2024 Southeast Best Projects
Merit Manufacturing - Cottrell Trailers Manufacturing Plant
Photo by Chris Goss Photography
Cottrell Trailers Manufacturing Plant
Gainesville, Ga.
Award of Merit
Submitted by: Choate Construction Co.
Owner: Cottrell Trailers
Lead Design Firm: Ruark & Wyatt Architects
General Contractor: Choate Construction Co.
Civil Engineer: Foothills Land Design
Structural Engineer: Haines, Gipson & Associates
MEP Engineer: AHA Consulting Engineers
The team developed 110 acres and constructed a plant with the goal of improving Cottrell Trailer’s production capabilities, ranging from painting to assembly of its auto-hauler fleets. The project evolved from an initial 400,000-sq-ft rectangular box to a 545,000-sq-ft plant designed to optimize assembly and office workflows.
Cottrell and contractor Choate Construction Co. collaborated using virtual reality technology for site planning and visualizing construction phases. Flexibility was maintained through multiple pricing evaluations and redesigns. Value engineering recommendations optimized construction methods and materials.
The construction process required major earthmoving and grading operations, including removing and repurposing nearly 2 million cu yd of dirt and rock. Adding to the challenge, crews worked during one of Gainesville’s wettest winters on record. The team was able to adopt a phased approach to avoid delays.
As part of the first phase, crews also installed a 600-ft-long bridge connecting two campuses. Additional challenges included installing one of the industry’s longest paint lines. Helicopters were used to install 50-ton RTU units, saving time and money.
Extensive safety measures were implemented, including constructing the gas line on the roof with enhanced safety protocols. The project was completed ahead of schedule and under budget with no recordable incidents and no lost-time accidents.
