When it comes to precast concrete solutions, scale is often a key factor — and Houston-based Locke Solutions has proven it can deliver on a truly grand scale.
Last year, the company successfully produced and shipped its largest box culvert ever. Bound for Bay City, Texas, the colossal structure comprised two headwalls and five 20-foot-by-4-foot-by-8-foot box culvert pieces. It tipped the scales at an astounding 490,000 pounds.
This landmark project showcases Locke’s capabilities in handling complex engineering and manufacturing demands within the precast industry. Chad Arpe, sales and marketing director at Locke, said the massive drainage products were built for a refinery that needed a new downstream water control structure.
The sheer size of the individual precast components required much planning and coordination throughout the entire process, from initial design and mold creation to curing and ultimately the specialized transportation to the jobsite. Arpe said Locke worked closely with the project’s general contractor and that the project design initially called for cast-in-place concrete box culverts.
“We got involved early with this project and worked with the general contractor to convert that to a precast solution,” Arpe said. “One of the key reasons for the pivot included the location of both the box culvert and the adjoining wing walls. It was going to be tough for them to do it as cast-in-place.”
The contractor was concerned about the sheer size of the precast pieces, but Arpe said Locke leaned on its internal engineering team to develop a viable solution.
“We have our own professional engineers that [create] all of their own drawings, calculations and solutions,” Arpe said. “So, we’re able to do these customized engineered solutions for our clients.”
Arpe said that in-house resource was one reason Locke was selected in the first place.
“That’s kind of what drove the project our way,” Arpe said.
Locke started the project in 2023, completed the design calculations, received approval by the general contractor and owner, and then delivered the final products all within a short timeframe of about 3 to 4 months (after drawing approval).
“That covered the full project scope,” Arpe said. “Including the wing walls on each side, the custom box culvert and the linear feet in between.”