DBIANE Award Competition 2017 [Silver]: Green Leaf Construction – F.W. Webb Central Distribution Facility

Project Name: F.W. Webb Central Distribution Facility
Owner: F.W. Webb Company
Contractor: Green Leaf Construction
Lead Designer: ci design, inc.
Major Participants:
Green Leaf Construction – Design Builder
ci design, inc. – Architecture,
Hayner/Swanson – Civil Engineering
Summit Engineering – Structural Engineering
Avid Engineers – M/E/P/S Engineering
Geotechnical Services, Inc. – Geotechnical Engineering
Canam – Structural Steel
Fabcon – Precast Wall Panels

Summary

The new F.W. Webb Central Distribution facility, one of the largest buildings in New Hampshire,
encompasses nearly one million square feet within its walls. The considerable project includes 48,000 s.f. of office space, complete with training rooms, and amphitheater. An additional 23,000 s.f. of finished space within the warehouse includes a fitness center and associated locker room facilities, café and break room, shipping & receiving offices, a truck detailing bay, forklift maintenance area, Zamboni room, and a Hazmat room. There is 152,000 s.f. of mezzanine and conveyor systems inside the warehouse, with the warehouse itself spanning an impressive 724,000 square feet! Ancillary to the building itself is a trailer snowscraper, a fueling island, and a tractor canopy.

The site in Londonderry, NH was chosen because of its accessibility and “shovel ready” nature, however,
the civil engineers and construction team faced a major obstacle. Site preparations involved over 500,000 cubic yards of cuts and fills, including over 120,000 cubic yards of rock that needed to be processed for fill material before the foundations could begin. As work went vertical, it became clear that the major challenge and opportunity was production – there was a huge volume of work to put in place, and that proper planning and oversight by the design-build team was critical to allow the crews to put some significant quantities in place within a finite window of time. The results were impressive – nearly a mile of footings, over 220,000 square feet of precast concrete wall panels, 1,500 tons of structural steel and joists and nearly 18 acres of rubber roof were installed in just over 6 months.

The key to the “one team” feel was early collaboration among F.W. Webb, Green Leaf, the design team and subcontractors, ensuring that constructability and feasibility were considered along each step of the design. Often times, in design-bid-build or even construction management delivery systems, the important subcontractor input is ignored or put off until after the plans are well underway and little can be gained. However, use of the inclusive design-build process meant that many potential obstacles were identified and resolved before construction began, preventing conflict down the road and presenting opportunities to save money and/or time along the way, which created value for F.W. Webb in the process.