Coastal Precast Systems

Coastal Precast Systems’ (CPS) customers have long looked to the company for innovative solutions to their building needs. “When someone has a complicated job, they typically call us to help them out,” says Paul Ogorchock, owner of the Chesapeake, Va.-based precast supplier. 

The company specializes in designing, manufacturing and installing precast structures for the marine and heavy highway construction markets. In addition, the company has in recent years manufactured columns, beams, balcony slabs and other building structures.

“The entire precast process is performed in-house from design and fabrication to delivery and installation,” the company says. “Our team includes qualified and experienced in-house engineers, drafters, estimators, accountants, CAD operators, project managers, sales team and more to help customers every step of the way regardless of the size or complexity of [their] project.” 

All of CPS’s products are built to the highest possible quality standards including those of the Prestressed Concrete Institute, American Concrete Institute and U.S. Department of Transportation. “We are committed to providing our customers with the best-quality precast products, competitive prices and timely delivery,” the company adds.

CPS’s 35-acre Chesapeake facility includes a 120,000-square-foot manufacturing plant, three barge-loading docks and railroad access, as well as a concrete batch plant that is capable of producing 150 cubic yards of concrete per hour. The company in 2015 opened a satellite manufacturing facility in Wilmington, N.C., that will place it closer to the Wilmington and Myrtle Beach, S.C., markets, where CPS is seeing an increasing amount of work, Ogorchock notes. 

‘Bigger and Heavier’

CPS recently applied its innovative thinking and high quality standards to manufacturing 60 large pile caps that are now being placed on support columns for the New NY Bridge project. A portion of the two-span bridge, which will replace the Tappan Zee Bridge crossing the Hudson River near Tarrytown, N.Y., is scheduled to open next year, with the entire $4 billion project slated for completion in 2018.

The company cast the pile caps in its Chesapeake facility, from where they were shipped to the bridge site for placement on top of the more than 80-foot-high columns. Each pile cap weighs approximately 300 tons. 

“We are taking something that would normally take two months to be poured in place and building it in 10 days,” CPS Vice President Dan McGhee says, adding that each cap takes contractors roughly four hours to place.

The New NY Bridge is being designed and built by Tappan Zee Constructors (TZC) LLC, a consortium of several world-renowned design, engineering and construction firms including Fluor, American Bridge, Granite and Traylor Bros., along with design firms HDR, Buckland & Taylor, URS and GZA. TZC is working closely on the project with a team of employees from the New York State Thruway Authority and the state department of transportation.

The bridge will feature eight traffic lanes, four emergency lanes, state-of-the-art traffic-monitoring systems and a dedicated commuter bus lane. The bridge will also include a bike and pedestrian path.

CPS last year applied its expertise to manufacturing concrete structures that were used as the basis for homes in a housing development in Bermuda. The structures were cast in pieces that included plumbing and electrical fixtures, then assembled on site. The homes have already survived two hurricanes, McGhee notes.

Both the bridge and home projects demonstrate what McGhee considers to be one of the biggest changes CPS has seen in its many markets over the past few years. “The one constant we’re seeing is that everything is getting bigger and heavier,” he adds.

Decades of Growth

The company traces its origins to 1946, when Ogorchock’s father, John “Jack” Ogorchock, started a trucking company in Brookville, Penn. “As the company kept pace with the rapidly growing post-war economy, Jack noticed that the construction industry was suffering from a lack of suppliers,” CPS says. “After purchasing a concrete ready-mix batch plant and three delivery mixers, the company soon gained the reputation of providing excellent service and quality concrete to the construction market.”

The company early in its history moved from Brookville to DuBois, Penn., and renamed itself DuBrook Inc. In the late 1980s, the company again rebranded itself as Concrete Precast Systems, a name it would keep until 2007, when it took its current name. 

Paul Ogorchock has served as president of the company since the late 1980s. CPS is now entering its third generation of family leadership, with Ogorchock’s son, Brian, serving as plant manager of the Chesapeake facility. His daughter, Kristen Ogorchock Neal, works as the company’s accounts payable and accounts receivable manager.

Paul Ogorchock remains involved with the company on a daily basis. “I don’t see him retiring any time soon,” McGhee says. 

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