The project team overcame a host of challenges to keep the $89.3-million project on schedule, including the discovery of unsuitable soils and material from demolished structures during excavation. Due to a historic gas spill, a gas mitigation system was required beneath the entire building, including all underground water tank foundations. The system features an HDPE/asphaltic membrane with venting locations to safely disperse gas vapors.

Each section of the system passed smoke containment tests before subsequent concrete pours, ensuring thorough coordination and quality control.

Photo by Edward Badham

Limited information had resulted in the under-design of the concrete foundation for a 250-ft tilting flume, used to measure the flow of water in open channels. Similarly, electrical service for the tilting flume, the 24-ft by 100-ft test basin/wave generator and tow tank required significant upgrades. Close trade collaboration ensured these changes were implemented without affecting the project’s critical path.

Detailed BIM coordination guided installation of 15 drains and 10 stainless steel supply lines within the test basin, ensuring alignment with concrete pours.

Because large hydraulics lab equipment had to be installed during construction, the team developed a unique scaffolding system to install overhead MEP infrastructure in confined spaces more than 40 ft high and obstructed by large, 500,000-gallon laboratory water tanks.

Several trades worked in confined spaces within the water tanks. Specialized training helped ensure trades understood the risks and safety protocols associated with confined space entry.

Photo by Edward Badham

To ensure safety around the tanks, hard barricades prevented exposure to water hazards. Workers inside these barricades wore personal flotation devices—a unique and critical safety consideration that led to a safe project.

The team also worked near two large water lines at the project’s entry area that could have significant public impacts if damaged. As a result, the team used soft dig and hydro excavation methods, ensuring the water lines remained intact and avoiding potential disruptions.

The team also took tornado safety preparedness. The building features a designated hallway as a tornado shelter for the end-user. This hallway was incorporated into the project team’s severe weather plan as the tornado shelter for the remainder of the project. It was installed early, providing a safe refuge during severe weather events for a significant portion of the project.

The project team logged more than 383,000 work hours with a zero recordable incident rate as well as a zero lost-time accident rate.