“We were able to level the field for him and use the dirt across the street, which saved a lot of money because hauling in dirt to this remote site would have been a problem,” says Yates.
Existing structure integration
Beyond the groundwork, the existing structures the expansion was being built around posed their own unique sets of challenges. To integrate all of the new and existing equipment, foundations and structural towers, KBD Group used extensive 3-D modeling during the design process. The architectural, mechanical and plumbing design was done entirely in-house by KBD Group utilizing Autodesk Revit 2012. To maintain streamlined coordination, the project’s structural elements, designed initially using a combination of 2-D and 3-D AutoCAD, were modeled in the main project model; pre-engineered metal buildings were integrated later.
“All equipment was modeled to ensure that it could fit into the tight tolerances of the spaces,” Yates explains. “This model was critical in coordination of all of the elements. Details were key to success of the installation, as equipment had to be accurate to very tight tolerances.”
KBD Group checked every beam, every motor, every access panel during the design process to ensure the proper space had been allocated for all the elements, Yates adds.
In addition to the installation of additional storage and new structures, KBD Group also constructed a new gravel access road and sediment basins, which included stripping, grading and erosion control on an eight-acre site.
On time and on budget
As with any major project, KBD Group was challenged to stay as close to the dollar amount outlined in the original contract as possible. With the help of efficient design and on-site construction coordination, any additional costs, which amounted to a 9.4% cost increase, were related to additions or unforeseen nature-related issues, such as additional Geopier foundations and Geopier casings due to poor soil conditions; owner-requested electrical additions; flood impact costs, tower structural modifications, and additional floor aeration system components.