
PROJECT SAPPHIRE – SITE DEVELOPMENT FOR AN ADVANCED MANUFACTURING FACILITY
By the Numbers
Metrics
352,000
CY Earthwork
28,000
TN Aggregate
3660
LF Underground Utilities
5120
LF Fire Protection Waterline
11,200
SF Design-Build Shoring
1800
CY Structural Concrete
Challenge
Executing a phased industrial site development program while overcoming significant weather-related delays, delivering a building pad, underground utility infrastructure, and a shored pit with concrete foundations on an accelerated development schedule.
Solution
Utilizing a unique to the industry earthmoving method, E.S. Wagner leveraged proactive planning to maintain project momentum despite challenging site conditions. Strategically applying chemical soil drying facilitated accelerated recovery after rain events at critical junctures. Demonstrating ESW’s diversity, the team designed, proposed, and constructed a shored excavation that included concrete foundations required for the long-term use of the facility with minimal impact to the vertical construction taking place around the foundation “pit.” The site and pad development, utility infrastructure, and shored pit and foundations were all completed on a schedule that was accelerated at the request of the end user during construction.

Project Scope
E.S. Wagner Company served as the site development contractor for a 21-acre industrial development delivered in multiple phases. The project included site clearing, mass grading, and 815,000 total square feet of building pad construction, requiring approximately 350,000 cubic yards of earthwork and more than 28,000 tons of aggregate base. Despite significant weather-related impacts, ESW utilized innovative “Cat and Pan” earthmoving methods and strategic chemical drying application to complete the earthwork and building pad while maintaining overall project momentum. Additional scope included installation of approximately 3700 linear feet of underground utilities, including water, sanitary sewer, and storm sewer systems as well as a 5100 LF fire water loop. ESW design-built a shored foundation concrete pit located in the southern portion of the primary pad that allowed for a 15’ excavation to receive the ESW-constructed structural concrete elements while minimizing impact to the surrounding vertical construction. ESW’s proactive coordination and demonstrated diversity allowed the project to overcome numerous challenges and maintain progress on the accelerated critical path.
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