The Ecolab warehouse and office space project is a large-scale build-to-suit industrial development located in Joliet, Illinois.
Ecolab encompasses a total building size of 677,000 square feet, including a warehouse with 308,000 SF of H3/H4 High Hazard storage and office space of 4,872 SF.
The Ecolab project aimed to develop a facility tailored to Ecolab’s specific storage and operational needs. From the initial groundbreaking to the final turnover, Peak Construction overcame numerous challenges, demonstrating our ability to deliver high-quality, customized construction solutions. This case study explores the key obstacles encountered and the innovative solutions implemented to ensure project success.
CHALLENGES AND SOLUTIONS
SHALLOW BEDROCK
Challenge: The Joliet site had shallow bedrock instead of the more typical clay soils, which posed significant limitations for the depth of stormwater management systems and trench foundations.
Solution: To address this, Peak worked with our site subcontractor to coordinate the use of specialized rock grinding wheel attachment on excavators to break the bedrock effectively. This solution required precise coordination between the excavation team, the foundation crew and the utility installation crew. By modeling the exact locations of foundations, storm structures and pipes into the excavators’ CAD systems, the team ensured accurate and efficient excavation, reducing potential time and cost impacts. This method was chosen over the more common hammer drill attachment, which would have extended the project, negatively impacting schedule and cost.
DESIGN CHANGES POST-GROUNDBREAKING
Challenge: Midway through construction, Ecolab’s need for additional hazardous chemical storage necessitated significant design changes. This required re-evaluation of storage areas, fire safety measures, overall layout, and significant code-related changes.
Solution: Peak initiated extensive weekly coordination meetings involving all stakeholders, including architects, consultants, and trade partners. These meetings allowed for real-time adjustments and ensured that all design modifications were accurately implemented. The original design, which included standard storage and a dishwashing room, was expanded to include additional high-hazard storage areas. This involved adding oxidizer rooms and toxic storage areas, which required specialized fireproofing and safety measures. Ultimately, the hazardous storage portion of the building had to be changed from Type II-B to Type I-B.
MUNICIPALITY PRIVATE FIRE LOOP DESIGN APPROVAL
Challenge: The municipality required a private fire loop system, adding complexity to the project’s fire safety plan. This system needed to meet stringent safety standards while ensuring operational efficiency.
Solution: Peak engaged the fire protection contractor early in the process and facilitated coordination between civil engineers and municipal authorities. The fire loop system was integrated into the building’s design, meeting all regulatory requirements. This involved creating a dedicated fire loop that included a public water main entering the building and then looping around to serve the onsite fire hydrants, all managed by the building’s fire pump. This system not only met safety standards but also reduced the municipality’s operating costs.
NON-UL CERTIFIED WHITE PRIMED METAL ROOF DECK
Challenge: The specified white primed metal roof deck was not UL certified for fire protection application, meaning fireproofing could not be directly applied to the underside of the decking.
Solution: After evaluating several options, including sandblasting and using intumescent paint, Peak decided to install metal lath, enabling proper fireproofing adherence. This solution involved meticulous planning and coordination with GCP and two of the largest fireproofing contractors in the state. The additional cost was managed within the overall project budget through careful financial planning, rigorous negotiating and leveraging savings from other project budgets.
ADDITIONAL HIGHLIGHTS
Ductile Slab System: To accommodate the heavy load of double push racks, Peak used a proprietary engineered slab system with fiber reinforcement. This system was reinforced to handle the specific load requirements, demonstrating Peak’s commitment to meeting client specifications. The stone sub base thickness was increased to six inches throughout the building pad, allowing for maximum flexibility in storage configurations.
OUTCOMES
The Ecolab project exemplifies Peak Construction’s ability to tackle complex challenges through innovative solutions and effective coordination. Despite facing significant obstacles, including mid-project design changes and technical difficulties, Peak delivered a high-quality facility that met and exceeded client expectations. This case study highlights Peak’s expertise in managing large-scale construction projects and their dedication to client satisfaction. The ability to adapt and innovate under pressure showcases our commitment to delivering outstanding results, regardless of the challenges faced.
Contact Peak Construction about your Industrial project today.
