The Shockey Precast Group

219 Stine Lane, Winchester, VA 22603

www.shockeyprecast.com

For additional copies of Structures, or for more information about

The Shockey Precast Group, call (540) 667-7700.

Visit our website at www.shockeyprecast.com.

PRESORTED

STANDARD

U.S. POSTAGE PAID

WINCHESTER, VA

PERMIT NO. 213

STRUCTURES

Project Name: Ft. Belvoir Commissary Facility

Owner: Defense Commissary Agency

General Contractor: Hoar Construction

Engineer: Defense Commissary Agency

Architect: The Jenkins Group, Inc.

Precaster: The Shockey Precast Group

The commissary located on the Ft. Belvoir military base has the

distinction of being the busiest—and the most profitable--commissary

in the Defense Commissary Agency system. So when its capacity could

no longer match the growing demand of base personnel, it was time to

build a second facility. The Shockey Precast Group was subcontracted by

general contractor Hoar Construction to provide architectural precast

wall panels for the new commissary facility, as well as architectural precast

arches and components for the separate entrance and exit vestibules.

Since the architectural wall panels would be braced to a steel frame being

erected just ahead of the precast, coordination and innovation were

required to ensure a successful and smooth project flow.

The Shockey Precast Group’s scope of work for the two-phase, 60,000

SF project consisted of a 44,000 SF commissary facility and a 16,000

SF entrance/exit vestibule. Shockey produced 50,000 SF of insulated

precast walls for the project; approximately 148 pieces of architectural

precast with thin-brick façade for the new commissary facility, and 115

arched pieces of architectural precast with thin-brick façade for the

vestibule. Shockey utilized Tekla Structures 3D modeling to guide precast

production, establish precast erection sequence, and coordinate precast

erection. The model provided a 3D rendering that allowed Shockey

Precast’s Engineering team to review the complex panels and coordinate

with the steel subcontractor’s reference model. Although the project

was not without obstacles, the use of Tekla Structures 3D modeling

contributed to greater collaboration among Shockey Precast’s Engineering

team and Field Services, as well as with other trades and subcontractors. It

also created a project flow that was remarkably smooth and successful for

the complexity of the project.

Stability of the structure was a primary concern during erection of the

commissary facility, as the precast wall panels were braced to the steel

frame structure. Because completion of the steel frame was delayed and

stability of the structure could not be guaranteed, Shockey Precast would

not begin precast erection until a third-party engineer had provided a

bracing plan that would ensure the safety and stability of the structure.

From a design and production perspective, the use of the Tekla Structures

3D model helped Engineering provide an accurate brick count to

production for order. A 3D rendering was also included on the shop

tickets, for enhanced visualization. Engineering received a 3D model

from the steel erector, and was able to integrate this model with the

Tekla Structures model of the precast to review the overall structure and

identify discrepancies and potential problem areas.

The Tekla Structures 3D model was also helpful for developing the

erection sequence, and allowed Shockey Precast erection crews to see

potential erection challenges before they were encountered in the field.

From the erection perspective, the biggest challenge offered by this

complex project was its location on a military base. Complying with base

Tekla Structures 3D Model Provides Innovation for Fort Belvoir Commissary Success

The Shockey Precast Group 219 Stine Lane, Winchester, VA 22603 www.shockeyprecast.com

Spring 2016 Issue 4

STRUCTURES

Bracing of the precast arches was one challenge faced during precast erection.

SPG erected 148 pieces of architectural precast for the commissary facility.

regulations and protocol for working onsite required extensive

coordination by Shockey Precast Field Services, as all personnel working

onsite were required to go through inspection daily prior to being

allowed on base. The trucks delivering precast were also required to

go through inspection, and normal permit load regulations did not

apply on a military base. Ensuring that Shockey trucks and personnel

were in compliance with base protocol and processes demanded careful

coordination by Shockey Precast’s Field Services team.

Through ongoing communication, the use of Tekla Structures 3D

modeling, and successful collaboration with general contractor Hoar

Construction, architect The Jenkins Group, Inc., engineer Defense

Commissary Agency, The Shockey Precast Group was able to meet the

numerous logistical challenges associated with this complex project

and provide Ft. Belvoir with a striking new commissary facility to

serve its personnel.

Design-Assist Process

In today’s construction market, time is short, funding resources are limited or phased, and speed is essential to a successful project. Many projects do not have the luxury of a process that includes lengthy design to 100% construction documents, bidding various packages, and reworking shop drawings before finally arriving at the actual construction phase. Owners are seeking ways to streamline design and to expedite the front end of the construction process in order to bring their projects to market faster and more efficiently than ever before. In response to this need for speed, design-assist and design-build have emerged as effective alternates to traditional construction processes. Over the past 10 years, The Shockey Precast Group has developed a comprehensive design-assistance process that supports Shockey’s integration and participation as a full member of a cohesive project design team. This early involvement in the design process enables Shockey to aid customers in making sound, informed design choices that best serve the financial and aesthetic needs of the owner.

A key advantage of the design-assist/design-build approach is that it brings the key players to the design table from the beginning stages of design, and eliminates the extended schedule associated with the traditional design-bid-build process. Particularly for projects with complex designs or aggressive construction schedules, the design-build approach can offer numerous benefits in terms of cost and time savings. As a member of the design-build team, Shockey can take the lead for all precast-specific and precast-related design issues, and can drive value engineering options. This approach facilitates the development of a workable design aligned with the owner’s vision and financial considerations.

Overall project design gains the most benefit when The Shockey Precast Group is involved in the development of projects that are less than 15% designed. Working with the owner, developer, or general contractor, our Business Development Team prepares a design-assist proposal, outlining

the specifics of Shockey’s role as a member of the project design team. This typically includes preparing and updating budget estimates, participating in constructability reviews, and using BIM to provide 3D project models. Members of the Shockey team also attend regular design team meetings, and communicate with other members of the project design team through face-to-face meetings, phone conversations, and written and email communication. The design-assist proposal establishes initial scope of work through the design process, and sets an initial Guaranteed Maximum Price (GMP) for the project. The iGMP typically includes a firm estimate for the design; however, the balance of the contract is determined as the design and scope of work are developed. A key advantage of Shockey’s early involvement in the design process is the focus we bring to optimization of precast components and trade coordination, considerations that can ultimately result in cost savings and reduction of the overall project schedule. Once the design process is complete, The Shockey Precast Group finalizes the construction estimate and provides a final GMP for the project.

Upon acceptance of the design-assist proposal by the owner or general contractor, Shockey assigns an Engineering Project Manager (EPM) to oversee the project through design development, to include design/detailing, budget, and schedule. The EPM serves as the liaison between the Shockey departments involved in the project (i.e. Project Management, Manufacturing, Warehouse, and Field Operations). The EPM also serves as the client point-of-contact on design and detailing issues, and is charged with the direct responsibility of ensuring the Design & Engineering process of a project is completed in an efficient and thorough manner. Once Shockey is awarded the contract for project construction, a Shockey Project Manager is assigned to work with the Engineering Project Manager and the project team through the start of production through turnover of the project to the owner.

As the benefits of design-assist and design-build have become more widely recognized in the construction industry, The Shockey Precast Group has gained considerable design-build experience encompassing both structural and architectural precast projects. Complex parking structures, in particular, benefit from the early involvement of a precaster in the design development process, yet Shockey’s design-build history includes numerous architectural precast projects as well. Following are some of our most notable design-build project successes:

WMATA Andrews Federal Center Bus GarageLocation: District Heights, MDOwner: WMATAArchitect: SYSTRA USAGeneral Contractor: Hensel Phelps ConstructionPrecast Scope: 116,000 GSF insulated wall panelsEstimated Completion: 2016

Social Security Administration National Support CenterLocation: Urbana, MD

Third-party erector E.E. Marr handled erection of 115 pieces of architectural precast for the commissary vestibule.

Iron Hill Corporate Center parking structure in Newark, DE, is one of SPG’s recent design-assist success stories.

Owner: General Services AdministrationArchitect: SOMGeneral Contractor: Hensel Phelps ConstructionCompleted: 2014Precast Scope: The 300,000 SF Social Security Administration National Support Center was constructed for the GSA to replace its original 30-year old facility. As a design-assist partner, The Shockey Precast Group managed the project’s remaining design-assist process and provided architecturally featured, insulated wall panels. The decision to use precast resulted in a structure that is cost effective, offers an excellent weather barrier, and reflects the GSA’s aesthetic vision for the facility. The Social Security Administration National Support Center was a DBIA 2015 National Design-Build Project/Team award winner in the Federal, County, State, and Municipal category.

SPG Utah ProjectLocation: UtahOwner: ConfidentialArchitect: ConfidentialGeneral Contract: ConfidentialPrecast Scope: Design-build of all-precast and partial precast confidential mission-critical facilitiesCompleted: 2013

Iron Hill Corporate Center Parking StructureLocation: Newark, DEOwner: The Buccini/Pollin Group / JP Morgan ChaseArchitect: Tim Haahs & Associates, Inc.General Contractor/Contact: BPGS ConstructionCompleted: 2013Precast Scope: The five-level Iron Hill Corporate Center parking structure features 705 parking spaces, and was designed to blend aesthetically and architecturally with the existing surrounding buildings. As a design-assist partner and specialty subcontractor, The Shockey Precast Group designed, manufactured, delivered and erected approximately 156,000 SF of structural precast for the project. BPGS Construction was awarded a 2014 Excellence Award by ABC Delaware for the project.

WMATA Southeastern Bus Garage FacilityLocation: Washington, D.C.Owner: WMATAArchitect: SYSTRA USAGeneral Contractor: Hensel Phelps ConstructionCompleted: 2012Precast Scope: As a design-assist partner on WMATA’s Southeastern Bus Garage facility, The Shockey Precast Group designed, manufactured and delivered approximately 460 structural and architectural precast components, including approximately 120 insulated walls with architectural thin-brick finish, as well as double tees, columns, exterior columns, column covers, shear walls, and beams.

Washington Headquarter Services Location: Alexandria, VAOwner: Duke Realty Corp, Alexandria, VA Architect: HKS, Washington, DC General Contractor: Clark Construction, Gaithersburg, MD Completed: 2011Precast Scope: The Washington HQ Services BRAC 133 was a design-build project that included construction of two parking structures and two office buildings, encompassing 1,700,000 square feet of structural and architectural precast. As a design-build partner, The Shockey Precast Group used Building Information Modeling (BIM) with the design team to plan and execute the projects and provided value engineering throughout the process. Shockey produced and erected approximately 2,980 pieces of structural precast for the two parking garages, and nearly 1,700 pieces of architectural precast for the two office buildings.

From the initial kick-off meeting through design, construction, and turnover, Shockey’s design-assist process brings the value of a cohesive, integrated team approach to the design development of a project, assuring that the finished project meets the owner’s aesthetic vision, practical needs, and budget.

SPG Welcomes New Employees

The Shockey Precast Group recently welcomed the following individuals to the Shockey family:

Joshua Vice, Field Coordinator – Joshua comes to The Shockey Precast Group with several years of experience as a Project Manager, as well as nine years’ experience as a Business Development Specialist. He has a B.A. in History from George Mason University, and an A.A.S. in Teacher Education from Northern Virginia Community College. He was previously employed by Midasco, LLC as a Project Manager.

Brennan Smith, Summer Intern -- Brennan is an intern with SPG’s Sales & Business Development department this summer, learning all aspects of SPG’s business development, sales, marketing, and estimating functions. He is a rising junior at Liberty University with a double major in Business Marketing and Project Management.

Recently Awarded Projects

• Queen Anne Tower (Conewago)• Falls Church Anglican Parking Structure, Falls Church, VA (Howard Shockey & Sons, Inc.)• Arlington Trade Center Expansion, Arlington, VA (Howard Shockey & Sons, Inc.)• Village at Cranberry Parking Structure, (Elford Construction)

Earn AIA CEUs

Earn AIA CEUs with a Shockey Precast plant tour or box lunch presentation on Total Precast Systems or Introduction to Precast Parking Structures. Visit www.shockeyprecast.com or contact Marketing Coordinator Terri Ward at 540.665.3215 or tward@shockeyprecast.com to sign up.

Connect with SPG

SPG is on Twitter and LinkedIn! Follow us at #ShockeyPrecast, stop by our LinkedIn page at The Shockey Precast Group, and check out our website at www.shockeyprecast.com.

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