HaysFarm

Summarize the project's program, features and achievements?

Hays Farm Office Building is a three (3) story tilt wall structure with cast in place brick veneer around the perimeter of the 1st floor. Each panel consisting of 6-9 openings to accommodate store front windows and entries. With twenty (20) panels in total ranging from 106,000lb to our heaviest panel at 192,228lbs. This facility is accompanied by a tilt up dumpster enclosure which matches the brick veneer and style of the building. A thoughtful and meticulous design component allowed for this striking multi story tilt-up office building to shine among the landscape.

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

Lot size, with less only 4.5 acres in its entirety, coordination between trades is an absolute necessity especially when utilizing a 300-ton crane for panel erection. Coordination with FAA personnel due to the buildings proximity to Redstone Arsenal posed a unique challenge to ensure the safety of both aircraft and personnel on the ground.

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

the sheer size of the panels constructed for this building with 50-60 embeds per panel to incorporate structural steel on the 2nd and 3rd floor mezzanines. The design and execution had to be perfect to allow zero errors on embed placement. On the exterior face of the panels (1st floor) consisted of individual bricks to be installed throughout 5,625sf (38,759) bricks in total installed by hand and upside down due to the exterior face of the panel being against the slab. During the erection of Hays farm the braces once installed and anchored to the slab had to be removed and reinstalled on the exterior of the building via helical anchors to allow for the structural still to be erected. This transition from interior to exterior bracing with a helical anchor system allowed for crews to relocate braces in the safest manner possible to ensure the mezzanines were poured efficiently.