The Shockey Precast Group219 Stine Lane, Winchester, VA 22603www.shockeyprecast.com

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The Shockey Precast Group 219 Stine Lane, Winchester, VA 22603 www.shockeyprecast.com

STRUCTURES

The parking structure for One Loudoun, a mixed-used development in Ashburn, VA, offers four structured levels and one on-grade level of parking. In order to meet the project’s fast-track schedule, The Shockey Precast Group teamed with sister company general contractor Howard Shockey & Sons, in a design-build approach with architect The Eisen Group. The SPG/HSS partnership proved to be beneficial for the owner and design team, as process and communication overlaps were able to be eliminated by having the Shockey team on board. Additionally, because management, manufacturing and erection were all performed by Shockey, the team was able to eliminate overlap with internal processes to save time and costs on the overall schedule. The project began on December 14, 2015 and was completed on March 3, 2016.

SPG’s scope of work included full design and erection of the 650-piece parking structure. The garage was envisioned as an integral part of the One Loudoun community, and so SPG and the design team worked through several iterations of color selection to ensure the building’s façade would blend with that of the surrounding architecture. Three different colors of precast were used, as well as a precast form liner to give a ribbed appearance to the spandrels. The structure also features a “picture frame” EFIS boarder along with a unique wood feature inside the picture frame. The 791-space, 252,530 SF precast parking structure was designed to feature smart parking signs and LED lighting, and an illuminated “ONE LOUDOUN” sign can be seen from the south and east elevations.

To meet the aggressive design-build schedule, SPG’s coordination and manufacturing teams developed a new process to ensure product flowed

to the plant at the exact time it was needed. Through this modified design-build process, the precast garage components were manufactured as needed rather than all at once.

The parking structure design features a stair that passes through a ramp wall, and while not uncommon, it did pose a challenge for the erection team. SPG engineers designed a lifting technique to allow the stair to hang vertically and then pull it though the ramp wall opening, all while being safely attached to the crane. This eliminated erection sequence issues and allowed the erectors to continue efficiently. Another unique challenge was the design and placement of the bollards within the double-tee floor slabs. SPG engineers developed an embed plate with extensive reinforcement to be cast in to the tee flange. The embed plate helped save the general contractor time and cost in the field because the base was already in place. Subcontractors were easily able to weld the bollard to the plate and move on to the next one, streamlining the installation process.

Developed by Miller and Smith, One Loudoun provides an integrated mix of more than 700,000 SF of retail space, three million square feet of Class A office space including the World Trade Center Dulles Airport, a luxury hotel, and more than 1,000 new upscale homes. The community has earned national and international recognition, and is the recipient of the “Smart Growth Award” from the Smart Growth Alliance. In 2015, One Loudoun received the Community of the Year award from The Great American Living Awards.

Design-Build Partnership Success: One Loudoun Parking Structure

The Shockey Precast Group 219 Stine Lane, Winchester, VA 22603 www.shockeyprecast.com

Summer 2016 Issue 5

STRUCTURES

STRUCTURES

To meet the fast-track schedule on the One Loudoun parking structure project, SPG teamed with sister company Howard Shockey & Sons in a design-build partnership.

Flipping the Model: SPG’s Inverted Design ProcessEvery precast project features some variation on the balance between cost, quality, and schedule. However, for one recent SPG project, a strong focus on schedule demanded special measures to achieve unprecedented speed to building construction. Faced with the challenge of providing an all-precast shell structure in such a timely manner as to meet a six month start-to-finish construction schedule, SPG approached the project from a new perspective and made the decision to invert the traditional design/build process. This radical Build/Design approach not only required flexibility and expertise by The Shockey Precast Group, but demanded complete owner support, as well as the use of a cohesive team with a single understanding and focus of the approach, to achieve successful execution of the Build/Design concept.

Based on the owner’s overall construction schedule, the SPG team developed the following project schedule:

Week 1: Award. Precast design start. Architect-of-Record and Engineer-of-Record start. General Contractor award. Week 3: Fabrication of typical precast components begins at SPG. Week 6: Full precast submittal. Fabrication begins at three (3) subcontract producers working for SPG. Week 7: Architectural and Structural Construction Drawings complete. Week 12: Precast erection starts two crews. Week 14: First phase erection complete. Delivery accelerates. Week 16: Precast completion.

Build/Design ApproachFull precast submittal normally occurs prior to the start of fabrication, but in the Build/Design approach, fabrication of the precast components began before the full precast submittal. While this inverted process flow presented its own performance risks, it also allowed SPG to meet a particularly aggressive construction schedule. In a traditional design/build scenario, SPG optimizes a structure by evaluating the entire structure and then designing for specific conditions. However, the highly-accelerated schedule of this particular project demanded faster and more “one-size-fits-all” solutions that would still retain SPG’s high level of quality while providing a robust precast structure.

Partnering for Project Success

The Shockey Precast Group used its expertise and experience to advise the client of potential areas of impact so that those potential issues didn’t develop into actual problems or project delays. Owner and general contractor buy-in and support of SPG’s role and project schedule helped to create a focused, cohesive team atmosphere that facilitated the Build/Design approach and resulted in a smooth project flow. The Shockey Precast Group’s industry and supplier partnerships also played a critical role in the company’s ability to meet the accelerated schedule. SPG subcontracted the engineering and drafting work, and the strong relationships between SPG and its subcontractors/suppliers enabled the company to manage a successful project.

Collaboration and Cooperation

Internal collaboration and communication also played a key role in ensuring that precast production and erection remained on track with the construction schedule. The Shockey Precast Group cleared its structural plant of other work and operated around-the-clock to manufacture the product. SPG’s Field Services team committed to using multiple crews and to erecting precast components seven days per week. Finally, the SPG Engineering/Project Operations team dedicated their complete focus and resources to the project for several months to enable completion of those activities.

In addition to its highly accelerated schedule, this unique project featured the challenge of long-span framing and very heavy loading. The success of SPG’s Build/Design approach was dependent upon successful industry and supplier partnerships, internal coordination and collaboration, and full owner support of SPG’s role and the entire Build/Design process. Through creative problem-solving and the thoughtful integration and management of these factors, The Shockey Precast Group not only met the owner’s schedule, but also developed an inverted design process that can be applied to future precast projects.

Project Profile: Howard Hughes Merriweather Parking Structure

The Shockey Precast Group was contracted by general contractor Harvey Cleary to design, manufacture, and erect the 378,848 SF Howard Hughes Merriweather Parking Structure in Columbia, Maryland. This project offered several interesting design and erection challenges, including coordinating site access and precast erection to accommodate the adjacent

Howard Hughes Merriweather office building construction site, which was located only 30 feet from the parking structure construction site. Since precast erection of the parking structure took place through the spring and into early summer, SPG’s Field Coordination team was also required to work around the concert schedule at Merriweather Post Pavilion.

Precast erection of Howard Hughes Merriweather Parking Structure at 85% complete.

SPG Welcomes New Employees

The Shockey Precast Group recently welcomed the following individuals to the Shockey family:

Janet Hayes, AutoCAD Operator – Janet comes to Shockey with several years of experience in design. Prior to joining Shockey, Janet worked as a Draftsperson for Jerry Jochum Architects and Kitchen & Bath Sales/Design.

Fredis Ramundo-Hernandez, AutoCAD Operator -- Fredis is a student at Lord Fairfax Community College with a double major in Civil Engineering and Mechanical Engineering he will complete online through Old Dominion University. Although new to drafting, he has experience with CAD, REVIT, and Inventor.

Recently Awarded Projects

• Shenandoah University Fieldhouse : , Winchester, VA (Howard Shockey & Sons, Inc.)• Confidential Data Center Project, Northern Virginia (Confidential Client)• Penn First Parking Structure, Philadelphia, PA

Earn AIA CEUs

Earn AIA CEUs with a Shockey Precast plant tour or box lunch presentation on Total Precast Systems or Introduction to Precast Parking Structures. Visit www.shockeyprecast.com or contact Marketing Coordinator Terri Ward at 540.665.3215 or tward@shockeyprecast.com to sign up.

Connect with SPG

SPG is on Twitter and LinkedIn! Follow us at #ShockeyPrecast, stop by our LinkedIn page at The Shockey Precast Group, and check out our website at www.shockeyprecast.com.

Flipping the Model: SPG’s Inverted Design Process

SPG NewsProject Profile: Howard Hughes Merriweather Parking Structure

Precast erection of the Howard Hughes Merriweather Parking Structure at 95% complete, with only 100 pieces to go.

For the nine-level parking structure with eight suspended precast levels, SPG produced and erected a total of 346,276 SF of precast. The structure’s design included two open sides of one monumental stair tower enclosed with window curtain walls with two elevator cores adjacent to it. The structure also features a second elevator tower designed to house two elevators. The elevator tower offered the challenge of being on a 25-degree angle from the parking structure’s South elevation. Due to the angle, it required skewed wall ends and skewed double tees in that area. The second stair tower features a glass window curtain wall to allow in light and provide an elevated view of the surrounding area.

The parking structure’s drainage system presented its own challenge. Due to an existing underground rainwater harvesting system for the adjacent office building, access was restricted for that part of the North elevation. This design feature required SPG to use drain piping that differed from what is used in typical parking structures. For most SPG parking structures, drains are piped to a center grid and the pipes drop straight down to underground pipes. For the Howard Hughes Merriweather Parking Structure, the unique drainage feature required SPG to install a drainage system that would exit the building all on one side into a LEED-certified drainage holding basin.

From a design standpoint, the precast had to accommodate an intricate exterior metal grating system that hung from the precast at different locations on each elevation. SPG created special spandrel shapes to accommodate the exterior hanging façade. Precast erection began on March 30, 2016 and was completed on July 5, 2016. Through the flexibility and resourcefulness of SPG’s team, precast erection was completed three and a half weeks early, with finishing completed in mid-August. The Howard Hughes Merriweather Parking Structure project is an example of successful communication, collaboration, and problem-solving by SPG and the project team to achieve maximum value for the owner.

Project Team:

Owner: HRD Development ManagementArchitect: Design CollectiveGeneral Contractor: Harvey-Cleary BuildersPrecaster: The Shockey Precast Group