Confidential Distribution Center

Summarize the project's program, features and achievements?

Confidential Distribution Center is a 350,000-square-foot, build-to-suit, cross-dock logistics facility designed to meet the growing needs of modern distribution and fulfillment operations. The project includes 18,500 square feet of dedicated office space and features 46 dock doors to support high-volume shipping and receiving functions. Designed with tenant-specific functionality in mind, the facility incorporates advanced material handling systems, including storage racking, structure-supported conveyor lines, robotic package retrieval systems, and in-rack fire sprinkler protection—ensuring safety and efficiency for complex warehouse operations.

The structural system of the building is composed of tilt-up concrete wall panels, a slab-on-grade concrete floor, and a roof supported by open-web steel joists and decking. The tilt-up construction method was selected for its cost-effectiveness, speed of installation, and long-term durability. This technique involves casting the concrete wall panels on-site and lifting them into their vertical positions using cranes—a process that minimizes construction time and allows for early enclosure of the building envelope, accelerating the overall schedule.

Beyond the structural and logistical efficiencies, the facility is also notable for its integration of modern industrial technologies and systems. The inclusion of tenant-supplied automation and robotics aligns the building with current trends in warehouse optimization. The design supports future adaptability as well, with clear heights and open floor plans that allow for equipment reconfiguration or expansion as operational needs evolve.

Sustainability and life-cycle performance were also key considerations. The use of tilt-up concrete panels contributes to energy efficiency through thermal mass benefits and provides excellent durability with minimal maintenance over time. Additionally, the open and modular interior layout promotes flexibility in use and longevity of the space.

Overall, Confidential Distribution Center stands out as a high-performance industrial facility that blends speed of delivery, cost-efficiency, and operational sophistication. The successful execution of this project demonstrates the effectiveness of tilt-up construction in delivering large-scale, customized logistics environments while meeting tight timelines and specialized tenant requirements.

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

The project team overcame several significant challenges to deliver the Confidential Distribution Center more than two months ahead of the contractual substantial completion date—despite 33 weather delay days during the 16-month schedule.

One of the most substantial site-related obstacles arose during early-stage earthwork. Over 200,000 cubic yards of rock had to be blasted and excavated to prepare the site. Approximately one-third of the building pad was located on deep fill areas, requiring surcharging with five feet of additional soil to accelerate settlement. These fill zones, reaching depths of 40 to 50 feet, were carefully monitored until settlement stabilized. Once complete, the surcharge was removed and the pad was soil cemented to create a stable subbase for foundations, slab-on-grade, and tilt-wall panels.

Through efficient coordination, the site contractor delivered the pad early, allowing vertical construction to begin ahead of schedule. Concrete foundations began in early February 2024, and by May 10, 2024, the majority of the slab-on-grade was poured and all tilt-up wall panels were erected and braced. The tilt-wall erection took only four days, highlighting the speed and efficiency of tilt-up construction.

Steel installation progressed rapidly, maintaining momentum and allowing subsequent trades to begin earlier than planned. This proactive sequencing of critical path activities—combined with agile problem-solving and vigilant monitoring of site conditions—enabled the team to overcome schedule, site, and weather-related challenges, ultimately delivering a complex facility ahead of time and within budget.

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

The most notable engineering complexity of the tilt-up panel design for Confidential Distribution Center centered around ensuring safe and effective panel erection while maintaining high architectural quality. A major focus during preconstruction was the evaluation of ground bearing pressure for the panel erection crane. The project team collaborated extensively—engaging the concrete subcontractor, panel erector, geotechnical engineer, and structural engineering team—to analyze the panel pick plan, crane track pressures, and soil bearing capacity.

This analysis revealed that the planned gravel access road alone would not sufficiently distribute the crane’s track loads. To mitigate this, a composite matting solution was selected and implemented to reduce ground bearing pressures to be within tolerances specified by the geotechnical engineer. This proactive planning ensured safe crane operation and prevented soil failure during panel erection.

Another unique feature involved the architectural treatment of the building’s main entry elevation. Instead of standard formliners, all reveal patterns were hand-set directly in the casting beds. This required meticulous layout and execution to achieve the clean, consistent lines and alignment across multiple large panels. This level of craftsmanship added visual depth and character to the building, while demanding close coordination between design and field teams to ensure structural and aesthetic success.

These engineering and construction efforts underscore the project team's commitment to safety, quality, and innovation. By successfully managing soil conditions and achieving a high level of architectural finish, the project demonstrates the potential of tilt-up construction to meet both technical and design objectives.