DLR Building S

Summarize the project's program, features and achievements?

• Building Footprint: 190,000 SF
• 154 Tilt-Up Panels
• Panel Layout: 160,840 SF
• Tallest Panel Height: 65’-11”
• Widest Panel Length: 28’-0”
• Heaviest Panel: 90.96 Tons
• 192,000 SF Slab Metal Deck on Steel Framing
• Bracing of Exterior to Helical Anchors & Deadman Weights
• Timeline: August 2023- September 2024

Per Digital Realty’s aesthetics, tall tilt-up panels surrounding a steel framed structure is the standard for their data center projects. DPR Construction moved forward with that design & development by partnering with Southland Concrete to deliver a product to their upmost satisfaction.

The biggest obstacle for this project was the mere lack of space around the building. The majority of the panels were cast within the interior slab on grade of the building’s footprint while the front of the building was able to utilize cast beds. This demanded precise planning between our team and the crane supplier to ensure sufficient spacing, access, and safety. In some circumstances the crane was literally up against a panel during erection. The communication between the field crew and everyone on site was imperative during the layout & scheduling to guarantee there were no issues moving forward as the project progressed.

The limited access around the project also meant the size of the crane used to lift panels was limited. As a resolution our field team filled exterior footings to create an access area for the crane to “crawl up the panel” to its destination. Once finished we would need to uncover the footings to allow for the panel installation. Again, a high level of coordination was required by our crews to establish flawless delivery and execution.

Although the project as a whole appeared fairly generic on paper, the immense amount of planning, coordination, and communication required to navigate the tight jobsite created a unique opportunity for Southland Concrete to work closely with the GC. This allowed also us to show our level of expertise while reflecting our flexibility to maneuver as needed based on the changing landscape. The final product presented to Digital Realty was one of high quality delivered on time and with exceptional safety practices.

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

Southland Concrete faced some obstacles throughout the project's construction. Our main challenge was the site's size and lack of space to properly conduct panel casts. This led to a more creative approach in our design & layout by casting most of the panels within the interior of the building footprint. What may sound like an easy solution, actually demanded precise planning and coordination with every team on site to guarantee there was adequate space, no scheduling conflicts, and the project's progression would stay on time.

To accommodate the tight space surrounding the site a smaller crane was utilized to gain access to the panels as well as our exterior footings being filled to create an access path or work area. The crane would use this avenue to "crawl" to its destination to reach a panel, and in many instances be up against another panel during the erection. This left no room for error. Once the panels were completed our team needed to uncover the once filled footings to resume the rest of the panel installations. Scheduling was key to delivering the seamless transition of each panel erection with the movement & phasing throughout the site.

These challenges showcased our ability to pivot when faced with a roadblock. Southland Concrete excelled throughout the duration of the project, giving us a unique opportunity to work closely with the client. We delivered a high-quality product reflecting our exceptional level of craftsmanship, on time, and with the highest value of safety.

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

The complex engineering for Building S was immediately addressed as the client, general contractor, and engineering firms recognized the sheer lack of landscape that surrounded the jobsite, and the delicate approach required to safely & strategically construct the building. Taking into consideration the crane path, the location of each 154 panel, and the aesthetics of where equipment & crews would be present a 'gameplan' was hatched between our team and the project's leadership. Each panel, its weight and size, had to be taken into account since many were cast within the interior layout with minimum space for lifting and placement. Any stress that could be placed on the interior foundation by the cast beds, the panels abutted up next to the crane, and the cranes movement within the tight site were thoroughly discussed and executed seamlessly to create a polished finished structure.