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Published Monthly by thePRESTRESSED CONCRETE INSTITUTE May/June, 1965Editor: Betty J. Ritter, A.I.A. Vol. 11, No. 5 and 6

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NEW TECHNIQUES IN MULTI-STORY BUILDINGSPrestressed concrete offers the architect and engineer an opportunity

to develop creative solutions to high-rise building problems

A 12-story structure in Durham, N. C.presents a look into the future of high-rise building techniques. Headquartersfor North Carolina Mutual Life Insurance Company, the $5 million officetower employs a Vierendeel truss systemcomposed of precast, prestressed concreteunits with exposed aggregate surfaces.The trusses, similar to those used onmany bridges to span between supports,create four identical facades for thetower (see cover).

Welton Becket & Associates, architectsand engineers for this unique building,designed a facade which simultaneouslyserves architectural and structural purposes. The precast, prestressed concreteframes combine the quality and character of ancient building materials withhighly advanced prefabrication and assembly techniques.

Rising from a broad podium, the 119ft. square tower has a slip-formed concrete core which extends 183 ft., the fullheight of the building, and measures 34ft. by 45 ft. Seven of the Vierendeeltrusses, each 20 ft. high and 119 ft. long,comprise each building side and are sup.

ported by two reinforced concrete columns on each wall, resulting in unusualcorner cantilevers. The trusses, at everyother floor, cantilever 34 ft. at each end.Precast, prestressed concrete girderswhich span 34 ft. lie the exterior to thecore.

Beneath the podium are two levels—a concourse floor and basement floor,with employees’ facilities including auditorium and cafeteria as well as printshop, loading facilities, mail and stockrooms, storage and mechanical equipment. At the southeast corner of the siteis a three-level parking garage.

The architect, Welton Beckett, FAIA,commented, “Our architectural design,while it represents a departure from pre.vious methods and techniques, was notconceived with the intent of being different, but to provide the highest qualitybuilding for our client at an economicalbuilding cost.”

The 219,800 sq. ft. project will be thetallest in Durham. Concrete Materials,Inc. of Charlotte, N. C. produced anderected the precast, prestressed concretetruss sections, girders, and double tees.

Trucked to the site, the massive precast truss sections were elevated fromthe vehicle by a 100-ton mobile towercrane and raised to the working level.There, the crane transferred them to amonorail, a job-developed device formoving the units to their final position.

The monorail is a 30 ft..high steelframe, assembled in sections to extendthe width of a truss bay (a third of thewidth of the building). Initially, it wasset up on the first floor for erection ofthe first truss; then, as each truss wascompleted, it was disassembled and re.erected on top of the truss. Two duplicate sets of monorails were used to facilitate erection on two opposite facadessimultaneously.

Aiming at completion of a truss levelevery 28 days, two crews worked simultaneously on opposite sides of the building to thread steel post-tensioning barsthrough the truss members. When twotruss facades were finished, the monorails were shifted to the incompletesides.

Exterior columns consist of 60 in. by40 in. concrete shell sections with a wall

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Precast concrete sections are assembled on steel bars by means ofthe self-supporting monorail conveyor system, and post-tensionedto form Vierendeel trusses. The monorail extends the width ofthe building and is assembled at each truss level.

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A precast concrete bottom chord truss section is li/tedto the monorail assembly rig. Weighing about 4 tonseach, chords have 4-ft. flanges and 6-ft. webs with preformed ducts to receive the tensioning bars.

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Architect: Walton Becket & Assoc.; Associate Architect; M.Materials, Inc.; Post-tensioning; Stressteel Corp.

A. Ham, Associates, Inc.; Consulting Engineer; Seelye, Stevenson, Value & lCnecht; P/C fabricator; Concrete

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(Right) Precast T.shaped truss chord isstrung on steel post-tensioning bars andpositioned. Grout is forced under pres.

Qsure into the voids surrou.nding the barsto encase the steel and bond it to theprecast concrete.

(Far right) Workmen post-tension thesteel bars from the cantilever ends ofthe truss. The hydraulic jacking equipment is carried in a cage suspendedfrom the top of the truss being stressed.

(Right) As each truss is completed, themonorail assembly rig is removed andplaced on top of the completed truss.The monorail assembly method wasselected after an extensive study of possible means of erection and proved to bean efficient and economical solution.

C(Far right) Massive quartz-faced whiteconcrete trusses, projecting boldly frontthe slim columns, are accentuated byhorizontal voids. The structure is saidto be the tallest precast, post-tensionedstructure in the nation.

thickness of six inches. Two interiorcolumns are incorporated into the cornerof the core and two are located outsidethe core, at the corner of the elevatorlobbies bordering the core. At everyfloor, to carry the prestressed concretedouble tee floor structure, a precast, pre.stressed concrete girder extends fromeach interior column to an exterior column. Fourteen 80 ft..Iong steel post-tensioning rods were threaded through thesleeves in the columns, extending out onboth sides of the column shell. The shellswere then filled with concrete.

DPieces of the top and bottom chord

members and truss vertical sections,which weigh eight tons each, were liftedto the monorail level by crane. After theprecast units were threaded on the post-tensioning rods, winchs pulled the unitsinto the desired position in the facade.

The center bay of each truss was completed in this manner.

Column shells for the second columnwere then placed while the cantilever section adjacent to the base column wasset. Shorter post-tensioning rods werethreaded through sleeves in the secondcolumn and coupled to the butt ends ofthe long rods inside the column.

When the second cantilever sectionwas erected, it was grouted and stressed.The monorails were then moved to theincomplete sides of the building and theconstruction procedure repeated.

As the trusses were completed, thegirders and double tees were set at theodd-numbered floors. The odd floorsoccur approximately one-third of theway up on each truss.

Installation of underfloor ducts wasbegun in preparation for placement of

the concrete floor topping, while the gird.ers and double tees were being set for theeven-numbered floors. The double teesalternate span direction at every floor;thus each 2-story truss actually supportsonly one floor load.

The stairs and one of the passengerelevators were installed in the servicecore during the early stages of the trusserection. The presence of these considerably aided job progress and accidentprevention.

An eight-page bulletin, available onrequest from the Stressteel Corporation,221 Conyngham Avenue, Wilkes-Barre,Pa., shows with photographs, text, anddrawings how the precast sections whichcompose the building’s outer frame weretied together by means of the Stressteelpost-tensioning system.

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SCULPTURAL HIGH-RISE:

0 LIFE TOWER

Construction of the tallest precast,Post-tensioned concrete structure in thenation, a 27-story home office for theGulf Life Insurance Company which willalso be the tallest building in Jacksonville, Florida, has begun on a 12-acreSt. Johns Riverfront site across fromdowntown Jacksonville.

Gulf Life Tower will be part of the$25 million Gulf Life Center, designedby Welton Becket & Associates, architects and engineers, which will also in.elude a multi-level, luxury motor hoteland a six-level parking structure for1100 cars. Kemp, Bunch & Jackson ofJacksonville are associate architects.

The 430 ft.-high tower will completelyexpose its sculptured structural frame onthe exterior. The structural frame issupported by eight tapered concrete columns, two on each side of the squaretower. Precast, prestressed concretebeams join the two columns at everyfloor and cantilever outward a distanceof over 40 ft. on either side. Each of thebeams will consist of 14 precast concretesegments strung together with highstrength steel rods and then post-tensioned by tighteiing fasteners on eitherend of the rods.

The building will be entirely supported by the exterior frame and by a central core. Precast, prestressed concretedouble tees will span between the exterior frame and the core at every floor.

The beam units are heavier in sectionat their juncture with the columns, withthe exterior faces flowing upward andinward as they narrow, creating a deeplysculptured facade. In order to fully expose the structural frame, the windowwall of the tower will be set back 15 in.from the inner face of the structure.

White quartz sand, white cement andlightweight aggregate will be used byCapitol Prestress Company to produce

Dthe white concrete frame so it will standout in bold contrast to the grey glassand dark window frames.

“Our design concept for the GulfLife Tower was conceived to capture thesolidity and vitality of a growing insurance company,” architect Welton

Becket, FAIA, explained. “in addition,we sought to utilize a material whichwould visually unify the several structures on the site.” he continued. “Weselected concrete for its design flexiblityand evolved the precast, post-tensioningconstruction as a single solution to presenting the bold image we sought, providing relative economy, shortening theconstruction time, and providing long-span, column-free floor areas which is adesirable characteristic of space for insurance company operations.”

A glass-enclosed lobby at the entrancelevel is recessed from a glass-enclosed,two-story-high bank on the second level,which is in turn recessed from the tower’swindow walls. Escalators will serve thebanking floor from the lobby as will thebuilding’s 12 passenger and 2 serviceelevators. On a concourse level willbe a 600-seat cafeteria overlooking theriver, an employee lounge and a largekitchen.

When completed, the center will beone of the show places of Jacksonville.The site will be completely landscapedand covered walkways and pedestrian

bridges will link all of the buildingsand the parking structure. Outdoor recreation areas will include a puttinggreen and shuffleboard area. A combination boat dock and gazebo will extendinto the river from the site.

The 1100-car parking structure willbe connected to the tower at the entrancelevel by a concrete bridge which will alsoprovide covered access at the concourselevel. The split-level structure will havecontinuous one-way ramps for in and outtraffic. Construction will feature precastconcrete columns and precast, prestressedconcrete tee joists spanning 63 ft. to provide column-free space. Exterior wallswill be a system of alternating horizontalbands of precast concrete panels withspaces for ventilation.

Main vehicular entrance to the sitewill be a wide roadway that encircles aspacious landscaped plaza elevated abovethe roadway. The roadway will providedirect access to the hotel and a suijterranean parking level. Precast concretebridges will span the roadway and provide pedestrian overpasses from the officetower to the central plaza.

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HIDDEN QUALITY AT WORKEase of handling and construction, rugged durability and dependable

performance are some of the characteristics of prestressed

concrete foundations and piles for land and marine use

One of the most exacting aspects ofany structure is the design of itsfoundation. Very often soil conditionsare critical, or other special conditionsexist which make the foundation designespecially difficult. It is in these prob.lem areas that prestressed concrete reallycomes to the fore by offering the designer many possibilities for creativesolutions which are not only economicalbut work efficiently.

Prestressed concrete piles, for example, can resist bending forces duringhandling and driving and are thereforeless likely to be damaged or to developpermanent cracks.

Prestressed concrete makes possiblea more effective utilization of smallercross-sectional areas which results insmaller, lighter piles. This is a definiteadvantage in marine installations wherefloating equipment is needed.

The combination of high-strengthconcrete and built-in compressive stresses which is found in prestressed concretepiles produces a high resistance tocorrosion by sea water.

Ability to withstand impact forces isalso a requirement of marine structures;prestressed concrete is inherently capable of resisting such forces.

The largest diameter prestressed concrete piles ever used in California weremanufactured and driven by Ben C.Gerwick, Inc. for a highway bridgeacross the Napa River at Vallejo. The54 in. o.d., 44 in. i.d., pretensioned pileswere produced in lengths ranging from76 to 123 ft. and shipped by barge tothe jobsite. The longest of these roundpiles weighed approximately 50 tons.Gerwick reports that they also producethese 54 in. sections for use as culvertsand water overcrossings.

Concrete design strength was 6,000psi, and 28-day strengths ranged from6,500 to 7,500 psi. All of the 239 pileswere cast as single monolithic units bythe long line pretensioning method.

Most of the piles were jetted to within 20 ft. of the tip elevation and then

driven to required grade by a Vulcan200C hammer. This hammer, one ofthe largest on the Pacific Coast, has anenergy of 50,200 ft-lbs per blow. Allpiles were subjected to very hard driving with negligible spalling on the pileheads. Piles were driven open-ended.

In addition to the 54 in. piles, 24 in.and 16 in. square prestressed piles werealso used. The 24 in. piles measuredfrom 123 to 127 ft. in length, and wereused for pier foundations both on landand water; whereas the 54 in. piles wereused only for the river foundations.

Northern New England’s first marineterminal constructed with precast, prestressed concrete is located in Portsmouth, N. H., the home of atomic submarines. The dock is constructed withprestressed crane and facia girders, andgiant tees, all of which span 35 ft. Theremaining structure consists of 20 ft.-

span prestressed transverse girders. Prestressed concrete was supplied by theStructural Concrete Corporation.

The structure is topped with a 12 in.cast-in-place concrete deck which completes the composite connections. Thedock was designed for 350 psi liveload, plus the crane and impact loads.

Two bridges from the shore to thedock are created with 50 ft. span pre.stressed box beams.

Lock and Dam No. I on the ArkansasRiver is the first of a series of fiveprojects by the U.S. Army Corps ofEngineers to make the river navigablefor barge traffic from the MississippiRiver to an area near Tulsa, Okia.

There will be 18 locks and dams onthe project, five of which require piling.On the plans and specifications, thecontractor was given the option ofeither precast, prestressed concrete piles

Engineer: Bond & Dougherty; PJC fabricator: Ben C. Gerwick, Inc.

Precast concrete vertical wall panels and prestressed concrete square piles, “I”girders, and deck slabs are used in the Vallejo Marina Vista Seawall at Vallejo,Calif. Deck slabs are 15 ft. long, 8 ft. 4 in. wide, and 6 in. thick; wall panelsare 16 ft. wide and 7 in. thick.

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During driving operations, Ben C. Cerwick, Inc. was ableto attain almost perfect alignment of the outer row of 18in. square piles in the Vallejo Marina Vista Seawall. Because precast vertical panels were designed to hang anthese piles, accurate alignment was necessary.

A 54-in.-diameter prestressed concrete pile, the largest everused in California, is unloaded from the shipping bargefor the Napa River bridge foundation at Vallejo, Calif.These sections can also be used as culverts and water over-crossings. Piles are 76 to 123 ft. long.

or steel H piles. On four of the projects,prestressed concrete piles were selectedby the low bidder.

Over 4,000 precast, prestressed pileswere manufactured in a plant which wasset up by Ben C. Gerwick, Inc. about30 miles from the jobsite. The piles are14 in., 16 in., 18 in., and 20 in. square,and range in length from 35 to 70 ft.A 475-ton test load was made on the 18in. piles.

A marina in Galveston, Texas is constructed completely of prestressed concrete. Dock piles, decks, and sheetpiling retaining walls are pretensioned;tapered beams in the finger piers werepost-tensioned by Prestressing Industries. The latter beams are either 50or 80 ft. long. The total marina area isapproximately 18 acres and providesdocking space for 400 boats.

The seawall at Vallejo, Calif. isinterestingly detailed, employing 14 in.and 18 in. square prestressed concretepiles, 36 in. -deep prestressed “I” girders,prestressed concrete deck slabs, andprecast concrete vertical wall panels.

The high bearing capacity of pre.‘ stressed concrete piles makes themequally effective in building foundations.

The Wells Fargo Bank Building inSan Francisco, Calif. demonstrates thestrength of prestressed concrete piles.The design load of the 18 in. square

piles for this project was 200 tons, anda 500-ton test load was successfully applied prior to the driving of the piles.

The piles, which are 132 to 138 ft.in length, have a steel H stub cast intothe pile a distance of four feet and isused for penetrating a rock layer at thej obsite.

Steel H piles were considered butthe precast, prestressed concrete pilesproved to be more economical.

In Canada, Winnipeg’s North ExdSewage Treatment Plant rests on precast,prestressed hexagonal concrete piles, 14in. across the flat, driven to refusal onbedrock some 60 ft. below the grade.If all the piles were placed end to end,their total length would measure over50 miles.

Prestressed concrete can also be usedadvantageously for other components inmarine structures. The Port of SeattlePier 46 transit shed has a barrel roofstructure which has a clear span of 150ft. The original design was based oncast.in-place concrete for the barrelvaults, but an alternate proposal forprecast, prestressed concrete vaultsproved to be the most economical. Theprecast, prestressed scheme required nosite formwork, and this resulted inmaj or savings.

The prestressed concrete producer,Concrete Technology Corporation, de

veloped a system of casting the barrelroof sections in full-length longitudinalstrips. Each barrel shell is formed offive such strips, measuring 3 in. thick,by about 8 ft. wide and 160 ft. long,including overhangs. The roof consistsof a total of 14 barrel vaults.

For the edge beam at each valley, 146ft..long, 58 in..deep I-shaped prestressedconcrete valley beams are used. Thesebeams were precast and then pre-andpost-tensioned to a 2,400 psi compressivestress.

The shell units were joined to eachother and to the valley beams by meansof lapping and welding the reinforcingbars which projected from the units.joints were then concreted.

Extensive general discussions of prestressed concrete foundation and piledesign considerations were publishedin the March, 1961 and December, 1962PCltems, and in the December, 1964Journal of the Prestressed ConcreteInstitute.

AASHO-PCI data sheets on squareand octagonal prestressed concrete pilesare currently undergoing revision. Approval of the revised and updated sheetsby the American Association of StateHighway Officials is expected late thisyear. PCI will publish the revised dataat that time.

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Prestressed concrete piles are driven for Lock and Dam No. 1 on the Arkansas River. The piles, ranging in length from 35to 70 ft., were delivered by truck from a production plant which Gerwick set up about 30 mites from the job.site.

Engineer: F. R. Harris; P/C fabricator: Structural Concret. Corp.

Northern New England’s first marine terminalconstructed with precast, prestressed concreteincorporates crane, facia, and transverse girders, and giant tees. Concrete pile caps supportthe girders. Composite connections betweenthe girders and pile caps will be created whena 12 in. cast-in.place concrete deck is placed.The close.up view below shows the girder andpile cap connection. The steel bearing plate isset to proper elevation and grouted; compositejoint is then cast.

Engineer: U.S. Army Corps of Engineers; P/C fabricator: Ben C. Gerwick, Inc.

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Engineer: Gardner Engineering Corp.; Post-tensioning: Prestressing Industries(Right) Prestressed concretedecks, piling, and tapered beamsform a marina for 400 boats inGalveston, Texas. All piling anddecks are pretensioned. The grace.fully tapered, post-tensionedbeams are 50 ft. and 80 ft. longand create a handsomely clean,crisp design for the marina.

(Left) All prestressed concrete membersfor the Galveston, Texas marina wereprecast at the jobsite. Casting beds arevisible along the left edge of the basin.Plans aie to erect a roof over all docking areas. The total area of the marinais approximately 18 acres.

Consulting Engineer: J.

(Right) Over 50 miles of precast,prestressed concrete hexagonalpiles were driven to refusal onbedrock 60 ft. below grade to pro.vide a foundation for an additionto the North End Sewage Treat-meat Plant of the MetropolitanCorporation of Greater Winnipeg,Manitoba, Canada.

F. McLaren & Assoc.; Aesoc. Engineer: W. L. Wardrop & Assoc.; P/C fabricator: Preco, Ltd.

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Engineer: Part of Seattle; P/C fobrkotor: Concrete Technology Corp.

(Above) Port of Seattle’s Pier 46transit shed is roofed with 14 pre.stressed concrete barrel roof shellswhich cover 91,000 sq. ft. of colzsmn-free area. The total cost ofshed construction and substructurewas $6.12 per sq. ft.

(Left) Barrel roof segment 3 in.thick, 8 ft. wide, and 160 ft. longis supported by a strongback as itis lifted into place on the Port ofSeattle’s Pier 46 transit shed.

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(Left) Prestressed concrete piles,132 to 138 ft. in length, supportthe Wells Fargo Bank Building inSan Francisco. Piles have a steel“H” stub cast into their tips. Thesteel stub penetrates 4 ft. into thepile and is used to bore through arock layer at the jobsite.

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ArchItect: John Graham & Company; Engineer: John A. Blume & Assoc.; P/C fabricator: Ben C. Gerwick Inc.

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Engineer: J. H. Pomeroy & Co.; P/C fabricator: Ben C. Gerwick, Inc.

(Above and right) Piles and deck unitsare precast, prestressed concrete in thewharves at the Port of Redwood City,California. An 8 in. cast-in-place concrete finish deck completes the assem..bly. Prestressed slabs are 8 in. thick, 5ft. 7 in. wide, and 14 ft. 2 in. long;piles are 16 in, square. Gerwick reportsthat they have built several marine projects which utilize this design and theyfind it to be quite economical.

(Right) As the jobsite sign indicates, an18 in. prestressed concrete pile is subjected to a 500-ton test load prior todriving of the foundation piles. Thedesign load of the 18 in. square pileswas 200 tons; the test load thus demonstrates the high bearing capacity of precast, prestressed concrete piles. Steel“H” piles were also considered for thefoundation, but the precast, prestressedconcrete piles proved to be moreeconomical.

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PCI MEMBER TO DEVELOPPERFORMANCE CRITERIA

New York’s State University Construction Fund, responsible for a $1.4billion construction program, has retained Irwin J. Speyer, a PCI Professional member, to assist in the development of performance criteria of building materials and methods,

In the first phase of the program,Speyer will develop performance criteria for precast and prestressed concrete. The criteria will be issued as aguide to contract architects for the development of plans and specifications.During the program’s second phase,Speyer will devise performance criteriafor precast, exposed aggregate wallpanels.

I. M. Pei & Associates, also retainedby the Fund, will develop performance

“ criteria for cements and aggregates.

REVISED ACI DETAILINGMANUAL AVAILABLE

An enlarged, revised edition of the“Manual of Standard Practice for Detailing Reinforced Concrete” (ACT315-65) is now available from theAmerican Concrete Institute.

Long nationally accepted as a standard reference work in concrete detailing, the manual’s new edition presentsdetailing practices which conform tothe ACI Building Code (ACI 318.63).

A chapter on precast and prestressedconcrete includes discussions of general principles of prestressed concretedetailing and prestressing procedures,and general considerations concerningthe use of precast and prestressed concrete in building and bridge construction.

The manual is available at $4.50 percopy ($3.00 to ACT members) from theAmerican Concrete Institute, Box 4754,Redford Station, Detroit, Michigan.

PCltems welcomes information on prestressed concrete applications. Send

material to: Editor, PCltems

BUEHNER ELECTED TOSCHOKBETON COUNCIL

At the semi-annual meeting of theSchokbeton Technical Advisory Board,Paul Buehner, president of BuehnerSchokbeton Company, was unanimouslyelected to the four-man Sc h ok beto nOperating Council which guides andsupervises the operations of the Schokbeton Technical Center. The AdvisoryBoard, which consists of all Schokbetonlicensees in the United States andCanada, met on May 17 and 18 at theTechnical Center in Mamaroneck, N.Y.

Thirty members representing theSchokbeton licensees attended the conference which was highlighted by a review of current Schokbeton projectsand technical development work.

An outstanding feature of the program was a two-hour talk by JohnHeald, “Converting to Schokbeton Pro-duction from Wet Casting.” Heald isvice president of Inland Schokbeton, adivision of Nebraska Prestressed Concrete Company in Lincoln, Neb.

Both Buehner Schokbeton and Nebraska Prestressed Concrete are PCIActive members.

ALFRED H. KRAAS1725 DeSales St., N.W.Washington, D. C. 20036

KENNETH W. MARQUARDT166 BirchwoodSan Antonio, Texas

V. SEETHA RAMIAH3620 Lorne Crescent, Apt. 303Montreal, Quebec, Canada

ALFRED B. SZULC8627 Atlantic Ave.South Gate, California

AFFILIATE

RAUL SERGIO FIGUEROLA13440 E. Imperial HighwaySanta Fe Springs, California

THOMAS W. JOYP.0. Box 477Orleans, Mass. 02653

W. K. KANPrestressed Concrete Products Co. Inc.P.O. Box 533Mandeville, Louisiana

.ISMAT U. KHAWAJAPrecon Murray Ltd.980 Yonge StreetToronto 5, Quebec, Canada

HERBERT I. KIDODept. of Transportation Bridge Design350 McCorriston St.Honolulu, Hawaii

WARREN S. MARSHALLThe Colorado Fuel & Iron Corp.Box 1920Denver, Colorado

KISHOR C. MEHTADept. of Civil EngineeringTexas Technological CollegeLubbock, Texas

PROF. FREDERIC ROLLTowne School of Civil &

Mechanical EngineeringUniversity of PennsylvaniaPhiladelphia, Penn.

GERALD W. UHING8929 Valley StreetOmaha 24, Nebraska

STUDENT

LEWIS ARELLANOInternational House500 Riverside DriveNew York, N. Y. 10027

BULK RATEU. S. POSTAGE

PAIDChicago, Illinois

PERMIT NO. 6374

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MEMBERSHIP APPLICATIONSAPPROVED BY THE

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PROFESSIONAL

GILLES GARNEAU9469 LajeunesseMontreal 11, Quebec, Canada

WILLIAM L GUTEBox 1562Alaska Dept. of HighwaysJuneau, Alaska

SABRI M. HAMADEH2623 E. McKenzie St.Fresno, California 93701

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205 W. WACKER DRIVE

CHICAGO, ILLINOIS 60606

Return Requested

May/June, 1965

Prtres5’i Corete InstItute

Mr. Russ11 Haeith

205 U. Wakcr DriveIii. 60606