Crutcher Structures

:TROY BLOCK

:Touchstone Corporation

:Construction of Troy Block included the redevelopment of a full superblock into two L-shaped towers of 12 and 13 stories, built over a five-story below-grade parking garage. Work included integration and stabilization of two historic facades on separate existing buildings. On the Troy Laundry Building, this entailed building a concrete “frame” to support the façade, cast in architectural board-form concrete, which nodded to the original construction. At the Boren Investment Building, which was located over poor soil, crews installed all new foundations to support the façade while the below-grade parking garage was completed.

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• In total, the project contains 1.4 million square feet of concrete decks.
• The below-grade structure is comprised of mild-reinforced flat slabs. In contrast, the above-grade structure is post-tensioned concrete slabs with wide shallow beams—a typical structural frame scenario in the Seattle market that allows for future flexibility.
• Work also included a significant miscellaneous steel scope, including feature stairs and decorative partitions.

:TERMINAL 106

:Trammell Crow Company

:Terminal 106 is an 850,000-square-foot two-story light industrial warehouse located on a 15-acre Port of Seattle parcel in South Seattle. It is the second multi-story warehouse built in the Northwest. Another distinctive feature of the project is a cast-in-place 35-foot-tall bridge that connects the truck court to an earthen ramp and an extensive site work package that includes 12-foot-high retaining walls.

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• The team is responsible for every part of the structural frame, including the management of the steel erection.
• Crews will form, place and finish approximately 64,400 cubic yards of concrete on the project, including 475,000 square feet of slab on grade, 345,000 square feet of slab on metal deck and 250,000 square feet of post-tensioned suspended slabs for the adjacent two-story parking garage and truck court.
• Work also includes formation, placement, finish and erection of roughly 160 35- to 52-foot-tall tilt-up concrete panels for the enclosure.

:DISCOVERY HALL

:University of Washington

:This Science, Technology, Engineering and Math (STEM) building was constructed for the University of Washington Bothell campus. This 79,000-square-foot LEED Gold facility includes wet and dry labs, classrooms, offices, a motion capture lab and 200 seat auditorium. The technically challenging structure included 4 stories of post-tensioned beams and mild reinforced slabs cut into the hillside. The auditorium included stair-stepped stadium seating placed over foam blocks and abandoned formwork.

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• The retaining wall work was carefully sequenced with mass excavation to optimize the import and export of soil.
• The winner of three AIA merit awards, this project’s pride is undoubtedly the concrete finish’s quality. Architect Thomas Hacker desired polished concrete slabs and natural board-formed interior walls. Our team collaborated with the other trade partners and modeled every aspect of the work in a federated building model. This computer modeling paid huge dividends with our architectural concrete work, where we exported the board jointing into our survey software and laid out every board in the field, ensuring every corner and intersection was aligned.

:HEALTH SCIENCES EDUCATION BUILDING

:University of Washington

:Integral with the UW Medical Center, this four-story, 100,000-square-foot building is designed as a multidisciplinary learning environment. As a key design-build, risk-reward team member, Crutcher Structures installed all cross-laminated timber (CLT), cast-in-place concrete, miscellaneous iron and extensive site concrete. The Owner and Architect, Miller Hull, strongly desired to use timber construction with long spans to eliminate classroom columns. Our solution was a composite CLT panel and concrete slab design.

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• Crutcher Structures doubled the productivity rates setting 34 panels (13,500 square feet) daily.
• To assure quality, the CLT panels were shop fabricated and delivered to the jobsite in perfect sequence with the steel erection to avoid double handling.
• Because the panels were weak in one direction, we custom-engineered a strongback apparatus to support the panel during rigging and placement fully. The team also treated the end grain of the panels with wax to avoid moisture infiltration and protected the panels during placement.
• Our site paving work included colored concrete, precast concrete, three types of sandblasted finish, seeded aggregate river rock, and site benches.

:BUILDING 6

:SeaGen

:Conversion of an existing tilt-up warehouse into a state-of-the-art life sciences laboratory. The team built a structural steel-framed mezzanine level within the high-bay warehouse to accommodate the extensive mechanical equipment.

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• Our concrete crews saw cut the existing slab on grade, performed selective excavation, and cast new or expanded footings.
• We removed 150 feet of exterior tilt-up panels to improve the building’s shear capacity and replaced them with a 30-foot tall, handset shear wall. A second, full-height shear wall was installed on the interior of the building. Both these concrete elements were cast full height in one continuous placement with great results.
• Our ironwork crews who set columns, beams, bar joists and metal decks. Because this was all interior work, it was not accessible with a crane. Therefore, the steel was set with a combination of equipment solutions including forklifts, chain falls, winches, and lifts.
• Through 4-D modeling, we carefully sequenced the steel installation with our prefabricated multi-trade racks to expedite the schedule and improve quality.

:VIA6

:Pine Street Group

:Via6 is a twin-tower, 24-story residential complex with 654 apartments and a three-story below-grade parking garage, built on a tight urban site in downtown Seattle. The structure for this roughly 750,000-square-foot building was completed in approximately 12 months.

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• Level 7 features a large deck with a cast-in-place amenity pavilion building with lounge spaces, entertainment areas and a demonstration kitchen for a local chef.
• The concrete structure comprises post-tensioned flat plate decks from Level 2 and above, with mild-reinforced concrete decks below.
• Crews beat the project schedule, turning over a deck in each tower every week and shaving a full month from the project schedule.
• A testament to the quality of the concrete work, the owner decided to leave many of the columns and core walls exposed (a change from the original plan). Our crews also formed, placed and finished a cast-in-place feature stair in the lobby.

:VILLAGE SOUTH PARKING GARAGE

:University Village

:This 316,000-square-foot cast-in-place structure is comprised of a 652-stall garage and over 90,000 square feet of retail, restaurant and medical office spaces. The project was challenging due to unique site conditions. The site, which is sandwiched between the 45th Street Viaduct and an active shopping center, sits on 25 feet of highly compressible peat, and the water table is just below the ground surface. Therefore, our foundations and grade beams were supported with innovative helical piles, load tested to 1M pounds.

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• The dual shear walls are supported by two-meter diameter drilled piers, installed to a depth of 100 feet and embedded 40 feet into the dense bearing layer below the unsuitable soil.
• To install our below-grade water quality vault, we designed and installed a sheet pile cofferdam that extended 60 feet below the working surface. Due to the proximity of the former Montlake Landfill, we coordinated with the civil and mechanical designers to employ a vapor extraction system to ensure methane gas was properly ventilated.
• To minimize impacts to ongoing shopping operations, we shared our construction entrance with shoppers, coordinated work activities and fencing locations daily and scheduled noisy work to off-hours.
• Our long-span, post-tension garage went up swiftly, placing 254,000 square feet of parking decks in 17 days.

:RAINIER SQUARE

:Wright Runstad & Company

:Rainier Square is a 59-story office, residential and retail tower built on one of the tightest urban sites in downtown Seattle. At 850 feet tall, it is the second-tallest building in Seattle, and is known for its distinctive shape. The building has won numerous awards for its innovative structural system which combines a concrete-filled dual-plate shear wall core with the structural steel frame, the first application of this technology in a high rise.
 
Our crews placed and finished over 1.3 million square feet of slab-on-metal deck and placed 27,700 cubic yards of concrete within the core, ultimately putting 70,000 cubic yards of concrete in place in a little over 10 months. Our team also formed, placed and finished two slosh tank dampers at the top of the building, which helps dampen sway at the top.

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• Working in collaboration with the structural engineer, steel fabricator and erector, we developed a sequence for erecting the building in only 10 months, shaving roughly 5 months from a traditional leading-core system.
• Work required developing a system to support the crucial first lift of the core within the 12-foot-thick mat foundation, ensuring that the remainder of the building could be erected true and plumb.
• The team collaborated with a local ready-mix supplier on a 10,000-psi concrete mix that could be pumped while overcoming enormous head pressures as the building rose to its final height.