ARCO CHALLENGING SITE SOLUTIONS CASE STUDIES
From methane gas mitigation on a former landfill to a 100′ site elevation change from 550,000 cubic yards of rock blasting, ARCO is expertly capable of solving the most difficult site challenges our clients face. As a design-build general contractor, ARCO addresses potential site challenges in the earliest stages of a project, ensuring that all decisions are made with full knowledge of their impact. By providing value-engineering solutions and site specific cost information prior to construction, we help our clients avoid unforeseen schedule delays or cost increases.
Below are just a few of the site challenges ARCO has overcome to bring our clients’ projects to life.
TRADEPOINT ATLANTIC
12 Projects Totaling 4.5M+ SF | Sparrows Point, Maryland
The Challenge: Former steel mill brownfield site that presented unique challenges across 12 projects.
ARCO’s Design-Build Solutions: ARCO provided design-build solutions unique to each project’s challenges and end-user needs, including the following examples:
- Handled various environmental conditions on each unique site
- Predug/predemolished underground obstructions to allow for accelerated schedules
- Encapsulated sites with impermeable surfaces or clean fill to meet the environmental design requirements
- Overlayed historical photos, historical plans, and survey data in order to relocate existing utilities around the new facilities, locate buildings and utilities to mitigate the obstruction/relocation costs and deliver facilities with accelerated schedules
Sample Projects:
- 298,283 SF Distribution Facility for FedEx
- 979,000 SF Distribution Facility for TradePoint Atlantic
- 150-Acre Multimodal Logistics Center for Volkswagen
- 350,000 SF Bulk Storage Facilities for TradePoint Atlantic
- 78,900 SF Distribution Facility for AlumaSafway
- 1,200,000 SF Distribution Facility Tenant Improvement for a Confidential Client
SCANNELL PROPERTIES | FEDEX GROUND
236,976 SF Automated Sorting Facility | St. Petersburg, Florida
The Challenge: Site located on an existing landfill.
ARCO’s Design-Build Solution: Methane gas mitigation system and pile supported structural slab and ground improvements for pavement areas.
Project Details:
- Constructed Over an Existing Landfill
- 350,000 CY of Import Fill
- Tilt-Up & Conventional Steel Structure
- Methane Gas Mitigation System
- 1,136 SF Security Building
SCANNELL PROPERTIES | FEDEX GROUND
361,952 SF Manual Sorting Facility | Boylston, Massachusetts
The Challenge: 120-acre rocky site requiring extensive clearing, rock removal, site elevation change ranging from 50′-100′, and 42′ retaining walls.
ARCO’s Design-Build Solution: Collaboration between ARCO, Civil, and the Geotechnical Engineer reduced cost implications associated with 550,000 CY of rock blasting and crushing, resulting in $2M in net project savings.
Project Details:
- Tilt-Up Construction
- On-Site Sewer Treatment System
- Infrared Warehouse Heating System
- Large Site Retaining Walls
- Subsurface Storm Water Infiltration Systems
- Solar Panel Ready Roof Structure & Electrical System
- Developed in a Cul-de-Sac
- 604 Car & 476 Trailer Parking Stalls
PERFORMANCE FOOD GROUP
230,385 SF Foodservice Distribution Facility | Mt. Olive, New Jersey
The Challenge: Rocky site with large boulders and elevations ranging from 835′ to 920′ and difficult weather conditions including 83″ of rainfall and 36″ of snowfall.
ARCO’s Design-Build Solution: Rock crushing and sorting, removal of 132,000 cubic yards of clay and rock, 45′ fills at the building pad, and 30′ retaining walls to address site issues and strategic activity sequencing and coordination to avoid schedule delays to difficult weather.
Project Details:
- 52,588 SF -10°F Freezer
- 14,530 SF 36°F Cooler
- 12,527 SF Cold Dock
- 137,588 SF Dry Warehouse
- 9,000 SF Office
- Tilt-Up & Insulated Metal Panel Construction
- Freon Refrigeration System
SCANNELL PROPERTIES | FEDEX GROUND
343,447 SF Automated Sorting Facility | Reno, Nevada
The Challenge: Lack of availability of utility services due to site location and constraints.
ARCO’s Design-Build Solution: Onsite septic system, propane gas service, electric utility run over the Truckee River, and 10″ water main bore under Union Pacific railroad tracks.
Project Details:
- 73-Acre Site
- 32′ Clear Height
- 5,180 SF Vehicle Maintenance Garage
- 3,070 SF Gateway Security Building
- 60 Mil TPO Roof Over Hybrid Roof Deck
COCA-COLA BOTTLING COMPANY OF NORTHERN NEW ENGLAND
200,275 SF Beverage Distribution Facility | South Windsor, Connecticut
The Challenge: Inefficient pavement, site utility, and storm sewer design due to site constraints.
ARCO’s Design-Build Solution: Value-engineered site design during preconstruction phase, decreasing overall project cost while providing the most efficient layout and cost-effective solution.
Project Details:
- 166,984 SF Warehouse
- 27,247 SF Office
- 6,040 SF Mezzanine
- Load-Bearing Precast Construction with Conventional Steel Frame
- Shrink Compensating Warehouse Floor Slab
- Underground Detention to Maximize Impervious Surface Area on Site
RAVING FAN SPOTLIGHT: VOLKSWAGEN
ARCO recently completed 78,720 SF and 87,570 SF vehicle processing facilities for repeat client, TradePoint Atlantic and end-user, Volkswagen. The state-of-the-art facilities are strategically located on a 115-acre brownfield site in Sparrows Point, Maryland and included extensive site paving.
Having previously completed 11 projects on the Sparrows Point brownfield site, ARCO had the knowledge and expertise to foresee and mitigate potential challenges prior to construction. This allowed the Volkswagen team to make informed decisions in the project’s earliest stages with full knowledge of the impact on budget and schedule.
The massive multimodal logistics center is able to handle an estimated 120,000 vehicles per year and created approximately 100 new full-time jobs. The vehicles imported through the new location are shipped to dealerships throughout the Mid-Atlantic, with the Sparrows Point site offering connections to two Class I railroads and close proximity to Interstate 95.
Learn more about our work in Sparrows Point here.
