building buzz
civil sector
edition 1 | Fall 2024
Managing Supply Chain Challenges with Progressive Design-Build Projects
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“Our clients are in the business of moving freight such as mined minerals, food products, and building materials that communities depend on. Our number one success metric is safely minimizing disruption to the train schedules, and we gear all of our operations toward that goal.”
Jim Holtje
Civil Area Manager, PCL Construction
Building Climate-Resilient Infrastructure for Tomorrow
Market insight
Investment in climate resilient infrastructure is imperative as climate-related factors contribute to increased droughts, floods, hurricanes and wildfires. In 2022, the United States faced 18 weather and climate disasters costing at least $1 billion, while Canada saw a record-breaking year of wildfires covering an area twice the size of Portugal. Without changes, climate-related infrastructure failures could cost Canada $300 billion over the next decade. Research by MIT's Concrete Sustainability Hub shows that such investments in climate resilient infrastructure often pay for themselves in just two years in hazard-prone regions. Every dollar spent on resilience can save up to $11 in long-term repair costs. With a history of over 325 transportation and 470 water and wastewater projects, PCL Construction integrates climate resilience into its work. Known for bringing innovative solutions to the table and cutting-edge technologies, PCL is at the forefront of these transformative climate resilient infrastructure projects gaining momentum across North America. Pioneering Climate-resilient Infrastructure Solutions in Water and Transportation When tackling climate challenges on diverse civil infrastructure projects, PCL has identified resilient solutions for clients in the transportation, water and wastewater markets. The team is collaborating with the Water Infrastructure Finance Authority of Arizona (WIFA) to tackle the pressing issue of water shortages within the state. In 2022, Arizona was asked to cut its Colorado River water usage by 20%, a response to exceedingly low water levels which further exacerbated the state’s water crisis. PCL is playing a pivotal role in formulating solutions to address the urgent water scarcity in Arizona. Unlike conventional project processes where clients typically identify a need and subsequently engage a builder, PCL's involvement with WIFA represents a unique approach. In this instance, PCL is part of the ideation phase, offering concepts and strategies to create projects that will effectively enhance the water supply in Arizona. “It's an exciting opportunity to partner with other industry leaders and be pioneers, focusing on holistic solutions right from the start,” said Richard Hewitt, vice president and district manager for PCL’s civil infrastructure division in the U.S. The issue of water scarcity isn't unique to Arizona; it's a widespread concern affecting numerous regions across North America. Communities are grappling with a range of challenges, such as droughts, contaminated groundwater and inadequate infrastructure for water access. In response, there's a continuous need for water reuse facilities to repurpose wastewater for non-potable and potable uses. PCL has experience building a variety of innovative water reuse and drought resiliency projects, including advanced water purification systems which are starting to gain traction across the U.S. Currently, PCL is working on an advanced water purification project in Texas, a multiple-stage treatment process that will transform treated wastewater into safe, reliable drinking water. The growing momentum in water reuse initiatives is just one facet of PCL's broader commitment to sustainability and climate resilience. This commitment extends beyond water management to encompass a wide range of climate resilient projects across various sectors, including buildings and infrastructure. PCL has identified and helped clients ensure projects are built for the future and can withstand extreme weather events. For instance, on the $400+ million St. Albert Trail to 97 Street segment of the Yellowhead Trail Freeway Conversion project in Edmonton, PCL reimagined the original approach of building an underground storm tank on a project to mitigate flooding concerns. “Instead of constructing a very large concrete storm tank beneath the road, the team advocated for raising the interchange to leverage gravity for efficient water drainage,” said Ian McKinnon, manager of PCL’s civil operations in Canada. “This constructability design value suggestion created a significant reduction of ongoing maintenance and helped prepare for a 100-year storm.” Similarly, on a design-build civil project in Miami, PCL’s attention to detail during the design stage paid off. Observing in the Building Information Model that electrical conduits below the elevated building slab were exposed to flood risks, the team made the critical decision to encase these conduits in concrete, a modification not originally envisioned but essential for long-term resilience. Envisioning Sustainability in Infrastructure Projects Not only does PCL bring expertise to climate-resilient infrastructure solutions but the company brings experience in Envision Sustainability Professional (ENV SP) certification. Envision is similar to LEED (Leadership in Energy and Environment Design) certification but applies to public infrastructure and focuses on the impact to communities while LEED applies to public or private construction and focuses on occupancy comfort and energy efficiency. According to the Institute for Sustainable Infrastructure, Envision was designed to help infrastructure stakeholders implement more sustainable, resilient, and equitable projects. To earn this coveted certification, projects are required to demonstrate their commitment to being carbon neutral, viable over the long term, resilient in the face of climate change, and designed to be both fiscally responsible and resource efficient. “There is a growing trend among clients who are increasingly inquiring about the Envision certification. This rating system, relatively new but rapidly gaining popularity, is particularly attractive to municipalities aiming to develop sustainable, resilient, and equitable civil projects,” said Hewitt. A noteworthy project in Salt Lake City currently stands as a prime example of the company's commitment to Envision credentials. This project, the second-largest public infrastructure project undertaken by the city will have the capacity to process 48 million gallons of wastewater while being strategically designed to accommodate future expansion and meet stringent water quality standards. In its pursuit of Envision certification, this project is targeting a minimum of 25% recycled material usage during construction, with a goal of achieving a 50% reduction in construction waste. So far, 77,000 tons of material have been recycled that might otherwise have ended up in landfills. Additionally, all excavated materials have been responsibly sourced or repurposed within a five-mile radius of the project site, emphasizing the commitment to sustainability and minimizing environmental impact. Precision Technology in Climate-Resilient Construction When it comes to building for climate resiliency, technology plays an important role. Software like PCL’s own technology Job Site Insights™ (JSI™) allows teams to monitor the humidity and moisture levels during construction with 100% precision and accuracy to maintain quality. This sensor technology monitors heat and moisture tolerances to ensure concrete foundations set to their maximum strength and can withstand extreme weather events such as a hurricane. PCL continues to use concrete JSI™ sensors to assure the right strength is achieved for the infrastructure they are building. “The other success we’ve had with our JSI™ sensor is during the application process of high-performance coatings used in water and wastewater treatment plant projects,” said Hewitt. These coatings are applied inside the tanks and JSI™ sensors help assure that the humidity and the temperatures are tracked so the coatings are being applied under the right conditions. “This type of technology is helping us apply quality thinking, so we know that what we’re building contributes to PCL’s vision of building a better future together with our clients, stakeholders and communities,” said Hewitt. With clients now actively incorporating climate resilience into their prequalification inquiries, this signifies a pivotal moment in our industry. “Not only are we building smarter and stronger, but we are also heeding the call to create infrastructure that can withstand the challenges of a rapidly changing climate,” said McKinnon. Across North America, there are investments like the Bipartisan Infrastructure Bill that dedicates $50 billion towards protecting against droughts, heat and floods in the U.S. Similarly, in Canada, the Climate Resilient Built Environment initiative designates $46.7 million toward climate resilient programs. “The path forward is clear: we must embrace the evolving landscape of sustainability and climate resilience, working hand in hand with clients to create a more resilient and sustainable future for all,” said Hewitt.
Keeping Freight Moving Across North America
St. Albert Trail to 97 Street segment of the Yellowhead Trail Freeway Conversion project in Edmonton.
Salt Lake City Water Reclamation Facility in Utah.
Lake Manatee Water Treatment Plant Filter Upgrades
Florida, us
Hextall Bridge
Calgary, alberta
Project Profiles
Building a Secure Future for America’s Water Resources
Engineering News-Record | enr.com
Ankur Talwar is shaping the future of infrastructure construction
San Luis Obispo Wastewater Plant Overhaul Flows Along
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Transportation
water and wastewater infrastructure
$5 billion+
in projects completed since 1986
470+
water and wastewater projects completed
60+
years of civil construction experience
325+
transportation projects completed
A Century of Excellence in Civil Infrastructure Across North America
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“Progressive design-build contrasts with the traditional model that often front-loads time and resources in the pursuit of a final price and award, potentially overlooking opportunities for optimal solutions along the way.”
Ken Slota
Director, Industrial & Manufacturing Process Water Group, PCL Construction
Today’s dynamic world of civil infrastructure presents many complex construction challenges. Project timelines can be extremely tight. Supply chain disruptions can cause budgets to spike. Arduous material procurement can derail project schedules. To meet these new challenges, traditional project delivery methods need to evolve — and the progressive design-build method, which addresses these challenges by redefining how projects are planned and executed, is at the forefront of this evolution. Progressive design-build departs from conventional project delivery methods by using qualifications-based criteria as a starting point. Once a team is awarded a project, the owner collaborates directly with the design-build team to finalize both the design and contract price. Progressive design-build fuses the design-builder element from traditional design-build with the collaborative pre-construction element of Construction Management At-Risk, creating a comprehensive model for a project. Much like traditional design-build, the progressive design-builder directly contracts with the design consultant and manages design costs. This shift in responsibility effectively transfers certain project risks from the client to the design-builder. Progressive design-build allows clients to have a higher level of input throughout the later stages of the design process. The client also benefits from stronger financially secure project pricing as the progressive design-build price is developed with a greater level of design certainty and a higher level of project planning compared to traditional design-build delivery. Progressive design-build also borrows principles from the Construction Management At-Risk (CMAR) delivery method, particularly in the context of pre-construction services. In CMAR, the construction manager provides pre-construction services, such as planning, scheduling, risk management and estimating. Progressive design-build similarly emphasizes a collaborative preconstruction phase where the design-builder works closely with the owner and stakeholders. One key feature that distinguishes progressive design-build is its inclusion of the contractor from the project's inception. The progressive design-build model assembles the right blend of expertise at the outset to tackle front-end design, planning, budgeting, and scheduling collectively. This allows for early and sustained collaboration, ensuring that project stakeholders do not operate in isolation. Instead, they come together as a cohesive team, investing time upfront to identify project milestones and secure an accurate project price. Across the United States and Canada, PCL Construction has successfully executed numerous progressive design-build projects within civil infrastructure sectors such as water, transportation, and mining. These projects stand as a testament to this innovative approach, providing evidence of its effectiveness in overcoming procurement challenges and optimizing supply chain management and schedule. Navigating Supply Chain and Procurement Risks Supply chain disruptions are significant impediments to construction project timelines and budgets. According to recent industry data, 63% of contractors say their biggest concern is project delays due to supply chain issues. The innovative approach of progressive design-build, however, can effectively navigate the turbulence of procurement and supply chain management. Progressive design-build projects give design-builders early access to data on lead times, which allows them to identify constraints and coordinate with stakeholders early on. The progressive design-build method empowers project teams to identify high-risk items and establish robust processes for monitoring and follow up. “It goes beyond simply awarding a project to a subcontractor with the expectation that they will handle procurement,” says Ryan Andrews, PCL construction manager based in British Columbia. “As the design-build lead, we have some influence on the materials and equipment being specified, and we can make informed decisions that include delivery details. Once awarded, it is our responsibility to our clients to ensure that trades are being held accountable by proactively checking the status of long-lead items ourselves.” By developing these processes at the outset, teams can identify mitigation measures as things change. To monitor supply chain and procurement challenges in the market, PCL leverages its global procurement group, which consolidates and shares data with teams to help guide decision making across the United States and Canada. On many projects across North America, extended lead times for procurement continue to pose challenges. For example, on the Tucson Airport Remediation Project, the procurement of pipe, estimated to take up to six months, threatened to significantly disrupt the project schedule. However, before the design phase reached completion, PCL ordered the pipe early based on its anticipated length and alignment. Through coordination with the project's designer, PCL successfully ensured that this early procurement decision seamlessly integrated with the evolving design and the project stayed on schedule. Efficiency And Flexibility in Accelerating Project Timelines Progressive design-build proves to be the ideal solution for clients whose projects are strongly schedule-driven and who seek contractor responsibility for the design. Take one of PCL’s projects in British Columbia for example. This $470 million mining operation on the side of a mountain presented a significant challenge — a tight 24-month timeline for completion. The client, accustomed to the traditional Engineer, Procure, Construction Manage Model, initially put a Request for Proposal out for various scopes of work. However, based on the submissions received, the client soon recognized these traditional approaches were not yielding the desired outcomes. Recognizing the need to align with their scope, budget and schedule requirements to sustain their operations, the client strategically pivoted towards a progressive design-build model, and PCL was awarded the job. “This transition proved instrumental in expediting the project's progress,” says Andrews. “Within a mere six months, our team transitioned design from zero to 100% Issued for Construction documents. Construction efforts proceeded concurrently with the ongoing design phase and as of today, the project stands at its halfway point, on track to meet the challenging two-year completion target. The team has embodied a ‘one team’ approach where the client and PCL are integrated and working in unison.” The progressive design-build model also offers a level of flexibility to help accelerate schedules. The team can identify scopes of work that can advance sooner than others. For instance, on the Luke 303 Water Reclamation Facility in Arizona, the PCL team had electrical panels delivered early to the site and installed, although the panels were missing components due to supply chain delays. This approach allowed PCL’s subcontractor to complete the field installation on schedule; then, once the missing components were delivered, the manufacturer sent a representative on-site to install and complete required factory testing. “Strategically using time not only expedites the project but also enhances cost-effectiveness. Progressive design-build contrasts with the traditional model that often front-loads time and resources in the pursuit of a final price and award, potentially overlooking opportunities for optimal solutions along the way,” says Ken Slota, Civil director of design build and non-municipal water. The ability to self-perform a substantial portion of the work in progressive design-build projects adds another layer of control and efficiency. PCL typically self-performs 50-60% of scope on its projects, providing the project team with a greater degree of schedule management. This approach allows critical aspects of the project to stay on track, making it an invaluable asset for schedule-driven projects. Although the progressive design-build approach may not be as widely recognized and used, it addresses many challenges that clients encounter. Project owners seeking early collaboration with contractors and innovative project delivery should consider progressive design-build for their next project. PCL’s expertise will guide them through this delivery method and offer solutions to supply chain and procurement challenges, ensuring on-time project delivery.
Luke 303 Water Reclamation Facility Expansion project in Arizona.
Florida, US
Keeping freight moving matters and PCL Construction, as a leader in railroad bridge construction, understands this well. With specialized railroad teams across North America, PCL is equipped to tackle the challenges and unique needs of railroad clients and has a proven track record of keeping trains running. Keeping railway lines operational drives the stability of the U.S. and Canadian economies. These countries rely on trains more than any other mode of transportation to move long-distance freight. “Our clients are in the business of moving freight such as mined minerals, food products, and building materials that communities depend on. Our number one success metric is safely minimizing disruption to the train schedules, and we gear all of our operations toward that goal,” said Jim Holtje, civil area manager for PCL Construction who oversees projects throughout the southeastern United States. Holtje has extensive experience overseeing the construction and rehabilitation of civil infrastructure, including rail bridges, across the U.S. He has worked on complex bridge projects, such as rehabilitating aging infrastructure, upgrading and automating movable bridges throughout the U.S., and replacing functionally obsolete bridge structures, during his 20-year career. PCL’s rail teams employ accelerated bridge construction techniques (ABC) to keep rail lines moving during construction or repairs. In this approach, the team reduces the onsite construction time of a project by leveraging a series of innovative techniques in the planning, design and construction phases. For example, a construction team using an ABC approach may lean heavily on the prefabrication of components. Materials such as replacement spans (the horizontal structure between two supports) or precast deck panels are manufactured offsite and assembled on the project site during prefabrication. This streamlines the construction process, improves the quality of materials, and enhances safety while shortening the schedule. Prefabrication was used on the Pearl River Bridge Replacement, a project whose success came down to a narrow 16-hour window. The 209-foot-long railroad truss span bridge crosses the Pearl River, located northeast of New Orleans. The bridge needed to be replaced, and PCL’s client, Norfolk Southern, needed the line operational during construction as it services a critical heavy freight and passenger line. The team prefabricated two through-plate-girder replacement spans, that were then installed within feet of the existing bridge. Prefabricating the spans and building the new bridge adjacent to the existing bridge minimized impacts on rail traffic. Existing spans were removed and replacement spans were slid into place in just 16 hours using a lateral slide system. The Warman Mile 60.8 Bridge and Borden Mile 90.3 Bridge Rehabilitation projects required more frequent closures. Both bridges span the Saskatchewan River in Saskatchewan, Canada, and remained active for Canadian National Railway (CN) throughout construction except during scheduled shutdowns. Span replacements called for round-the-clock closures, lasting between six to 72 hours, depending on the scope of the closure work. To make shutdowns as efficient as possible, civil construction manager Greg Schmidt emphasized the importance of planning and collaboration, “We do as much planning, prep work, and risk mitigation as possible ahead of time. Then, it comes down to communication, which includes weekly meetings, daily discussions, and closure plan reviews months in advance with key project stakeholders. Relationship building and constant communication are key to minimizing downtime and unnecessary disruption to rail schedules.” Controlling Traffic Flow While Constructing Movable Bridges This thorough approach to planning and close communication with clients is key in many of PCL’s projects building and maintaining movable bridges. For example, the Isabel Holmes bridge is an important feature of North Carolina’s transportation network and provides the necessary link between the City of Wilmington, Leland and the surrounding communities. PCL’s Special Projects division was awarded a bridge preservation contract, which included structural, mechanical, electrical, architectural and utility improvements while ensuring minimal disruptions to the traveling public. As an expert contractor in movable bridges, PCL’s team worked closely with the Department of Transportation and the designer to optimize traffic control plans allowing for daily, full-traffic access to the bridge while construction continued. PCL also used a solution provider mentality to solve the challenges that arose such as the installation of submarine cable. While the cable was only permitted to be installed in two months, outside of an in-water Atlantic sturgeon work moratorium, the team revised the layout of the cable to minimize the material lead time as well as the time allotted to complete the work within this critical schedule. With over 30,000 work hours performed, PCL’s team allowed for the safe and reliable movement of people and goods throughout the entire construction process, providing the communities of North Carolina with a sturdy, dependable bridge for years to come. Ready to Respond Even the most meticulous plans must be prepared for unexpected challenges: Damage from third-party collisions, impacts from barges, and failures caused by aging infrastructure may necessitate emergency repairs to railroad bridges. To get clients’ lines up and running as soon as possible, PCL has emergency response teams strategically positioned throughout the U.S. that can deploy when needed. Holtje describes PCL’s ability to quickly mobilize when needed, “We have a great team of people across our organization that are highly specialized and technically knowledgeable in how these systems work. They can be where we need them when the phone call comes in. It takes a pretty special individual to have that kind of flexibility in their life and to have that kind of passion. We’re lucky to have quite a few of those individuals, and we bring that value to our clients.” Emergency repairs, by nature, always seem to occur at an inconvenient time; but even when calls come in when the office is closed for a holiday break, PCL is ready to immediately take action and deploy a team. This was the case in 2023 when a bridge in a remote area in Alabama experienced a structural failure, impacting freight traffic on a joint line utilized by two PCL clients. Despite the issue occurring over a holiday weekend, the first PCL employees were onsite and assessing the situation within just a few hours of receiving the call. The next morning, PCL forces began working around the clock until the bridge was returned to full operation less than 120 hours later. In this short time, the team: Prepared detailed emergency repair plans. Developed temporary work plans for jacking and hoisting. Mobilized two barges, a tugboat, a 100-ton crane, four manlifts, a mobile fabrication shop, and three shifts of skilled iron workers. Sourced and procured the necessary milled steel and structural fasteners. Fabricated and erected over 2,800 pounds of structural steel. Within 120 hours, the bridge was fully operational for freight traffic. Overcoming Complex Logistics The remote location and limited access to many railroad bridges pose logistical and scheduling challenges. In addition to in-house railroad bridge experts, PCL leverages a network of experienced, dedicated subcontractors they partner with on rail projects across the U.S. and Canada to solve even the most complex logistical problems. “There are a few key subcontractors that we work with often. Some of them have followed us across the country for 30 years as we respond to meet the needs of our clients,” says Holtje. Clients benefit from PCL’s long-term relationships, which can be crucial to the success of a project. Together with subcontractor partners, PCL is able to implement lessons learned from previous work as well as day-to-day learning on a project. This adaptive and innovative approach to projects results in high-quality work delivered on the required schedule – which keeps the steel wheels rolling across the country.
Pearl River Bridge replacement project in Louisiana.
FLORIDA, US
