Novell - Divide and Conquer
DPR Construction Inc.
To meet the original schedule despite a five-month later start, DPR approached the job as two smaller projects, hiring dual subcontractors for trades such as structural steel, metal decking, and fireproofing.
In order to consolidate a half dozen offices scattered throughout Silicon Valley, the giant networking software developer Novell is centralizing its California operations in a new corporate campus. This project comprises more than 530,000 sq. ft. of new building space in phase I alone.
The four- and five-story structures and parking garage that were originally planned for the 32-acre site were redesigned when Novell's new CEO wanted a more collegiate campus atmosphere with lower buildings. This resulted in two four-story buildings, two three-story buildings, a two-story commons building, all surface parking, and a start date of August instead of May.
Dual Subs = Cost Savings
Determined to keep the same completion date, the project team, including Shore Associates, HOK Architects, Novell, and DPR, had to rethink their initial plan. Needless to say, "thinking out of the box" was encouraged. Of the many ideas that helped speed the project, one clearly had the greatest impact - to approach the five-building campus as two smaller projects of three and two buildings each. Two subcontractors were hired for trades such as structural steel, metal decking, and fireproofing.
With the shortage of manpower in the area, splitting up the huge project resulted in more manageable work for each subcontractor. By having two subs in the field working simultaneously, the work was not only completed earlier but with savings to the owner. Excessive overtime was avoided both in the field and in the shop, as the fabricators were now able to meet the schedule.
Tight coordination and teamwork eliminated design duplications and shared the benefits of field problem-solving. Meeting notes and other forms of communication were transferred between subs so they could learn from each other. The open communication, however, did not discourage natural competition between the field crews - steel erection rates routinely exceeded 115 pieces per day. Using multiple subs resulted in getting the sub's "A" team on all buildings, enhancing productivity, quality, and safety.
Winterization
The later start also put the project five months closer to "El Nino" season. Knowing how even an average rainy season can stop a job in its tracks, the team went into action to completely prepare the 32-acre site. All site utilities were expedited as well as grading and paving. By late October a half lift of asphalt was installed, providing a permanent staging and mobilization area.
In addition to the typical underground site utilities, Novell required conduit and vaults for a massive telecom data wiring and cable network to be installed. This included 90 four-inch datacom fiber conduits located in one duct bank, a total of over 80,000 lf of this underground conduit, and numerous huge vaults.
Four Week Gain
Some of the more conservative methodologies used in typical construction were challenged in order to expedite the schedule to beat the rains. One consideration was to begin fabrication of the production piles without the benefit of an indicator pile program. As a team, DPR, Middlebrook + Louie structural engineers, soils engineers Harza, and Novell determined that the risk was minimal compared to the possible gain on the schedule. By reevaluating the soils test the team felt comfortable that the specified 60 ft. piles would be sufficient, and by precasting them without waiting to confirm this via an indicator pile program, four weeks were cut from the schedule.
Flexibility in Interior Work
Self-performing the wall framing and drywall is also helping to keep the project on schedule. DPR's use of in-house drywall crews provides maximum flexibility and control over the project. The wall system activities and MEP installation were tightly coordinated to ensure the MEP work proceeds efficiently and systematically from overhead rough-in through full height and ceiling height wall rough-ins and ultimately to trim-out and start-up without any conflict with the wall system progress.
Power Teams
With all the added challenges in expediting the job, the glue that really held it together was a strong system of teamwork. This started out with a day-long high performance team building session to establish the mission and set specific project goals, and continued with monthly "stand and deliver" sessions to review the progress. The project remains on schedule to meet its original completion date. This is no surprise to Novell's owner representative Jim Merryman. "I knew DPR would a find way to make it happen. They've got a good track record of doing just that."
