Mapletree | Warehouse
Project
L.R. Costanzo (LRC) served as the General Contractor in the reconstruction of an existing 1.4 million square foot, cast concrete warehouse. This project required the team from LRC to lower the outside earth by 4 feet to provide a concrete dock approach for the installation of 69 new, cross-dock doors. In addition, the team relocated electrical, gas, and water utilities; created a new loop road; and built an expansive parking area.
Challenges
- Main utility lines were discovered to be on the exterior of the building in front of the loading docks at a depth that impeded dock installation
- Unsuitable soils were found throughout the site
- The existing stormwater basin was deemed inadequate for the new loading dock installation based on current regulations
Solutions
- Identified the most cost effective utilities re-routing to both the interior and exterior
- In order to avoid trucking costs, the team found an on-site location to efficiently utilize the unsuitable soils by creating landscaping berms
- In lieu of redesigning an additional storm water basin, the outlet structure was lowered to save a substantial cost and avoid a major delay
Construction Details
- Utilized state-of-the-art scanning equipment and precision layout to confirm that the building’s existing tilt up concrete wall was originally designed to accommodate the new dock door openings
- Created 69 new dock doors by saw cutting, removing existing concrete, forming dock pits, and installing overhead doors, shelters, and levelers
- Built underground stormwater detention system to meet new regulations
- Installed 1800 cubic yards of concrete for loading dock approach
