PCI JOURNAL
Sculptured Precast Concrete Soundwalls Beautify Maryland Interstate 216 Baltimore, Maryland
Between the towns of Laurell and Scaggsville in Howard County en route to the city of Baltimore, Md., a 1-mile (1.6 km) stretch of Maryland’s Interstate 216 needed to have its vehicle noise levels shielded from a highly populated community. This could have been done with conventional concrete soundwalls, which have been used successfully in many parts of the country. In this instance, however, the owner (the Maryland State Highway Administration [MSHA]) wanted something special. At a minimum, the MSHA wanted a safe, functional, aesthetic sound barrier, but it also wanted to showcase the natural wildlife of Maryland without distracting motorists. Thus was born the idea of integrating sculptured life forms into the soundwalls.
To carry out this assignment, MSHA commissioned Creative Design Resolutions Inc. (CDR), a professional design firm that has gained national prominence in converting nature’s life forms into sculptured murals (see Creative Design Resolutions Sculptural Art Forms on the following page). Also on the team was engineer of record JTE Civil Inc.
In an effort to reintroduce the natural environment that was being obscured by the 3-mile-long (4.8 km) interstate highway expansion of Maryland I-216, CDR created an innovative approach to sound barrier design. It designed modular sound barriers representing flora and fauna, including trees, birds, water, and landscapes. With these natural murals, the design firm created a calming atmosphere that has radically changed the way commuters view their daily travels.
These nature murals were incorporated into approximately 8% of the total square footage of barriers on the project. The concept was to use a simulated brick pattern with the nature murals being used in four select locations along the project. By using them in prominent locations that are highly visible and closest to the highway, these enhancements create a visually stimulating environment for both commuters and residents. Also, by incorporating faux brick into the nature murals, the sound barriers integrate with the surrounding architecture and infrastructure.
The aesthetics of these sound barriers are not only cost-effective but create an environment that the traveling public can enjoy. These murals also instill pride in the local inhabitants. In addition to its size, approximately 25 ft (7.6 m) tall, one of the most impressive aspects of this nature mural project is the way that the panels are modular and can be reconfigured into an infinite number of unique combinations. A total of 216 nature mural panels were used in this project. Each panel is 7 ft (2.1 m) high and 16 ft (4.9 m) wide for an area of 112 ft2 (10.4 m2). The project uses 30 of the 36 panel designs from CDR’s Forest, Sailboat, and Geese series. Each of these three series comprises 12 subsections. The total dimensions of each of the three series is 21 ft (6.5 m) high and 64 ft (19.5 m) wide for an area of 1344 ft2 (125 m2). The total square footage of the structure is 326,130 ft2 (30,330 m2).
Although the project only used 30 unique panel designs, these nature panels were reused and reconfigured into different arrangements along each of the four roadway locations. The total size of the four sections was approximately 25 ft × 8000 ft (7.6 m × 2440 m), and the relief of the panels is 4 in. (102 mm). These nature murals were designed to integrate seamlessly using conventional precasting methods.
Once the plans and drawings were complete, formliner manufacturer Creative Form Liners Inc. created scale models and full-sized patterns based on the designs. All design details were carefully handcrafted by this supplier.
The formliners were manufactured from fiberglass with a gray alkaline-resistant gel coat surface, a reinforced core, and wood reinforcing ribs. The formliners were fabricated from fiberglass to be lightweight, high-impact resistant, and easy to handle so that time and money were saved in installation costs. These liners were used over and over again and maintained a high level of detail within the 4 in. (102 mm) relief.
Precaster Concrete Safety Systems used these formliners to cast the sound barrier panels. Using carefully controlled castings, the precaster did an excellent job in maintaining the level of detail and high relief in each of the castings. This relief allows for a much stronger design that creates shadows and depth. The surface finish of the concrete was exceptionally good, without any blemishes or other defects. Indeed, motorists are able to see and appreciate the intricate designs from a great distance, as well as close at hand.
The panels were manufactured at the precaster’s plant in Bethel, Pa., and were transported by tractor trailer to the project site, a distance of about 140 miles (220 km). The general contractor of the project was Corman Construction Inc.
The concept for enhancing the sound barriers of Maryland I-216 into a sculptured art form was first proposed in the summer of 2001. It took another four years before the concept became a reality. This involved the detailed design of the sculptured panels through many discussions and visual displays with MSHA administrators and the engineer of record and then translating those designs for the precaster. The sculptured sound barriers were finally installed in the summer of 2005. The erection process took only six weeks.
The total cost of the project was about $24 million, with the cost of the sound barrier portion amounting to about $6 million. The owner, engineer of record, designer of murals, precaster, and contractor are all pleased with the quality and aesthetics of the final product. More importantly, the motorists and local community are enjoying the nature murals.
The sculptured sound barriers on this project have advanced the state-of-the art design of such art forms. It is said that the average American spends more than two weeks per year traveling to and from work. When applied properly, these sculptured designs can make the commute more interesting while still being safe. The designs are not only aesthetically pleasing to the motorists but also represent the locality’s natural landscape, evoking pride and inspiration within the community.
This project won a 2006 PCI Design Award for Best Custom Solution— Bridge. The jury comments were as follows:
These innovative sound barriers meet the context-sensitive requirements of the community; the panels reflect the area landscape, using images of trees, birds, clouds, and sailboats. There are over 216 panels made from mirroring 30 unique designs, which allow for standardization to reduce cost and facilitate faster construction. This project opens many possibilities for aesthetics for other projects of this type.
CREDITS
Owner: Maryland State Highway Administration; Baltimore, Md.
Designer of Soundwalls: Creative Design Resolutions Inc.; Brentwood, Md.
Engineer of Record: JTE Civil Inc.; Lorton, Va.
General Contractor: Corman Construction Inc.; Annapolis Junction, Md.
Precaster: Concrete Safety Systems; Bethel, Pa.
Precast Specialty Engineer: Rummel Klepper and Kahl LLP; Baltimore, Md.
Form Liner Manufacturer: Creative Form Liners Inc.; Brentwood, Md.
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