Knelsen was awarded the contract to manufacture and install precast concrete for the new 1.25-million-square-foot LOWE’S Warehouse. Manufactured 418 precast insulated wall panels. Images below showcase stages of the installation process.
Site Visit — Survey, Layout, and Site Access
Mobilization — Crane, Crew, and Equipment
Panel Lift — Two Line Turn Crane
Installation — Position, Plum, and Secure Connections
Seal Seams — Caulk Panel Seams (Horizontally & Vertically)
Enright Capital Ltd.
Industrial Warehouse Condos
One of Knelsen’s manufactured and installed precast insulated wall panel projects within the City of Calgary. This project features 9” wall panels with 3” insulation with a unique brick inlay using form liners during the casting process.
Building Size — 73,000 s.f. Floor Space & 16,500 s.f. Mezzanine
General Contractor — Dawson Wallace Construction Ltd.
Product — Precast Insulated Wall Panels and Spandrels
Panel Specification — 9” with 3” Insulation
Special Finish — Brick Form Liner
Max Panel Size — H: 34’ x W: 10’
Number of Panels — 184 Pieces
Production Days — 35
Installation Days — 16
Form Liner — US Formliner (aka. Reckli)
ENMAX Power Corp
Downtown Electrical Network
Downtown underground power projects continually face challenges with space and time, making turnkey solutions a welcome consideration. The Knelsen Precast Modular vault design is used under city sidewalks to house large transformers needed to power surrounding buildings. This design allows for flexibility in length, grade level, and surface finish while also clearing bridge decks, elevated guideways, and tight city streets during transport to the site. The end results are accelerated installation, reduced surface disturbance, and flexibility in surface finish.
Product — Modular Vault
Size (Ends) — L: 2.56M x W: 2.45M x H: 3.0M
Size (Middle) — L: 2.56M x W: 2.75M x H: 3.0M
Rebar Projection — H: 480mm
Connection — HSS
Ducts / Openings — as Required
Traffic Load — 80% of CL-625
Production Days — 4-Piece 10 Days
Installation Days — 4 Hours
Underground Electrical Utility
Knelsen Precast offers a simple, fast, and effective solution to the installation of concrete-encased duct banks with the use of precast duct banks. These are generally cast in 3-meter lengths for easy handling and offered in multiple configurations—using 4, 5, 6, or 8-inch pipes. This precast solution will minimize onsite workers and traffic closures while enabling same-day excavation and backfill versus onsite rebar assembly, casting, and curing. Additionally, precast quality and in-house testing provide improved product performance and fitment on-site while also contributing to improved safety by reducing open excavation and the number of workers in the trench.
Project Type — Underground Electrical Utility
Contractor — Manitoba Hydro
Product — Precast Concrete Duct Bank
Configuration — 3 x 4 (with 4-Inch DBII Duct)
Traffic Load Rating — CL-625
Residential Applications: Standard + Custom
Steps, Decks, Window Wells
The Knelsen Precast plant has been producing standard and custom precast steps for key developers and builders throughout Alberta for more than 20 years. Each step is cast in steel forms, producing a high-quality finish and dimensional accuracy. Our forming systems allow for flexibility in dimensions, while our in-house team delivers design considerations and drafting support to meet simple or complex project needs for a wide range of use cases.
1 Piece Steps — 1 to 6 Rise Max (up to 16’ Wide)
1 Piece Stair Wells — 2 to 6 Rise Max (up to 4’ Wide)
1 Piece Decks — Max Dimensions: L: 13’ x W: 9’ x H: 5’
Window Wells — Max Dimensions: L: 8’ x W: 3’ x H: 3’
Knelsen has contributed to several key underground electrical utility projects throughout Western Canada. Most recently, our Precast Division worked on the new 30-acre, 304,000 sq. ft. plant owned and operated by SOFINA Foods in Calgary. This project required four large electrical vaults on-site, as well additional offsite vaults, to deliver power to the new plant. All vaults meet Canadian Traffic loads of CL-625, featuring 6-inch knockouts all around and providing maximum flexibility for current and future needs.
Product — Precast Electrical Vault
Vault Dimensions — L: 2800mm x W: 4040mm x H 2374mm
Duct Terminators — 152mm (6”)
Pulling Irons — 25mm (1") Galvanized
Concrete Mix — Sulphate Resistant Concrete
Soil Cover — 700mm
Traffic Load Rating — CL-625
Production Days — 1 Vault per Day
Set-Up/Placement — 3 Hours per Vault
City of Calgary
LRT Bridge Deck Panels
The City of Calgary LRT bridge design called for the use of precast concrete deck panels in tandem with cast-in-place elements for accelerated construction and long-term durability. These panels were constructed off-site under controlled conditions within our precast plant and brought to the bridge site ready to be installed and connected. The benefits of using these precast full-depth bridge deck panels include high-quality durable materials, minimal on-site construction, and increased safety for construction crews.
Contractor — PCL Construction
Product — Precast Concrete Deck Panels
Concrete Mix — City of Calgary HPC Mix Design
Reinforcement — Full Stainless-Steel Rebar
Rebar Volume — 210 kg. per Cubic Meter of Concrete
Design Feature — Offset Rebar Connection
Piece Size — 5000mm x 2500mm x 275mm
Piece No. — 42
Installation — 6 Days
Calgary Farmers Market
Knelsen’s Precast division is proud to have been selected as the supplier of precast wall panels, featuring various architectural finishes, for the new Calgary Farmers Market building located in the northwest community of Greenwich. The new buildings will support over 70 local, family-owned businesses, including a variety of amenities.
Designer — Stantec
Contractor — Clark Builders
Installer — Con-Steel Ltd.
Project Type — Commercial Retail Building
Building Style — Recessed Facades, Arches, and Towers
Building Size — 61,645 Sq. Ft.
Product — Insulated Wall Panels & Spandrels
Panel Finishes — Thin Brick, Textured, and Ribbed Panels
Panel Specs — 10” Thickness with 4” Insulation
Max Panel Size — H: 35.5’ x W: 10’
Reinforcement — Prestressed
Form Liner (Brick) — Innovative Brick Systems, LLC