Project Description

The PCI Big Beam project focuses on designing, coordinating fabrication for, and testing a prestressed concrete beam that satisfies competition requirements for strength, serviceability, and constructability. The beam is designed for the standardized loading configuration specified by PCI and will be fabricated at TPAC’s precast facility before testing at NAU.

Beamline Structural develops the analytical model, supports fabrication and transport logistics, and compares measured test results to predicted cracking load, ultimate capacity, and midspan deflections.

Project Location

The project is based at Northern Arizona University in Flagstaff, Arizona. Beam fabrication is performed at TPAC’s precast facility in Phoenix, with the completed beam transported to the NAU Engineering building and Structural Laboratory for storage, instrumentation, and full-scale testing.

Project Constraints

• Beam span and load configuration as prescribed by PCI Big Beam competition rules.
• The size and clear height of the NAU structural test frame constrain the maximum overall depth of the beam.
• The total beam weight is limited by the lifting and handling of NAU’s forklifts and moving equipment.
• Fabrication must fit within TPAC’s bed availability and production schedule.
• Transportation from Phoenix to Flagstaff must avoid damage and premature cracking.
• Concrete variability is addressed through cylinder testing at multiple ages.
• All work must be completed within NAU semester timelines and PCI submission deadlines.

Tasks & Gantt Chart

The project scope is divided into ten major tasks, including research and preparation, beam analysis and design, engineering shop drawings, fabrication and site visits, delivery and setup, beam testing, documentation of project impacts, deliverables, and project management. The schedule begins on October 21, 2025 and extends through May 8, 2026 for a total project duration of 199 days.

Full Gantt Chart: View Schedule (PDF)

Staffing

Staffing Roles & Qualifications

• Senior Engineer (SENG)
  • Bachelor’s degree in Civil Engineering with emphasis in structural analysis and design.
  • Licensed PE and SE in the State of Arizona.
  • 17 years of experience in prestressed concrete, load rating, and structural review.
  • Provides high-level technical oversight and QA/QC for design calculations and drawings.
  • Ensures code compliance and supervises the STEG and INT.
• Structural Engineer (STEG)
  • Bachelor’s degree in Civil Engineering.
  • Licensed PE in Arizona.
  • 8 years of experience in structural design and shop drawing preparation.
  • Leads beam analysis and develops/verifies engineering models.
  • Directs INT work and supervises LBT during material testing.
• Engineering Intern (INT)
  • Enrolled in an ABET-accredited civil engineering program.
  • Completed upper-division coursework in structural analysis, reinforced concrete, and mechanics of materials.
  • 2 years of internship experience.
  • Assists with research, preliminary calculations, drafting, and documentation.
  • Supports LBT in processing test data and works under STEG direction.
• Lab Technician (LBT)
  • Upper-division engineering student with one year of laboratory experience.
  • Experienced in concrete materials testing and specimen preparation.
  • Conducts sampling and testing required to validate mix properties.
  • Works under STEG for technical direction and coordinates data collection with INT.

Staff Hours by Task and Role

Cost of Engineering Services

The total estimated cost of engineering services is $82,787, which includes personnel labor, travel, structural laboratory rental and consumables, software licensing, forklift and operator time, and subcontracted beam fabrication and delivery by TPAC.

Staffing and Cost Summary