DPR SPW concrete crews needed to deliver a super flat slab for the high bay space within the warehouse. They worked closely with the engineering team to redesign the foundation slab to achieve a maximum degree of floor flatness to accommodate the semi-autonomous forklift operations and racking system planned for the space.
A key challenge for the project team was tying the new cGMP warehouse into the owner’s existing facility, which remained in full operation throughout construction.
To meet the challenge of delivering a super flat floor, DPR worked closely with the engineer and floor consultants to redesign the foundation slab – changing the aggregate, the rebar for the expansion joints and the control joints to achieve the highest degree of quality and flatness. Since differential ground settlement on site could impact the final floor flatness, DPR built up the foundation pad six feet and then let it settle for several months as SPW concrete crews worked closely with other project team members to iron out the foundation’s design details.
DPR brought several value-added solutions to the construction process. This included suggesting a cost-effective, Internet of Things-based rapidly deployable sensor technology that was used to pretest the cGMP spaces prior to the validation stage.
The goal: ensuring that temperature and humidity were effectively controlled without the need for destratification fans in the high bay storage area, a design change the owner hoped to avoid.
“That pretesting device fleshed out a lot of issues prior to actual commissioning and cut the time on that validation effort considerably. It was a very affordable way to add a lot of value to the process.”
Project Manager, DPR Construction
World of Concrete
Golden Trowel Award 2018
The most prestigious award in concrete flooring, Golden Trowels are given annually in recognition of the flattest and most level floor slabs produced in the world.