Click on an image below to see different 3D model views of the Peyton House structure


 

 

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

  • Improved thermal performance/reducing energy consumption
    The lack of joints and associated infiltration as well as the precast panels low permeability greatly helped with humidity and thermal control.
  • Increased open space of floor plate
    Use of precast allowed thinner walls and floors systems, maximizing the ocean frontage while providing excellent sound and fire protection.
  • Aesthetic versatility
    The use of the brick form liner proved reliable and credible. With great care by the engineers, the original brick design patterns were fully satisfied in the finished design.
  • Cost-Benefit
    There was significant cost benefit by greatly reducing the construction erection time over a conventional concrete shell.
  • Helped meet sustainability goals
    By its very nature, concrete is a sustainable element.
  • Improved fire resistance
    The inherent high fire resistance of the precast problems easily exceeded all prescribed fire code requirements.
  • Accelerated construction
    The total precast solution’s most appealing attribute was its savings in cost and time. In the end, the team saved the owner some $700,000 and the project was completed four month early.
  • Improved safety and security to occupants
    Precast was an ideal material of choice to address life safety issues, given its fire-retardant capabilities.
  • Structural versatility
    Precast was used throughout the structures and proved to be extremely versatile in addressing challenging site conditions.
  • Improved storm resistance
    The precast panels were invaluable in addressing storm surge and wave resistance requirements. Since the new buildings border the Atlantic Ocean, the precast was engineered to meet modern building codes in regards to wind speed requirements, FEMA storm surge and resistance to wave action forces.
  • Minimized construction site disturbance
    Access to the site was restricted to a small two-lane road and the site was closely bordered by other operating facilities. This made the use of precast significantly more attractive, since there were fewer coordination issues and site mobilizations, as well as significantly reduced noise levels.

 


 

Photos via GATE Precast Company

PEYTON HOUSE

Location:
Ponte Vedra Inn & Club
Ponte Vedra Beach, FL

 

Schedule:
Project Start: 01/2019
Precast Erection Start: 5/21/19
Precast Erection Completion: 8/16/19
Project Completion: 06/2020

 

Cost:
Total Cost of Precast: $4.3 million
Square Footage: 49,247 SF

Involved Companies

Precast Concrete Producer

Gate Precast Company
402 Zoo Parkway
Jacksonville, FL 32226
gateprecast.com

 

Precast Specialty Engineer

LEAP Associates International
11307 North 52nd Street
Tampa, FL 33617
leaptampa.com

 

Architect

Architectural Design & Planning Group
400 West Morgan Street
Raleigh, NC 27603

 

Engineer

ONM&J Structural Engineers
200 Ponte Vedra Blvd
Ponte Vedra, FL 32082
onmj.net

 

General Contractor

Danis
10748 Deerwood Park Blvd
Jacksonville, FL 32256
danis.com

 

PCI Certified Erector

Specialty Concrete Services
37920 Highway 19
Umatilla, FL 32784