The Hub at Ontario International Airport - Phase 1

Summarize the project's program, features and achievements?

This project comprises nine speculative industrial buildings adjacent to Ontario International Airport in California, totaling approximately 4,263,000 square feet. Phase One, which commenced in 2024, includes the construction of the first four buildings over 2,000,000 square feet of slab-on-grade and nearly 600,000 square feet of tilt-up wall panels.

The design philosophy prioritizes “Best in Class” standards for functionality, sustainability, and long-term regulatory compliance, particularly in light of California's evolving building and energy codes. The project was conceived with the tenant experience in mind, ensuring flexibility, durability, and low operational costs through innovative and sustainable construction techniques. Key features include the use of composite tilt-up panels via the Total Integrated Panel System (TIPS), a mix design optimized for reduced embodied carbon, and solar installations compliant with CALGreen requirements. The buildings also incorporate advanced thermal insulation systems, low-impact development (LID) stormwater strategies, and drought-tolerant landscaping. These elements combine to significantly reduce environmental impact while enhancing long-term building performance.

The achievements of Phase One include not only successful early delivery under an aggressive schedule but also measurable reductions in embodied carbon, energy demand, and construction waste, setting a precedent for sustainable industrial development in the region.

What obstacles were overcome related to the schedule, budget, program, specification, site, etc. on this project?

The project faced a highly ambitious timeline, with the goal of completing all slab work and wall erection for four buildings in just five months. This challenge was compounded by the site's proximity to Ontario International Airport. Crane operations routinely entered the airspace used by approaching aircraft, requiring temporary closure of an active runway on several occasions.

Overcoming this constraint required exceptional coordination between the construction team, airport operations, and municipal authorities. Detailed scheduling, real-time communication, and advanced planning ensured the work proceeded safely and efficiently without compromising the airport's operational integrity.

Please communicate any engineering complexities or unique features of the panel design for this project?

The tilt-up panels were engineered using a fully composite design via the Total Integrated Panel System (TIPS). One of the project's tallest panels reached 60 feet in height, designed with a 3-4-2.25" configuration achieving full structural performance with just 5.25" of concrete.

Designing for this minimal thickness in a seismically active region presented significant engineering challenges. The team had to optimize the structural capacity and composite behavior of the panels while adhering to strict seismic codes. The result was a system that maintained structural resilience and long-term durability while drastically reducing material use.

What is the potential for this project's impact on the community and/or environment?

The project delivers tangible sustainability benefits to the surrounding community, particularly through reduced energy demand. With enhanced envelope insulation and on-site solar power, the facilities place far less strain on California’s energy grid, which is frequently stressed during peak hours and extreme temperatures. By reducing this demand, the buildings indirectly help preserve power availability for local residents and critical services supporting grid stability and public welfare. Furthermore, long-term resilience and minimal maintenance requirements will reduce the environmental and operational burden on the area. These elements position the project as a responsible and forward-thinking development that serves not just its tenants but the broader community and environment.

Demonstrate how Embodied Carbon was reduced through smart design and/or material innovation.

The project achieved substantial embodied carbon reductions through a combination of innovative material strategies and efficient panel design.

Concrete Mix Optimization: All concrete used for slabs, tilt-up panels, and sitework was reformulated to include Type 1L cement (instead of standard Type II/V), 20% fly ash, and CarbonCure technology.

• Type 1L cement offers a ~10% reduction in carbon intensity compared to traditional Portland cement.
• Fly ash, a byproduct from coal combustion, was repurposed as a supplementary cementitious material, reducing cement content while diverting waste from landfills.
• CarbonCure technology injects captured CO? into the concrete during mixing, where it becomes mineralized and permanently stored, further lowering net embodied carbon.

Tilt-Up Panel Efficiency: Originally designed as 9.5" solid panels, the exterior walls were redesigned using the Total Integrated Panel System (TIPS), resulting in a composite structure only 5.25" thick, reducing concrete volume by 42%.

• This design innovation also significantly cut reinforcing steel requirements, from 6.5 lbs/sqft down to 2.4 lbs/sqft, a 62% reduction in rebar usage.
• The reduced panel weight also enabled downsizing of foundations and footings by an additional 12%, further conserving materials.

Quantified Carbon Savings: A third-party life cycle analysis estimated the following embodied carbon reductions:

• Exterior walls: 41% reduction
• Site concrete: 36% reduction
• Slab-on-grade: 31% reduction
• Foundations/footings: 28% reduction

By integrating performance-based design and sustainable material innovations, this project significantly exceeds baseline embodied carbon performance for industrial buildings of this scale. Please review the third party analysis performed by Branch Pattern for a more in depth look at embodied carbon savings. A life cycle analysis is also currently underway by Gaia Development which should hopefully be available within the next 4-6 weeks.

Provide information on strategies implemented to minimize and reduce waste during construction, such as recycling or re-using materials.

The project was constructed in compliance with the latest Title 24 and CALGreen requirements. As part of this, a comprehensive Construction Waste Management Plan was implemented. All waste was sorted on-site by material category - such as concrete, metals, wood, and cardboard - with each stream weighed separately. This ensured maximum recoverability and documentation of diversion rates. Non-recyclable materials were kept under the threshold mandated by CALGreen. Additional waste minimization strategies included:

• Reusable formwork used extensively for the tilt-up panels.
• Reduced concrete and steel volume via the composite panel design, which lowered both material inputs and associated waste from overages or cut-offs.

These efforts resulted in a high diversion rate and significantly minimized landfill impact for a project of this scale.

Provide information on strategies implemented which aid in resilience/durability concerns.

Resilience and long-term durability were core design priorities for this project. Tilt-up concrete construction was selected over alternative systems due to its superior longevity, fire resistance, and performance in extreme weather. The use of composite sandwich panels further improves durability by protecting insulation between two layers of concrete, eliminating the degradation risks associated with exposed or mechanically attached insulation systems. The building is located in a high seismic risk zone. By adopting the TIPS composite design, wall weight was significantly reduced, thereby lowering seismic loads on the structure. This enhances safety without compromising performance. Together, these strategies extend the building's service life and reduce the frequency of maintenance and replacement, which supports long-term sustainability.

Provide information on energy efficient design and construction practices, including the use of energy efficient materials and systems.

Operational carbon was reduced through a combination of improved envelope performance and on-site renewable energy.

Envelope Efficiency: The original design included 2" of polyisocyanurate insulation (R-12). Through the TIPS system, this was upgraded to 4" of expanded polystyrene (EPS), increasing the effective R-value to R-16.

• This represents a 33% improvement in thermal performance, leading to an estimated 8% reduction in heating and cooling energy demand.
• PS was selected not only for its thermal performance, but also for its low global warming potential (GWP), as it does not use harmful blowing agents.

Renewable Energy Integration: The buildings incorporate roof-mounted solar panels in compliance with CALGreen requirements. These systems will offset peak electrical demand, helping to alleviate strain on California's already burdened electrical grid, especially during high-demand summer months.

These strategies work in tandem to significantly lower the operational carbon footprint over the life of the building.

Provide information on any strategies that reduced stormwater runoff volume and mimicked the natural hydrology of the site.

The project implemented multiple strategies to manage stormwater and reduce water consumption:

Rainwater Management:

All site runoff is directed into subsurface containment systems located beneath parking areas. These detention systems temporarily store stormwater and gradually infiltrate it into the subsoil, effectively restoring natural groundwater recharge patterns disrupted by development.

Water-Efficient Landscaping:

• The project incorporates hydrozoning and native, drought-tolerant landscaping to minimize irrigation needs.
• An on-site recycled water system is used for irrigation, further reducing potable water consumption.

Construction Water Reduction:

Through the use of composite tilt-up panels, the total volume of concrete was significantly reduced, thereby cutting the amount of water required for mixing and curing. It is estimated that this design change alone will save over 600,000 gallons of water during construction across the full project scope.

Provide information on strategies implemented which aid in resilience/durability concerns.

The most impactful construction innovation in regards to sustainability employed on this project was the use of composite tilt-up panel construction, based on methodologies validated by the Tilt-Up Concrete Association's recent research. Rather than traditional solid panels, the team adopted the Total Integrated Panel System (TIPS), which integrates concrete wythes with a continuous insulation core into a fully composite system. This approach allowed for:

• A 42% reduction in concrete thickness per panel
• A 62% reduction in reinforcing steel
• Smaller foundation systems due to significantly lighter wall panels
• Enhanced insulation embedded directly into the panel system

The successful application of composite tilt-up panel design on a large-scale industrial development showcases how modern tilt-up construction can evolve to meet sustainability goals without compromising strength, durability, or speed of construction. It also demonstrates the potential for broader industry adoption of advanced panel systems in response to climate and code challenges.

Provide information on innovative construction techniques which aided in achieving sustainable goals.

The project delivers tangible sustainability benefits to the surrounding community, particularly through reduced energy demand. With enhanced envelope insulation and on-site solar power, the facilities place far less strain on California's energy grid, which is frequently stressed during peak hours and extreme temperatures. By reducing this demand, the buildings indirectly help preserve power availability for local residents and critical services, supporting grid stability and public welfare. Furthermore, long-term resilience and minimal maintenance requirements will reduce the environmental and operational burden on the area. These elements position the project as a responsible and forward-thinking development that serves not just its tenants but the broader community and environment.

Provide information on obtaining relevant sustainability certifications, such as LEED, Passive House, Living Building Challenge, or other green building certifications.

The project has been formally submitted for LEED Silver certification under the LEED v4 for Building Design and Construction: Core and Shell rating system. Key strategies contributing toward certification include:

• Use of low-carbon concrete mixes and CarbonCure technology
• Significant reduction in embodied carbon via composite tilt-up panels
• Energy efficiency measures that exceed Title 24 baseline requirements
• On-site renewable energy generation
• High construction waste diversion rates
• Water-efficient landscaping and irrigation

Project documentation, including EPDs, mix designs, waste tracking, and energy modeling, is currently under review. Certification updates will be provided as they are made available.

Give examples of innovative materials, novel procurement or construction strategies, and using tilt wall design to showcase exceptional performance in any of the above categories.

This project embodies a pioneering spirit of innovation through the application of composite tilt-up panels on such a large scale. This is not a common practice in this area. By fully integrating structural, thermal, and sustainability performance into a single panel system, the project pushed the boundaries of conventional tilt-up methodologies. This approach significantly improved environmental outcomes, reducing embodied carbon by up to 41% in some areas. It also simplified compliance with future-focused energy and code requirements�adding long-term value to tenants and investors. Ultimately, the tilt-up strategy was not only critical to achieving sustainability targets, but also instrumental in delivering a smarter, more resilient, and future-ready industrial development.