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PROJECT SAPPHIRE – SITE DEVELOPMENT FOR AN ADVANCED MANUFACTURING FACILITY

Sector

Commercial & Industrial

Client

Moltus Building Group

Location

Rossford, OH

State

Ohio

Status

In Progress

Site Size

76 Acres

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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