Category: Industrial

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Key Safety Considerations in Tilt Panel Picks

The practice of lifting and positioning large concrete panels, often weighing 150 tons or more, can be fraught with hazards. Any failure in handling these panels can lead to catastrophic consequences, including serious injuries or fatalities, as well as substantial damage to property, delays to the schedule and more.

To optimize safety, the following strategies must be utilized in conjunction with an experienced team:

1. Planning and Designing

Proper planning and engineering are foundational to safe tilt-up construction. This includes:

• Structural Analysis: Panels should be designed with proper reinforcement, considering all forces they will be exposed to during lifting and positioning. A qualified structural engineer must be involved in panel design.
• Lifting Inserts and Hardware: The right materials, inserts, and hardware must be chosen, ensuring they can handle the forces exerted during the tilt process.
• Crane Roads & Terrain Analysis: Proper haul roads must be designed and engineered to ensure the load of the crane will be supported by the surface on which it will sit. The crane might be positioned outside the building area, within it, or a combination of both, during the pick process. Each surface must be extensively analyzed by licensed and qualified engineers.

2. Training and Qualification of Personnel

Handling tilt panels requires specialized skills. Key considerations include:

• Training: Workers should be trained on specific procedures, safety regulations, and potential hazards.
• Certification: Using certified crane operators and riggers who understand the dynamics of lifting heavy panels is vital.
• Site Specific Safety: Every individual site must be evaluated prior to picking panels to determine the plan for safety, including who will be involved, what tools they need, and what the exit routes are in the event of catastrophic failure during panel placement.

3. Equipment Selection and Maintenance

The right equipment ensures safe and efficient lifting. Key aspects include:

• Crane Selection: Cranes with proper capacity and reach must be selected. Other factors, including but not limited to crane transport routes and placement, must be considered.
• Equipment Maintenance: Regular inspections and maintenance of cranes, rigging, and other equipment are essential to prevent mechanical failure. This kind of failure is both costly and can also be dangerous to onsite crews and operators.
• Slab Protection: If the crane is placed on the floor slab, analysis must be completed to ensure the slab can withstand the crane load. Measures such as temporary matting, outrigger locations and increased structural capacity of the slab will all be considered prior to the pick.

4. On-site Safety Measures

Safety practices during the tilt process should include:

• Safety Barriers: Establishing clear safety barriers around the lifting zone to keep unauthorized personnel away.
• Communication: Ensuring clear and constant communication between the crane operator, ground crew, and supervisors.
• Weather Considerations: Monitoring weather conditions and postponing lifts during high winds or other unfavorable conditions.

5. Emergency Preparedness

Having a clear emergency response plan is crucial. This includes:

• Emergency Training: Regular drills and training on what to do if something goes wrong.
• First-Aid Availability: Having first-aid facilities and trained personnel on-site.

Utilizing Case Studies to Increase Safety

Analyzing previous accidents in tilt-up construction can provide valuable insights. One common theme in many incidents is a failure in communication or oversight. Such failures might be addressed by implementing comprehensive safety protocols and ensuring all team members are aware of their individual responsibilities.

As usual, prevention is the best medicine. A good plan prior to beginning this work is the key to maintaining a safe jobsite.

Final Thoughts

Safety during tilt panel picks in construction is not just a matter of compliance with regulations; it’s a vital aspect that protects lives and investments. By embracing a safety culture that includes proper planning, training, equipment selection, on-site safety measures, and emergency preparedness, construction companies can greatly reduce the risks associated with tilt-up construction.

The rewards for prioritizing safety in tilt panel picks go beyond just preventing accidents. It fosters a more efficient and harmonious working environment and ensures that projects are completed on time and within budget. In a competitive industry where reputation matters, a strong commitment to safety can also become a valuable asset, setting companies apart and cultivating trust with clients.

Perlo has completed hundreds of tilt buildings in our 65+ year history. We have even been labeled the ‘Tilt Kings’ because of our strength in this market. If you’re interested in a new building, get in touch with us today.

Featured Tilt-Up Projects

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Tualatin-Sherwood Corporate Park

Located on the bustling Tualatin-Sherwood Road, this 32-acre development is home to three new, speculative, tilt-up industrial buildings. The project needed more than one million cubic yards of excavation work, new utility tie-ins, and public street improvements. In addition, a soil nail shotcrete retaining wall, large water retention ponds and several new EV charging stations were added to the design.

Like any project, the team encountered detours along the way. Project Manager, Jacob Klein, explained that the preparation of the site required extensive rock blasting. Because of this, added precautions were necessary to maintain safe working areas and to coordinate concrete pours around the blasting. Vibration monitors were used to ensure no concrete was damaged in the process. We featured much about this project in a previous article, discussing the complexities of the site logistics for this work.   

112th & Myslony

Like the TS Corporate Park, these two new concrete tilt-up industrial buildings are located on the highly visible Tualatin-Sherwood Road. The sitework performed by the project team was extensive and included installing an underground stormwater detention system. From the beginning, there were several factors the team discussed during preconstruction that needed extra attention. Extensive planning was necessary to complete this work, including:

• Managing a very tight jobsite to accommodate the building size and configuration.
• Implementing the city’s requirement for an 80% increase in stormwater detention systems
• Management of the increased budget due to the added stormwater detention requirements.

Additionally, Superintendent Tracy Robinson remarked that a street and utility extension was required and had to be completed in conjunction with the site construction. Since this new street extension was also the only site access, it was difficult to complete the new buildings while maintaining construction flow.

Shredding Systems, Inc.

This project consisted of the construction of two new concrete tilt-up buildings with a combined 57,400 SF for Shredding Systems Inc., conveniently placed next to their existing facility in Wilsonville, Oregon. One of the buildings included around 3,000 SF of wood framed office build-out and mezzanine space.   .

From the beginning of the project, the team faced an enormous obstacle in that the project had originally been designed 15 years prior. The project team worked diligently to coordinate with ownership, civil engineers, and utility companies to address the existing utility locations that conflicted with the dated plans. In addition, several trees had grown significantly into the locations of the footings and utility easements. of the City of Wilsonville is affectionately know as Tree City, USA. As such, Project Manager Lainee Perala reflected that “we had to engage an arborist and the city each time we worked near a tree or were considering removal”.

Final Thoughts

In construction, there will always be challenges to overcome. Perlo Practice #3, Success Isn’t a Straight Path, speaks to our ability to adapt during our work, learn from each project and take responsibility for every choice and every action. We set the bar high, but know that there is always room to grow, and that is what drives our success.

Thank you for joining us as we reflected on some of the projects we completed in 2022. We look forward to the next year and the many projects it will bring!

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Leupold + Stevens

Perlo developed this new distribution center adjacent to the Leupold & Stevens active manufacturing plant and constructed the building utilizing concrete tilt-up panels, metal decking, and built-up roofing. In addition to the main warehouse area, this project features a thickened slab for heavy material storage, two separate office spaces with custom finishes, a stormwater detention system, and public right of way improvements to accommodate a widened driveway.

The project team collaborated closely with the Architect, CIDA and Developer, Stratus Real Estate Developers throughout the preconstruction, design, and permitting process. The permitting process was complicated by the location of the building, since multiple jurisdictions weighed in on the project including the city of Beaverton and Washington County. Clean Water Services also required extensive permits and inspections. Building constraints also included maintaining access to the existing Leupold & Stevens manufacturing facility.

Reilly West – GXO

Constructed in Hillsboro, Oregon, this fully insulated, 27,000 SF concrete tilt-up building with steel decking is complete with racking, offices, break rooms, restrooms, and conference rooms, as well as both a walk-in cooler and freezer, and electric forklift chargers. In addition, the site includes twenty-seven dock doors, vehicular parking, electric vehicle charging stations and a large bio-swale and landscaping.

This unique project presented a myriad of obstacles that offered Perlo an opportunity to rise to the occasion to deliver successful results for the end-user. These obstacles were met with quick and creative thinking, extensive planning and coordination with all parties, and confidence in the capabilities and experience of the team. These obstacles included:

• Extensive rainfall (99 days with at least 1/10^th of an inch from August to June)
• Supply chain issues and delays in the delivery of the electrical gear and emergency backup generator
• Challenges in acquiring permits

Sandy Industrial Lot II

This sprawling industrial building was built on 8-acres in Portland, Oregon and features twenty-five dock doors, dock levelers, and 3,500 SF of office space. The projected required extensive sitework to remove and reuse what seemed like a never-ending supply of boulders and the integration of an eyebrow canopy to conceal required sprinkler heads.

During preconstruction, an extensive amount of planning was done to work with the site conditions and grades. Unlike most tilt buildings, the new tilt panels were installed about 11’ under the exterior finished grade, which dramatically complicated the tilt-up process. A specialty material was used for the backfill to ensure the panels will withhold the loading.

West Coast Self-Storage

Located in Happy Valley, Oregon, this project consisted of the ground-up construction of a 57,000 SF, three-story self-storage building and the remodel of an existing 41,000 SF tilt building. With a combined 98,000 square feet, Perlo completed both buildings in a compressed 11-month timeline. Each building’s design features high-end exterior finishes and architectural towers to meet the requirements of the local jurisdiction..

When asked about what made the project unique, Superintendent Mike Lutz had one word: “location.” The jobsite was in close proximity to a major roadway which required that the project team maintain strict traffic control measures to ensure all scheduled deliveries could access the site with ease. In addition, because of its dense, urban location, the site was small and difficult to manage.

Final Thoughts

Perlo Construction is never one to shy away from a challenge. We understand that in construction, every detail counts. Perlo Practice # 9 is to “Finish Strong: even if you get 99% right, they’ll only remember the 1% you get wrong”. We know that if we dig deep and ensure no stone is left unturned, we can meticulously execute our planning to deliver high-quality projects each and every time.

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StorQuest Self Storage

This recently completed project features a 4-story, ground-up, self-storage facility in Happy Valley, Oregon. The project included a daylight basement, metal truss roofing, and a covered loading dock. The unique design included varying pitched roofs at different elevations and cultured stone on the corners of the building. Additionally, the project was built on a hillside next to Rock Creek, which required our teams to excavate and export substantial amounts of dirt from the site. 

Due to rising costs, the project team sourced all materials during preconstruction to guarantee the project stayed on budget. According to Project Superintendent, Joe Kane, one of the greatest challenges of the project was the size of the building site. Because the site was so small, the material had to be stored offsite and trucked in ’just-in-time’ for installation. In addition, getting the concrete trucks and pump truck on site for pours was difficult, there was just enough room to back a single truck in. The others had to wait down to street to avoid blocking traffic on busy Sunnyside Road.

Herzog-Meier Mazda

This project consisted of the new, ground-up construction of a two-story Mazda showroom, the remodel of an existing service and parts sales building, and the addition of a new, ground-up service, detailing, and photo booth building.

From the preconstruction phase, special considerations and planning needed to be made to accommodate existing conditions and ongoing showroom operations, including:

• Large, underground water retention storage facility
• Site logistics
• Customer safety

Like so many projects completed within the last couple of years, supply chain disruptions presented an enormous obstacle for the team, but they were able to draw from recent experiences to enact strategies to keep the schedule on track.

True Terpenes

Located in Hillsboro, Oregon, this project consisted of a 22,000 SF tenant improvement in an existing office and warehouse space for a CBD production tenant. The scope of the project included constructing a second-level mezzanine, new office spaces, conference rooms, and a manufacturing space with clean rooms and warehouse storage.

To prepare for the project, special considerations needed to be made in the design to consider existing conditions, such as mechanical units, office spaces, and a stained concrete floor. The mezzanine was constructed above an existing office space which, according to Project Manager Adam Smelley, posed some challenges.  

Dragonberry Produce Expansion

This new 29,700 SF tilt-up concrete distribution center is located in Canby, Oregon and is the second facility Perlo has built for Dragonberry Produce. The building included a 6,100 SF cooler and a 2,500 SF freezer with high-speed doors, a natural gas generator, and two high-end office areas with a future separate tenant build-out area for nut processing. The site includes a loading dock, passenger car parking, two swales and drywells for storm water management, a truck scale, and two drive aisles for access.

There were two driving factors in the design of this project: flexibility and sustainability. As the Northwest’s premier specialty produce distributor, it was important to the client that their freezer have a dual function as both a freezer and cooler. To accommodate this, adjustments were made in the design, including a glycol system installed under the slab-on-grade to protect the concrete from freezing. Additionally, although natural gas generators are not common, this system was selected because it is more sustainable than diesel generators.

Final Thoughts

Perlo embraces the opportunity to prove our ability to adapt to and persevere over any challenges or adversity that might arise in the course of our projects. Our Perlo Practice #2, “Solutions show up as problems” is the core of our approach to any project. We pride ourselves on the creative and innovative thinking our team brings to the table that ultimately drives our success. We look forward to continued growth across the Pacific Northwest and beyond.

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Bay Area Hospital Pharmacy Renovation

Completed in the Bay Area Hospital in Coos Bay, Oregon, this project was unique in that the work was completed within an existing and occupied hospital. The renovation and expansion focused on the Clean Suite, Receiving Area, Office, and Medical Supply Room. The project also included a new exterior shaft and mechanical room that had to be constructed around and fully enclose the existing shaft and mechanical rooms.

Preconstruction required inventive planning with the design team and hospital ownership. Schedule delays from the air handler unit manufacturer resulted in a shift to the design with a removable section of the exterior wall so that the air handler could be craned into place after the construction of the new mechanical room was complete. Another unique aspect of this project included maintaining existing pharmacy operations by assisting the ownership and design teams in acquiring the necessary permits to temporarily relocate the pharmacy during construction. According to Project Manager, Taylor Regier, “this allowed the project to be constructed in essentially one phase.”

DSW3 Burlington

This project included the development of a 25-acre site and a new 111,000 SF Amazon Delivery Station. The concrete tilt-up building includes dock doors, employee break areas and restrooms, extensive sitework, and also included the installation of extensive infrastructure for several electric vehicle charging stations.

Located North of Seattle, this delivery station was constructed in the airspace enforced by the Federal Aviation Administration. Project Manager Joshua Swake describes “working in FAA air space and having to navigate their requirements was both a special consideration during preconstruction planning and an ongoing challenge, as well.” With consistent communication and record-keeping, the team was able to keep the schedule on track.

Block 10 Tenant Improvement

Located in the heart of downtown Vancouver, Washington, this multi-story built-out in a new mixed-used building was completed by our Special Projects Group. Impressive details bring out the true personality of this building with floor-to-ceiling windows, high-end finishes, and unique construction materials utilized throughout. One of the more unique features is the use of Falkbuilt wall paneling, which is a sustainable, prefabricated wall covering that helps improve installation efficiencies when compared to drywall.

A key challenge of this project was that the tenant improvement was occurring at the same time that a separate general contractor was completing the shell. This combined with the urban location of the building meant that our SPG team had to ensure clear communication and collaboration with the core project team as well as the other contractor to successfully complete this unique project.

Ridgefield Industrial Center

Recently completed on a 50-acre site, this speculative warehouse space consists of concrete tilt-up panels with open web joists and a metal deck roof system as well as thirty-six feet of clear height throughout. Preparing site required coordination with local authorities for extensive wetland mitigation and included public right-of-way improvements.

The project team faced record levels of rainfall during the construction work. As we discussed in a previous post titled, “Wet Weather Construction Challenges”, these conditions have an enormous impact on the schedule and scope of work. Project Manager Nate Brown explained that creative scheduling to pour concrete in tight windows of time was a large part of their strategy.

Final Thoughts

Perlo embraces the opportunity to prove our ability to adapt to and persevere over any challenges or adversity that might arise in the course of our projects. Our Perlo Practice #2, “Solutions show up as problems” is the core of our approach to any project. We pride ourselves on the creative and innovative thinking our team brings to the table that ultimately drives our success. We look forward to continued growth across the Pacific Northwest and beyond.

Welcome back to Episode 8 of the Perlo Podcast! Podcast host Elissa Looney, Director of Strategic Initiatives at Perlo Construction, is joined by Devin Koopman, Vice President of Construction, and Joe York, General Superintendent. In today’s podcast, we’re going to explore site logistics in construction, which are a critical piece of the planning and execution of construction sites.

What are Site Logistics

Site logistics can be thought of as the foundation that sets up an efficient and safe construction site while making the process easy and keeping the project on schedule. It involves factors such as:

• How crews move around the site
• Where materials are stored
• Where signage should be located
• How traffic and equipment can efficiently move in and out of the site
• How to keep crews and visitors safe
• Where to locate job trailers

Devin notes that schedule logistics are rarely shown in the drawings and often don’t get as much attention as they require. It is critical to be proactive and consider all items of a project when planning site logistics. Preconstruction efforts are the “recipe” for an effective project. When preconstruction takes place, we look at the current plan and drawings for the current site logistics and try to understand what the end result will be. Logistics range from job to job and are a huge factor in a successful project outcome.

When considering the current climate of supply chain issues and long lead times, it may be necessary to procure materials early. In this case, project teams must be able to purchase or lease extra land offsite to hold materials. Joe explains that our teams have had to get creative and think outside of the box to find additional storage area for materials.

Elissa adds that having space for materials shortage has become a much bigger factor in today’s day and age, as companies aren’t able to get “just-in-time” delivery if they want to guarantee that they will receive the materials on time.

“The fact is that there aren’t as many large lots for people to develop anymore,” remarks Joe. He elaborates that because of this, it can be difficult to find space to lay down materials, park trucks and trailers, and actually build the building. According to Joe, “if you can’t get a neighboring property to make your footprint larger for the build, you’ve got to get creative.” Planning ahead for these aspects of a project gives teams more opportunity to be innovative when utilizing space and being proactive when addressing potential issues.

How Do We Use Site Logistics to Create Efficiencies on Jobsites?

Devin uses an example about concrete to answer this question, noting that here at Perlo, “we like to pour concrete, and we like to pour a lot of it.” He goes on to explain that often times, our teams conduct concrete pours at 2AM to maximize efficiencies. Early morning pours are great, according to Joe, because there is no traffic and the concrete gets poured before the weather gets too hot in the summertime. When there are anywhere from 50-70 trucks expected to come and go from your project with concrete at a dark hour, site logistics become that much more important. Factors to be considered can range from how to get the trucks in and out to where the pump trucks need to be staged and even accommodating for residential neighborhood time restrictions. “Time is money, so you need to get them in and off your site as quickly as possible,” explains Devin.

One way to accomplish this is with directional signage, especially when dealing with third-party companies that may not be as familiar with the site as the project team. Elissa adds that a big part of site logistics includes the process during emergencies. It is crucial, and even lifesaving, to ensure that emergency vehicles have proper access to and from the site, with clear access routes and individuals available to wave them down.

Joe agrees, and remarks that orientation of a project always includes information on where crews should meet in the case of emergency, where emergency vehicles can access the site, and other important logistics.

How Do Jurisdictions Affect Site Logistics Plans?

Between jurisdictions ranging from federal, state, county, city, and even local neighborhood associations, site logistics plans can vary astronomically. One of the biggest variances is in regard to permitting. Certain jurisdictions may not inspect the same items that project teams are accustomed to in the Portland Metro Area. There is often a steep learning curve to understand what a specific jurisdiction requires and what works on a given site.

Joe gives an example of a project in Eureka, California, that restricted the altering of any land with a specific “weed of interest”. On a similar project in Sacramento, California, crews had to get trained up on how to deal with protected animals on the jobsite, such as lizards. And on another project, teams even dealt with planning around migrating turtles. These examples just go to show that there are factors that simply can’t be planned until you understand the geographical area that your jobsite is on, and enforces why project teams need to stay on their toes and keep an open mind and backup plan handy.

“What makes sense on day one might not make sense on day 60.”

Do Site Logistics Plans Change Throughout the Project?

According to Devin, site logistics can be like a football game. To have a successful site logistics plan, you need to “call audibles”. Calling an audible in football refers to when the play is changed at the line of scrimmage by yelling out a new play. “The fact that you may be digging a utility trench for the electrician on the same day as your concrete pour means you’ve really got to roll with the punches.” explains Devin.

Manpower Loading and Site Logistics

We quickly backtrack to site efficiencies, specifically related to trailer placement, crew parking, access to the building, and how all of those factors tie into crew efficiencies. Joe notes that it all ties back to working the job backward. When thinking about tenant improvements, the ability to find milestones in the schedule and make a plan of logistical attack can help avoid stacking trades on top of one another and creates ease of scheduling subcontractors.

Although site logistics may have gotten more complicated with COVID-19, Joe remarks, “I think it gave us insight on how we can do better.”

Final Thoughts

Site logistics in construction are critical to a successful construction project and an enjoyable experience. There is a fine balance between preplanning, being proactive, and adapting on the fly, and site logistics give you the best opportunity to do just that. A big thank you to Joe York and Devin Koopman for their insight on today’s topic! Make sure to subscribe to The Perlo Podcast wherever you get your podcasts.

Welcome back to Episode Seven of the Perlo Podcast! Podcast host Elissa Looney, Director of Strategic Initiatives at Perlo Construction, is joined by Superintendent George Trice and Project Manager Nate Brown, two members of the project team for one of Perlo’s current projects in Ridgefield, Washington.

Overview of Ridgefield Industrial

Ridgefield Industrial is a 480,000 SF core and shell concrete tilt-up warehouse on a 50-acre site being built for Specht. Project teams are about three-quarters of the way through the project, with the total duration spanning about eleven months.

George Trice, Project Superintendent at Perlo Construction, explains that the walls have already been tilted and the roof is about 70% completed. In this specific project, project teams are waiting to pour the truck loading docks until the last minute to allow time for a potential tenant to come in, as they are hoping to do some tenant improvements later on. The team is currently ahead of schedule, and they expect to finish the project a month ahead of schedule.

George explains that although they are now expecting to finish the project a month early, this wasn’t always the case. Times were tougher over the winter, but the crews were able to tackle a few critical items early, such as the truck aprons, that pushed the project schedule ahead.

Nate Brown, one of Perlo’s Project Mangers, states that he’s learned quite a bit since being out on the site. As a visual learner, being on the site in person a few days a week to see what’s going on has allowed him to learn exponentially about building in commercial construction.

General Process of Concrete Tilt-ups

The process for concrete tilt-ups is generally straight-forward. From stripping the site and concrete-treating the soil to digging footings for the slab, the end goal is the have the panels come off the ground when it is time to tilt. One unique factor of concrete tilt-ups is that you don’t run the slab where the wall is going to be. As panels tilt up and sit on footings, there is about a 10-foot gap between the wall and the slab. Once the roof is tied in, project teams start backfilling and do a pour-strip around the building. This is critical, as both the rebar that is coming out of your panels and the roof system all have to tie into the slab perfectly.

Site Challenges

George and Nate explain that the biggest challenge on this site was the rain. Every pour that the team conducted was followed by rain, which meant that bond breaker couldn’t be added to the slab. Bond breaker is what keeps the newly poured panel layers from sticking to the slab and is a necessity for panel tilts. The project team and field crews had to take a more innovative route to solve this problem by working over the weekend when the weather was nicer to get as much water off the panels as possible.  

Final Thoughts

Like what you hear? Check out the full podcast to see a tour of this in-progress project!

The industrial real estate market has been booming for several years and is anticipated to continue its upward trajectory for the near future. Fueled by increases in e-commerce, a strong economy and a heightened desire to keep inventory levels high, the demand for industrial buildings remains strong. In fact, Q3 2021 saw a record-breaking 448.9 million square feet of industrial space under construction in the United States.

A lesser discussed topic in the industrial market is that of continued maintenance. Concrete tilt-up buildings make up a large share of the industrial market, and while they’re relatively simple building systems, they do require maintenance over time.

Today, we will spend some time discussing the common maintenance items that building owners and users should keep in mind to keep their assets in premium condition.

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As part of the close-out process, a good general contractor will provide contact information for the installing subcontractor team so the owner can consider retaining them for ongoing maintenance.

Depending on the complexity of the roof system, the location of the building and the contractual agreement, roof maintenance will most often be performed on a quarterly or semi-annual schedule. It’s important to review the terms of the warranty documents for each particular roofing system. Neglecting roof maintenance will negate any warranties.

Final Thoughts

No matter which piece of the building we discuss, proactive maintenance is far more cost-effective than reactive maintenance. Engaging specialty contractors to complete regular maintenance protocols from the time the building is complete and over the course of its lifetime will lead to lower costs over time, a higher quality space and, in the case of leased space, happier tenants.

Continuing with our Year in Review series for 2021, this week we’re focusing on a few of our industrial projects. From ground up construction to tenant improvements, our teams have completed projects in a variety of sub-markets this year.

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Frederickson DWA7

The Frederickson DWA7 project consisted of a new, 144,000 SF tilt-up concrete building to house an Amazon Distribution center. The new building features two 42,000 SF canopies and twelve high speed roll-up doors for van loading usage, a concrete loading dock with fourteen dock positions outfitted with pit levelers and overhead doors. Additionally, there is 14,000 SF of office and multiple remote restrooms.

To carry out the work, the teams logged and cleared a 38-acre site, constructed a full public road extension through the site, completed wetland mitigation and six stormwater infiltration galleries.

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224 Logistics Park

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OBRC New Office Building and Warehouse

This new can and bottle recycling center consisted of a new concrete tilt-up building with 38,000 SF of two-story office space and 103,000 SF of 28-foot clear height warehouse. The office space included a large entry vestibule, multiple restrooms and breakrooms, open workspaces, and executive offices. Uniquely, OBRC required Quiet Rock on all exposed warehouse to office demising walls, and all MEP penetrations had to be sealed to reduce warehouse noise and fumes from infiltrating the office.

Site preparations included a large retaining wall and an abnormally deep sanitary pump system, as well as extensive groundwater control with a new wetland mitigation pond. The presence of excessive groundwater required installation of dewatering well points during earthwork, site development and foundation installation. Permanent groundwater infiltration detention systems were installed to handle the excessive underground water and direct it to the wetland.

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Columbia Distributing Headquarters TI

In addition to Columbia Distributing’s new warehouse in Canby, Perlo’s teams completed a second generation build-out for their new West Coast office headquarters, as well. This reimagined office space now includes workstations, private offices and 48 ancillary areas including conference rooms, a breakroom, collaboration areas and even a pub.

By expanding into this new space, the company is further allowed to grow and remain in close proximity to their warehouse. The space included high end finishes, complete with indoor plants. The pub is a highlight of the space. Perlo built the original core, shell and former tenant space, so we didn’t find any surprises in terms of the building itself. However, the project was  constructed in the height of the pandemic as well as the wildfires that ravaged the region. In spite of all this, the team kept the project on schedule.

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Composites One

The Composites One building includes a new, concrete tilt-up warehouse which needed to comply with H3 occupancy requirements. Of the 73,000sf of new building, 45,000 SF is being utilized by Composites One for their composite material distribution business which serves the hi-tech and wind energy manufacturing sectors. The remaining portion was built as speculative warehouse space for a future tenant, which Perlo recently completed for Article.com.

The project was built on a mitigated wetland, which had to be reviewed and approved by the Army Corp. of Engineers before construction could begin. In addition, this land was potentially an archeologically sensitive site, which meant that there was the possibility for native American artifacts to be found during excavation operations. This meant that a full-time archaeological representative had to be onsite to ensure no elements were disturbed if found.

Elements of the project included a small office, specialty auxiliary rooms for their materials that required specialty HVAC systems for temperature control and exhaust, as well as explosion proof wiring.

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Final Thoughts

Stay tuned for next week, when we look back at more of our completed in 2021 projects!

We have recently received a lot of questions about one of our most visible projects located at the corner of Tualatin Sherwood Road and 124^th in Tualatin, Oregon.  That question is a resounding, ‘what is that large rock pile for?’ The simple answer is that this temporary mountain of crushed rock is a result of a mining operation to flatten a site that had 60’ of elevation change prior to the work beginning. Today we’ll explore beyond the large rock pile and provide an overview of the work taking place at Tualatin Sherwood Corporate Park (TS Corporate Park).  This 32-acre development is striving for LEED certification and will be home to three speculative industrial buildings with a completion date in early 2022.

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The Excavation and Mining Work

To level the site, excavating company Kerr Contractors is completing more than 1 million cubic yards of excavation work, including the blasting and mining of nearly 600,000 cubic yards of rock. The visible rock stockpile is made up of roughly 1/3 of that yardage, with the prior 1/3 already consumed by off-site locations, and about 1/3 left to be mined and relocated. 

The mining operation has consisted of blasting at least once weekly since the work began. The largest blasting work has been completed previously, with more surgical blasting and mining continuing from now until nearly the end of the year to round out that scope of work.  

To complicate the mining operation, the construction of the new concrete tilt-up structures began long before the blasting work was planned to finish. To accommodate the concrete pours, Perlo and Kerr teams have regularly coordinated to prevent damage to the new concrete. Some strategies to avoid concrete damage include:

• Timing blasting to avoid vibration within at least 7 days of any concrete pour.  This may require blasting twice in lieu of once so that rock crushing operations can be maintained while concrete is poured and cures.
• The installation of vibration sensors in the ground to track movement due to blasting and ensure that vibration levels are low enough to maintain the integrity of the building structures.

The mining operation is running 7 days per week and 24 hours per day to maintain the owner’s desired schedule.  Permitting took place through the City of Sherwood, as well as Tualatin Valley Fire and Rescue to ensure that communication and safety between the local areas and the site are well planned and maintained. So why is there such a large pile of rock? Quite simply, the mining and crushing is taking place faster than the rock can be sold and consumed off-site.  We anticipate that all the rock will be removed by year-end. Until then, we watch it grow, change, and soon be minimized to a level site. 

Site Utility Tie-ins

Previously undeveloped, the site needed all new power, water, storm and sewer systems to be installed. Logistically, tying these utilities into the site has been one of the challenges of the work.  The new sewer line, for instance, had to be tied into the existing city sewer system located across Oregon street at the Western corner of the site. The 12” pipe had to run very near to a local dental office, with boring under Oregon street to be completed. In addition to standard utility connections for the buildings, the development will include several new electric vehicle charging stations, complete with the infrastructure to provide adequate power to these units.

Unique Site Features

Aside from the significant excavation work, the site includes some unique features:

1. A soil nail shotcrete retaining wall that is 15’ tall at its highest point.
2. A natural rock wall adjacent to the shotcrete wall where the primary rock mining work is taking place. This wall is 40’ at it’s highest point.
3. A new street extension to bring Cipole road into the site, complete with a new streetlight.
4. Significant lengths of lock + load retaining walls near the street.
5. Large onsite water retention ponds for stormwater management.
6. Electric vehicle charging stations.

Critical Site Logistics

The presence of more than 75 trade workers and truck drivers each day means that site safety and clear logistics planning are critical to delivering a successful project. Though the site is quite large, much of it has been taken up by the mining operation and storage of rock. Additionally, there is the construction of three buildings, sitework, and the trucking needed to export the rock all taking place at the same time. These factors make for a logistical challenge that has taken expertise and extensive communication to overcome.

Some of the strategies we are using to ensure the safety and efficiency of the site include:

• Amy Cook, a full time safety team member on the site to help maintain a safe construction site.
• Regular site meetings with all subcontractors involved are held to maintain communication and coordination.
• Clear signage and traffic routes onsite.
• Pre-determined materials laydown areas and crew parking locations.
• Extensive pre-planning and routine reviews and updates to that plan as the work progresses.

Extensive communications protocols, pre-planning and some creativity have led to a safe, clean and organized site.

LEED Certification

All three buildings are aiming for LEED certification at completion.  Some strategies used to attain this certification include minimizing contaminants in all building materials, and sourcing local materials. Additional measures for LEED certification will take place for the tenant improvement work when the spaces are leased to a tenant.

Final Thoughts

The TS Corporate project has been a shining example of complex site logistics and communications strategies.  As one of our more publicly visible sites, it has been an honor to have the opportunity to talk to so many community members about the work being completed there. We look forward to completing the project this Fall.

If you’d like to know more about our construction services or want to get in touch, please visit our services page or contact us here.

With significant challenges resulting from the COVID-19 crisis, it has taken extra dedication and teamwork from our people, clients, design partners and subcontractors to keep pushing through and getting things done. We take pride in delivering projects on time, with the utmost quality, no matter the circumstances. We wanted to celebrate this by looking back at some of projects in 2020 and give shout outs to the teams that brought the projects to life.

In partnership with our building community this year, we have:

We are grateful to have so many partnerships within our community that allow us to employ the best people in the industry, and to positively impact the communities we live in.

Project Highlights

Although we work in nearly every market sector, Perlo is best known in the industrial market. So it only makes sense that we pay homage to this sector first. This week’s blog is dedicated to a few of the industrial projects that we completed in 2020.

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Despite what 2020 has thrown at us, we continue to push through for our clients. Join us next week for part two of our 2020 year in review series!

Types of Buildings and Uses

Industrial real estate serves a variety of end-users and may include light manufacturing, warehousing and distribution, showroom space, light office, retail, movie production, or food storage and/or production, among other things. Buildings may be constructed in a variety of ways, most commonly of the following types:

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In previous generations, concrete block was commonly used for exterior wall systems, but seismic concerns and inefficiencies with constructing large buildings has largely phased this method out. There is some speculation that Cross Laminated Timber (CLT) may be considered in the future for exterior building skins on industrial projects, as focus shifts towards more sustainable construction practices. 

The size of industrial projects varies greatly from small footprint buildings for single businesses, to warehouse and distribution centers spanning over one million square feet. In general, these buildings include wide open floor plans, often with rows of racking, equipment and forklift operations. Interior clear heights – the height from the floor to the underside of any obstructions at the roof structure – also vary, with heights climbing in recent years to 40 feet and beyond.

Industrial developments typically need easy access to freeways or other modes of transportation, such as airports or marine ports, and in more recent years are moving closer to consumer locations with the rise of e-commerce. They also require large, preferably flat parcels of land, ranging from a few acres, to 40 acres or more for very large buildings. Area traffic, permit and development fees and access to utilities such as power, water and gas also play a role in site selection. 

The Rise of Technology in Industrial Developments

One factor increasing the complexity of industrial market construction is the rise of technology use. Automation through the use of robotics has been on the rise for years. Forklift guidance technology via guide wires that are embedded in concrete slabs has been a part of warehouse construction for quite some time.  Increasingly, we are seeing even more technology that must be included in our building packages to accommodate loading and unloading at dock doors or embedding technology for driverless forklifts. It’s possible that as automation increases, the need for a skilled labor force nearby will decrease. These larger industrial buildings could then be located in increasingly rural locations, where land is more readily available and is less expensive.   

What Makes Developments Pencil

Development of industrial projects are all about dollars and cents, and a budget bust of even one dollar per square foot can mean a project doesn’t move forward. The material components that make up most of these types of buildings include:

• Concrete
• Rigid Insulation
• TPO Roofing
• Structural Steel
• Rebar
• Lumber

An increase in the price of these items can certainly affect whether a project moves forward or not. 2020 has seen relatively steady prices for projects. Some materials prices have decreased, and though labor prices continue to rise, many contractors are looking for innovative solutions to keep costs down, perhaps in anticipation of an economic downturn, to ensure they have a healthy backlog of work. 

In addition to tracking materials and labor pricing closely, the large site sizes that accompany industrial projects require careful consideration of the excavation work needed. In fact, one of the largest risks to an owner in terms of cost and schedule delays is the site work package.  Complications with building sites can arise from a variety of factors, including, but not limited to:

A Cyclical Market

The real estate cycle is cyclical, and the industrial market is no different. Depending on supply and demand, we observe locally that the industrial market shifts between speculative construction and build-to-suit. In other words, when the market is ‘hot’, developers are willing to construct speculatively, without having a tenant in place to occupy it at the time they begin construction. When the market slows, we see developers wait to build until they have a tenant pre-arranged to lease the building, and then they build it to suit that tenant’s specific needs.

At the beginning of 2020 in the Pacific Northwest, we were very near the point in the cycle where developers were slowing their interest in speculative construction and moving towards build-to-suit only. With the onset of the COVID-19 pandemic, this trend has accelerated.  However, construction of industrial product has not stopped. As JLL reported in June, the pandemic has accelerated e-commerce demand within the US, as consumers seek to order more of their goods online. We are still seeing a need for these types of buildings across the Northwest.    

Though developers have shifted to a more cautious approach for development this year, they have not stopped purchasing land for future development. Investors have continued to buy and prepare for new developments and are poised with ‘shovel ready’ land when the right deal comes along. 

From the time land is purchased, an owner can expect the design and permitting process to take a minimum of six to twelve months, followed by the actual construction time. With this in mind, owners have to consider that if they endeavor to develop their own building, they will have to be prepared for an extended amount of time for the development and construction process to be complete.  

The Future of Industrial Real Estate

In the past several decades, we have seen changes in both the building types and materials used for constructing them, which has increased efficiencies in construction and utilization. However, increasing regulation of building codes and a lack of available land in some locations is making development more challenging. In the Pacific Northwest, we are seeing projects extend up and down the I-5 corridor more than in years past, as the supply of large, developable parcels decreases. 

At the same time, the rise in e-commerce needs across the country is inspiring some retailers to build smaller footprint distribution centers that are closer to their consumers in lieu of having only a few large distribution centers across the country. It will be interesting to see if this trend also lends itself to redevelopment of brick and mortar locations into small distribution hubs as consumers choose to buy online and demand fast delivery. 

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The COVID-19 pandemic has also led to questions about the domestic supply chain. Will we see manufacturers make efforts to move production facilities back to the US? If so, the industrial real estate market will certainly benefit.

For the immediate future, all signs point to a strong build-to-suit market in the industrial space. We anticipate that deals will become more creative in terms of redeveloping existing property and responding to the needs of the booming e-commerce market.

If you are considering an industrial development, our preconstruction teams excel at providing preliminary budgets for consideration. Reach out here to start the conversation.