Gate Precast Company Produces Ultra-High Performance Concrete Roof Panels for St Elizabeths East Gateway Pavilion in Washington, DC

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Lightweight Ductal® Ultra-High Performance Concrete roof panels were manufactured offsite at Gate Precast’s Ashland City, TN manufacturing facility. Precast concrete was chosen for its design flexibility, durability, weather resistance, structural performance and its ability to meet an accelerated schedule.

Lightweight precast concrete Ductal panels have unique combination of exceptional strength and precision aesthetics.

Gate Precast Produces Ultra-High Performance Concrete Canopy Roof System (Photo Davis Brody Bond)

Having Gate Precast on the project team was a great benefit. The meticulous attention to detail throughout their involvement on the project solidified the success of the Ductal® panels. Cody McNeal, AIA, LEED AP BD+C, Davis Brody Bond

Gate Precast Company, a leader in the design and manufacturing of precast concrete systems, has completed the construction of a lightweight Ductal® Ultra-High Performance Concrete (UHPC) roof system for the new St Elizabeths East Gateway Pavilion in Washington, DC.

Designed by Davis Brody Bond (Washington, DC office), the Gateway Pavilion (also known as G8WAY DC), is a 16,400 sf open-air, multiuse facility that sits on a two-acre site and connects the original St Elizabeths east and west campuses. The Gateway Pavilion is a beginning sign of the redevelopment planned to bring new life to the historic 180-acre campus by creating one of the largest mixed-use developments in the District. Albeit the Pavilion was designed as an interim facility, the design team hopes it will be a permanent structure.

With sculpture-like qualities, the lightweight precast roof is approximately 400 ft long x 25 ft high x 60 ft wide at its broadest point. In addition to providing shelter below to visitors of the multi-purpose park, the Pavilion’s design includes a landscaped area above the roof for a relaxing view of the U.S. Capitol.

“Precast Ductal® panels were chosen for the canopy roof system for their unique combination of exceptional strength and precision aesthetics. Ductal’s structural properties allow our panels to achieve greater spans while providing an incredibly durable finish, a priority given the project’s public nature,” according to the project’s architect, Cody McNeal, AIA, LEED AP BD+C.

Gate Precast worked closely with Ductal® representatives and the architect, sharing a 3D model of the individual cladding panels for the roof. Through close coordination prior to pouring the first panel, the team was able to eliminate installation and design conflicts prior to construction. Gate Precast then developed the best method for casting the 1.75 inch thick custom-shaped panels. The panels were installed in 23 days without any significant modifications or delays.

Commenting on his experiences with Gate Precast and the use of Ductal®, McNeal said, “Having Gate Precast on the project team was a great benefit. The meticulous attention to detail throughout their involvement on the project solidified the success of the Ductal® panels. They often went above and beyond their contractual obligations to ensure the panels were cast, handled, and installed correctly. I am thoroughly impressed with their people and look forward to the next chance I get to work with their team again.”

Using Ductal® on this project presented exciting challenges for Gate Precast, according to Doug Flory, Gate Precast Capitol Region Sales Manager. “Our goal was to find a more cost-effective solution which, with the help of Ductal®, allowed us to minimize weight and maximize economy of the structure,” he said. The thin, clean lines are paramount to the Pavilion’s sleek design. The light, floating effect of the Pavilion’s roof illustrates the untapped potential of Ultra-High Performance Concrete.

The Pavilion was constructed in four months and opened to the public on Oct. 23. Visually, the Pavilion has enhanced the identity and character of the East Campus, stimulating revitalization of this national historic landmark.

Credits

  • Architect: Davis Brody Bond
  • Precaster: Gate Precast
  • Structural Engineering: Robert Silman Associates
  • General Contractor: KADCON
  • UHPC Supplier: Lafarge North America

Gate Precast Company is a subsidiary of Gate Petroleum Company, a privately-held diversified corporation headquartered in Jacksonville, FL. Gate Precast has become one of the largest and most diversified precast concrete producers in the United States with eight manufacturing facilities and is known for its design-assist collaboration with design teams. Annually, the company is recognized as a top subcontractor by Engineering News Record Magazine and wins Best-in-Class PCI Design Awards for a wide range of projects.

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Jane Martin
@gateprecast
since: 03/2010
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