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Rudolph Libbe Builds U.S. COEXCELL HQ in Maumee By Irwin Rapoport CEG CORRESPONDENT
Rudolph Libbe Inc., of the Rudolph Libbe Group, has made solid progress on the construction of the multi-million dollar, 82,500sq. ft. combined headquarters, manufacturing facility and warehouse building for U.S. COEXCELL in Maumee, Ohio. The work started last May and will be completed in early 2020. Rudolph Libbe is design/build contractor and its crews are self-performing the site work, concrete, masonry and carpentry. GEM Inc., also of the Rudolph Libbe Group, is performing the steel erection for the Varco-Pruden pre-engineered metal building, as well as the installation of the plumbing, HVAC, and electrical systems. U.S. COEXCELL designs and manufactures specialty blow-molded drums and packing systems, and the new building will more than double the company’s manufacturing space. The building, designed by Poggemeyer Design Group in Bowling Green, Ohio, will include Varco-Pruden insulated metal panels, a 10-ton bridge crane and an isolated air-conditioned and dust-free manufacturing space. The pre-engineered metal building with a production bay and “clean room” type area was designed to be easily expanded. The design also ensures that manufactured products can be rapidly transferred to the warehouse section and then to the loading docks. “There is an auxiliary equipment area adjacent to the production bay with conveyors serving as the go between for the process,” said Holly Henn, Rudolph Libbe’s project manager. “The warehouse is for product storage, and there is a small office area tucked into the warehouse area for employees. Poggemeyer Design Group and Rudolph Libbe Group have worked closely to develop a construction-friendly design and installation with flexibility for any necessary revisions. Poor soil quality has required more excavation, larger spoil piles, landscaping mounds and premium backfill as necessary.”
Steel erection for the building began on July 22 and was completed in November.
In terms of road construction, crews will be building a parking lot, a fire access road and a truck loading dock and staging area. The complex, close to the Anthony Wayne Trail, is being built on 10 acres of forested property. “The congested site required careful coordination of material delivery and staging,” said Henn. “As many trees were saved as possible. Every project is different, but we research and plan every one thoroughly and try to anticipate every challenge. In nearly 65 years of business, we have a great deal of experience in dealing with weather, soil conditions and other challenges.” The earth work and site prep operations began on May 20. The owner subcontracted the tree removal to a tree clearing company. “It was strip and pile, with larger piles required due to poor soil conditions,” said Henn. “GPS was used on the dozer. A drone was used for elevations and a propeller was used for cut estimates. Excavated materials were stockpiled on site for removal later. Poor soil conditions always present a challenge, but we have the experience, knowledge and technology to manage those issues.” The foundation was installed between June 18 and July 12.
“The foundation consisted of footers, grade beams and column footers,” said Henn. “We placed the footers first, then placed grade beams and piers to connect the footers, making one structural unit. On one line of foundations, poor soil quality required us to excavate more soil than anticipated and pour slightly deeper footers and grade beams, but we’re always prepared for that type of challenge. The foundation work went very smoothly overall.” The placement of the underground utilities — gas, electric, communications, storm, sewer and water lines — started on July 17 and was completed on Oct. 22. “The storm system was installed first because designed elevations had to be maintained for the water to travel to the designed elevation outputs,” said Henn. “Then the sewer system was installed, followed by the other utilities.” The placement of a retention pond, as well as additional site work, lasted from May 22 to Aug. 5. “Trees were removed to create the retention pond, which has a capacity of 7,930 cubic yards and averages nine feet deep with three deeper sediment pools located in the bottom,” said Henn. “We used an excavator
to dig the pond down, a dozer to shape the pond banks and planted grass seed to stabilize the banks.” Steel erection for the building began on July 22 and completed in November. “Steel erection started from the auxiliary/crane bay on the east side of the building and we worked our way west to the warehouse area,” said Andy Moya, GEM Inc.’s project manager of steel erection. “We started Varco-Pruden wall panels at the end of August and were complete in October. The Metl Span panels were unloaded and staged around the building until it was time to install. We installed a ceiling liner panel first to help with the roof being fully covered. The Varco-Pruden standing seam roof was installed afterward.” Underground plumbing was completed in August. “Work started in mid-September on the above-ground plumbing and gas systems, which are being installed in stages to maximize efficiency and stay on or ahead of the schedule,” said Paul Anderson, GEM Inc. project manager of the mechanical work. “Completion will coincide with completion of the building in mid-February.” Anderson noted that GEM Inc. laserscanned the existing facility and before construction began, Rudolph Libbe Group’s Virtual Design and Construction (VDC) department generated a full 3D model of the building to precisely locate plumbing, electrical and HVAC systems. In addition to Henn, Moya and Anderson, the team includes Christian Simpson, preconstruction services; Ron Kuzma, pre-engineered building coordinator; Dennis Costell, superintendent; and Brad Delventhal, business development, all of Rudolph Libbe Inc.; and Brian Ferree, GEM Inc. electrical project manager. “We hold weekly subcontractor meetings with regular updates to the construction schedule,” said Henn. Peak days have approximately 25 workers on-site, including those from various local and regional subcontractors. see CREWS page 6