PEYTON HOUSE

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Background

The owner of a 1928, AAA Five Diamond-rated resort wanted two new three-story structures completed prior to tourist season, while keeping nearby facilities operational throughout construction.

While there was significant pre-construction work, the schedule accelerated significantly once precast began arriving at the site. The all-precast installation – columns, elevator towers, stairs, framing, beams, walls, and a complicated architectural precast exterior – took only nine weeks, compared to a full year with traditional masonry construction.

In the end, total precast proved to be a viable and potentially cost-saving option. The structures easily exceed all wind-load requirements, while addressing life safety issues, reducing the overall construction duration (resulting in earlier owner occupancy), and dramatically reducing the number of on-site trades and personnel during construction. There were challenges along the way, but the precast producer proved its resilience through an innovative, collaborate approach to design. Ultimately, the project team matched the new precast buildings with the brick of the other existing poured-in-place structures in the complex, while simultaneously reducing cost and erection times.

Through excellent engineering end exceptional coordination between contractor and precast producer, the buildings were completed on time with minimal disruption to ongoing resort operations. The buildings were well received by the community and successfully integrated new technology and materials with old school charm.

By all accounts, the total-precast construction of two structures at a 92-year old Florida beachside resort was a “home run.” The project – including precast columns, elevator towers, stairs, framing, beams, walls, and a complicated architectural precast exterior – took just nine weeks to complete, compared to a full year with traditional masonry construction.

It was a tall order. The owner wanted to keep the resort completely operational throughout construction, and have everything completed in time for peak season. As such, total precast proved to be a viable and cost-saving solution. By choosing precast, the project team simultaneously reduced the overall construction duration (resulting in earlier owner occupancy), dramatically minimized the number of on-site trades and personnel, exceeded wind-load requirements and addressed life safety issues. This while seamlessly matching the resort’s existing design palette.

All of the work was performed on an extremely tight site. An occupied facility and the resort’s main swimming pool were right next door, both fully functional throughout construction. Additionally, access was restricted to a small two-lane road. This made precast significantly more attractive, as it required less coordination, fewer site mobilizations and reduced noise levels.

Matching the painted brick of the existing buildings – without actually using any brick – was a stroke of genius. To make it happen, the precast provider poured the mix into a customized form liner that mimicked the pattern and texture of the brick. By doing so, they matched the brick flawlessly while simultaneously reducing cost and erection times. Precast also allowed designers to simplify wall assemblies, provided superior vapor barriers and improved sound attenuation between guest rooms. Additional inherent fire protection was an added benefit.

Of course, the total precast solution’s most appealing attribute was its savings in cost and time. While there was significant pre-construction work, the schedule accelerated significantly once precast began arriving at the site. Through it all, the contractor collaboratively worked with both the design team and precast producer to work out the details. Ultimately, the team saved some $700,000 and completed the project four month early.

There were challenges along the way. Strict zoning commitments, high expectations from the community and a complex design were all potential threats. Through it all, the precast producer proved its resilience by taking an innovative, collaborate approach to designing solutions.

Design Challenges

The structure situated right on the Atlantic coast, the structure is subjected to high hurricane force winds.

Situated on an extremely tight site between existing buildings, the ocean and the coastal highway precision was critical.

Since the structure is seaward of the coastal construction line (CCL), the area – perpendicular to the wave action – of any structural elements that extend below the base flood elevation (BFE) to the foundation must be strictly minimized. This severely limited the size/location of lateral force resisting shear walls.

Construction needed to be completed on a very tight schedule to meet seasonal room demand, as the entire site was surrounded by an active five diamond resort. A complex, often non-repetitive floor plan and associated wall layout was needed to satisfy desired room configurations. The exterior skin needed to respect the resort’s historic brick facades and create the illusion that it was truly a brick façade. Community expectations and acceptance of the finished product were extremely critical to the project’s success.

Of the 800 precast mark numbers on the two buildings, only 68 had more than a quantity of one each.

 

High Performance Attributes

 

Photos via GATE Precast Company