAY CONSTRUCTION

www.cell-crete.com

UNDERGROUND CULVERT STRUCTURES

Project Description: The Colton Crossing is a major crossing of the BNSF and UP rail lines in Southern California. The project involved the construction of a 1.4-mile-long overpass to remove the chokepoint and elevate two UP east-west tracks above the BNSF north-south line. Why Lightweight Cellular Concrete?: With settlement and movement concerns for standard MSE backfill and the high cost of building cast in place walls or a bridge, Lightweight Cellular Concrete and MSE panels was accepted as the most efficient method to lift the new rail line. The Lightweight Cellular Concrete and MSE panels created a lightweight self supporting mass of cohesive fill behind a MSE Panel facade . The fill has a compressive strength (psi) seven to ten times stronger than typical compacted soil. Additional benefits were realized by limiting the amount of truck traffic to one (1) truck for every 120 cy’s of material, the seis-mic benefits of lightweight fill and overall speed of construction.

Colton Crossing Colton, CA Total Cubic Yards: 220,000 Project Savings: $109 million and 9 months

…”Estimated to cost $202 million and scheduled to open in 2014, the project wrapped up eight months ahead of schedule and cost $93 million primarily be-cause of innovative construction methods and a com-petitive marketplace that resulted in lower-than-expected bids”, the owner said in a press release.

Recent Example: West County Connector, Los Angeles, CA

RESEARCHREPORT

SLIPLINED - CASING & CARRIER

ELASTIZELL PS - SLIPLINED PIPE

ELASTIZELL PS - ABANDONED PIPE

ABANDONED

Quality formwork is recommended.

ELASTIZELL EF (Engineered Fill)ELASTIZELL EF (Engineered Fill)

SOLUTION

DISCUSSION

ELASTIZELL EF is often a Cost-E�cient Solution in Other BridgeApproach Applications.

Recent Example:Bay Bridge,Oakland to San Francisco

Recent Example:Bimbo Bakery,Portland, OR

Another application

Specially designed ELASTIZELL EFfooting pad (six feet thick) for

bridge abutment and wing wall.ELASTIZELL EF was also placed

about 14 feet thick behindthe abutment and wing walls.

I-405 ProjectLos Angeles, California

for CALTRANS

RESEARCHREPORT

BRIDGE REHABILITATION

PROBLEM:

SOLUTION:

Totem Lake, WAUnacceptable loads

on structure

PROCEDURE:

CONCRETE BOX CULVERTS

STEEL ARCH CULVERTS

RESEARCHREPORT

ASSUMPTIONS

REMARKS

West County Connector Long Beach, CA Cubic Yards: 75,000

With over 900,000 daily trips, the con-

gested 6-mile West County Connector

project is a partnership between OCTA

and Caltrans linking high occupancy vehi-

cle (HOV) lanes/carpool lanes on I-405

with those on SR-22 and I-605 to create a

seamless carpool connection amongst the three freeways.

The project had 8 proposed MSE walls

with Cellular Concrete, design heights

ranging from 6 feet to a maximum of 33

feet. Total length of these proposed

walls is 3,982 linear feet. Due to the

presence of a firm to stiff clay layer present between typical elevations of El. +15 to +22 feet (top of lay-er) to El. +3 to +8 feet (bottom of layer), the wall foundation soils generally have low bearing capacity and potentially large settlements under wall loading.

With Cellular Concrete’s lower cost compared to traditional ground improvement alternatives, the West County Connector benefitted from significant savings in time, less uncertainty of the total settlements and rates of settlements, and ease of construction.

Additionally, in the confined high traffic area where these HOV connectors were located, eliminating truck traffic from traditional backfill material was a big win for OCTA. Each truck of cement provided up to 120 cubic yard of Cellular Concrete compared to 10+ trucks of traditional backfill to equal the same volume.

Project Description: The Doyle Drive project is the reconstruction of the Northbound access to the Golden Gate Bridge. The project involves 5 major contracts including new bridges and tunnels. Why Lightweight Cellular Concrete?: A new detour is included in the project that was constructed over soft soils. It was originally designed as Geofoam behind a 14’ high cast-in-place wall. The contractor chose to value engineer using the Caltrans CRIP program. They proposed Lightweight Cellular Concrete and a welded wire wall. Lightweight Cellular Concrete behind Welded Wire Retaining Walls was a tremendous cost savings option reducing the construction schedule and big savings on the cost of materials and labor. Even higher savings than a typical switch since a permanent face was never installed! Additional benefit of 70% less material to haul away when the detour is removed. Lightweight Cellular Concrete and welded wire retaining walls have become an inexpensive way to build a wall of any height. Simply put on precast wall panels, shotcrete, or stucco for a tough finish.

Doyle Drive San Francisco, CA Cubic Yards: 13,000 behind a Welded Wire Retaining Wall Project Savings: $2 million

y =

0.94

48x

+ 11

3.81

R²

= 0

.447

050100

150

200

250

300

050

100

150

200

250

300

350

400

Fric

tion

Angl

e =

45 d

egre

es

Cohe

sion

= 11

3.8

psi

-DRA

FT-

0

10

0

20

0

30

0

40

0

50

0

60

0

70

0

80

0

90

0 20

.025

.030

.035

.040

.045

.050

.055

.060

.0

Compressive Strength (psi)

Dry

Density

(pcf)

"A

ppro

xim

ate

ly 3

-5 p

cf

belo

w c

ast density"

Ce

ll-C

rete

Co

rpo

ratio

nD

ry D

en

sity v

s C

om

pre

ssiv

e S

tre

ngth

Typ

ica

l Te

st R

esu

lts (

28

44

te

st re

su

lts)

Short Form SPECIFICATIONS

BASICPHYSICALPROPERTIESELASTIZELL EF(Engineered Fills)

1. SCOPE OF WORK: 2. MATERIALS: 4. MIXING AND PLACING:

3. MIX DESIGN:

5. TESTING:

6. SPECIAL CONSTRUCTION METHODS:

Please contact the ELASTIZELL CORPORATION OF AMERICA foradditional speci�c design values and more detailed speci�cations.