When the Philadelphia Zoo began planning a new flamingo habitat, they needed more than just a splash of pink — they needed infrastructure.

That's where Oldcastle Infrastructure — Telford plant — stepped in, transforming what started as a small add-on into a custom-built drainage system that would quietly support the vibrant life above it.

The project for the Philadelphia Zoo originally involved a series of large precast slabs that were delivered and installed in succession. Then, partway through the project, the contractor returned and explained that, in order for the products to function properly, drainage components also needed to be installed.

"We try to make it so that we are as much of a one-stop shop around here, so, of course, it was no problem to do this smaller project," said Jeff Barndt, field services manager of Oldcastle Infrastructure — Telford Plant.

This was a unique project for the team because it required them to create smaller drainage and filtration components, which were different from their usual large-scale projects with products like box culverts.

And it's not every day that crews get to help contribute to an animal habitat.

"I had guys coming up to me saying, ‘We're really doing what now?'" Barndt said. "Then they heard it was for flamingos, and it became a punchline."

Despite the jokes that the project inspired, the crew got to work.

The task at hand was to help manage the runoff that entered the flamingo habitat. This was done using a series of trench drains equipped with specialized filters. These filters were installed on site and incorporated small catch basins — technically referred to as such by the team. The Oldcastle crew fabricated the drain systems, which varied in size. Some were quite large, while others were relatively compact — tall, but only about one ft. by one ft. internally.

Each drain was fitted with a grate, and the end sections included a finished grate to prevent debris from falling into the drain. These grates also allow for easy access during cleanouts. Beneath the grates, a special filter media was installed to capture impurities and prevent unwanted materials from entering the stormwater system once runoff exits the pen.

"This was definitely different from the larger box culverts that we typically handle — those are often 10 by 12 feet, 8 feet tall and poured in multiple sections," said Garrett Hoffman, the heavy cast production manager of the Telford plant. "We're used to pouring those in the same steel mold day in and day out. But this one was a challenge: it was small, outside our usual scope and just not in our wheelhouse."

Unlike typical construction sites, the zoo presented a unique logistical puzzle. The facility remained open to the public throughout the project, which meant deliveries had to be timed with surgical precision. Materials were transported via pickup trucks with flatbeds, escorted through winding walking paths before the morning crowds arrived.

"It was definitely a first," Hoffman said. "I've been to nuclear bases and army facilities, but never a zoo. I had to be escorted through the paths early in the morning, and the flamingo pen was gated off and fenced with privacy screens so visitors wouldn't see two dozen guys working behind the scenes."

Once inside, the crew wasted no time. Installation of trench drains and catch basins began almost immediately. A few days later, filter media was added beneath the grates.

"We made it work," Barndt said. "Our guys are used to no two projects being alike. Once we figured out how to do it, production and installation went smoothly."

The Oldcastle team produced this project in several phases from September 2024 to January 2025. The entire project was completed in approximately six to eight weeks. Despite the logistical hurdles, the team found joy in the work.

"It was fulfilling," Barndt said. "I nerd out about this stuff. I love being able to point something out to my friends and family and say, ‘We did that.'"

For many of the crew, the flamingo habitat project became more than just another job. It was a chance to contribute to something visible, something joyful. Barndt explained that many crew members from the plant take their families to the zoo, and now they can point out to their family that they contributed to the flamingo pen.

"There's something about knowing your work is a part of a place families visit," Hoffman said. "It's not just another nameless project. It's a flamingo habitat, and we helped build it."

So, next time you visit the zoo with friends or family, keep an eye out because your favorite animals just might be getting a little help from precast concrete.

(Article reprinted with permission from the National Precast Concrete Association. Emma Quasny is the communications specialist of the NPCA)