Wesex Headquarters

Wesex Headquarters

Wesex Headquarters

The Challenge

They say the hardest thing for an architect to design and the hardest thing for a builder to build is their own space. The obvious challenge of this job was doing both. By utilizing our design software and photoreal rendering engine, we were able to make quick changes on the fly and poll the office with options so that everyone felt included and invested in the process. Seeing everything in the model ahead of time allowed for quicker debates between our Chief Construction Officer and Chief Design Officer regarding the right blend of cost efficiency and aesthetic quality.  

Revit’s design option feature allowed for a fast, iterative approach to space planning, where we were able to evaluate layout, fit and finish to meet just about everyone’s needs – including perfectly positioning Greg’s office to seclude him from distractions (anyone who knows him knows he has ADHD), and providing attractive yet highly durable flooring options for our resident Great Dane to run laps with his toys when not invited to meetings. We were able to mitigate arguments by having all of the data in one place and quickly being able to prove or disprove theories by cutting sections and perspectives on the fly. This allowed the key members of the design & construction team to remain two steps ahead – we knew traditional ductwork was not a viable option given the constraints of the existing building before the Project Manager even came in to present the strategy. This project was our true case study for all things BIM.

The Solution

Wesex Headquarters is a 5,500 square foot high-tech office facility designed by our Chief Design Officer. The building is situated in West Middlesex, PA, once known as a pioneer in the Shenango Valley at the center of the iron business. Though founded in 1954, Wesex functions as a youthful technological start-up, implementing the latest design software to create integrated,  innovative design & construction solutions. This project served as both a catalyst and a testing lab for those principles.

The project includes a brand new insulated composite tilt-up concrete structure consisting of 16 panels totaling 2,892 square feet. This new structure sprouts off of an existing pre-engineered metal building, formerly a local bank, which has been completely renovated from head to toe. The design serves to harmoniously merge two construction methods that Wesex utilizes frequently for their clients while showcasing many of the industrial products and solutions that we employ on a daily basis.  The space can be designed as a high-tech hub for our design/engineering team, but it doubles as a showroom for our clients to see the products that will go into their own spaces. Items from coiling overhead doors to exposed joists and wide flange beams were used in unconventional ways to create a sleek, modern, industrial space. 

Year Completed

Tilt-Up Panels Used

Months to Complete

Technology Driven Office

BIM Highlights

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No Drawings Used in the Field

Our field team managed the entire project through a Data Vault on the site allowing for real time updates in the cloud.

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Zero Clashes in the Field

All coordination was done in Revit to eliminate untimely coordination between trades.

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Live Budget Updates

All items in the Revit model were assigned cost codes to allow for value engineering prior to final procurement & sourcing.

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Betters Warehouse

Betters Warehouse

Betters Warehouse

The Challenge

This building was a unique situation – the owner needed a complete turnkey facility within 6 months of giving us the go-ahead. This included the design/permitting phase, which essentially forced the ultimate fast-track solution – often designing details in tandem with construction. (We’re talking sketch up a change the morning, have it built in the evening).

The entire job was sequenced seamlessly with a clear critical path – the timing of every pour and every trade carefully managed to ensure no hold-ups and shorten the duration nearly to the breaking point. We worked day and night shifts, and our design & construction team co-located nearly 24 hr hours a day on-site to stay a day ahead of any issues that arose before they were able to cause a delay. The client even threw us a few curve balls – but hey, we love a good challenge.

The Solution

Located on a 75-acre parcel along the Ohio River in Aliquippa, PA, this 200,000 square foot warehouse and distribution facility was constructed for Betters Real Estate Holdings, LLP. As the Design-Builder for the project, Wesex oversaw all disciplines for design and construction throughout the project. 

The building is currently set up for a single tenant within the building; however, the overall design is prepared to accommodate anywhere from a single tenant to up to four separate tenants. Also included within the building is a climate controlled secure storage space measuring 20,000 square feet, and a 2,000 square foot office component.

Year Completed

Total Cost ($Million)

Months to Complete

Amazing Result

BIM Highlights

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Start to Finish

This was the first job our Chief Design Officer (at another firm at the time) and Chief Construction Officer did together from start to finish and fully in BIM.

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Birthplace of Integration

We often cite the Betters Job Trailer as the birthplace of our fully integrated BIM model.

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Sub-Contractor Buy-In

Some of our key subs embraced our Revit models and started relying on them for field layout, quantification, and clarity. This enabled answers to get to the field rapidly – often via iPad.

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Philips Respironics

Philips Respironics

Philips Respironics

The Challenge

We ran into a challenge on this project when the gas company decided to institute a new mandate restricting us from the usual 5 lbs of pressure to 5 oz. This pushed our gas line from a 2” threaded line hung from the joists to a 10” welded line mounted on the roof – with considerable impacts to both schedule and budget. Our BIM modeling capabilities engendered an out-of-the-box solution that involved prefabrication & optimizing part sizing to greatly reduce the cost impact and decimate the potential schedule delay. 

This project was designed in AutoCAD by the Owner’s Architect and completely re-modeled in Revit prior to and during construction – our BIM models are that essential to how we work.

The Solution

We served as the Design-Builder for the new 260,000 square foot office, service center, warehouse, and distribution facility for Exel, Inc./ DHL Supply Chain (Developer) and Philips Respironics | Sleep and Respiratory Care (Tenant). The facility is located in Westmoreland County’s Westmoreland Distribution Park North in East Huntingdon Township.

This food-grade facility was designed and built using insulated concrete tilt-wall panels. This innovative building method allowed the structure to be fully operational in roughly nine months from the commencement of site preparation. 83 concrete tilt-wall panels were formed on the floor slab, and stand 40-feet high with varying widths averaging 28-feet wide. Roughly 8,550 cubic yards of concrete were used on the project site.

Year Completed

Tilt-Up Panels Used

Months to Complete

Amazing Result

BIM Highlights

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Prefabricated Parts

Optimized part sizing to greatly reduce the cost impact and decimate the potential schedule delay.

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No Drawings Used in the Field

Our field team managed the entire project through a Data Vault on the site allowing for real time updates in the cloud.

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Zero Clashes in the Field

All coordination was done in Revit to eliminate untimely coordination between trades.

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Miller Industries

Miller Industries

Miller Industries

The Challenge

Miller Industries needed to consolidate operations of two separate facilities within 15 miles of each other in Mercer and Hermitage, PA. Their project scope included not just a building addition, but a renovation of their entire existing facility, which had understandably taken some abuse over the years.

This required careful coordination to limit disruption of their ongoing production. To make matters more interesting, there were also some challenges present on the area of their property that was slated for the new addition, requiring the creative problem-solving expertise of both our team, and our Civil Engineering partners.

The Solution

Miller Industries is the world’s largest manufacturer of towing and recovery equipment, with executive offices in Ooltewah, Tennessee, domestic manufacturing operations in Tennessee and Pennsylvania and foreign manufacturing operations in France and the United Kingdom. We helped to expand Miller’s investment in Hermitage, PA location by constructing a 127,200 square foot building addition to house expanded manufacturing functions and upgrading their existing 90,000 square foot building.

Together with CEC, we were able to navigate and mitigate the challenges of their site and provide a clean, safe, efficient space for their production to continue. In addition to this work, Wesex has also provided equipment relocation and installation support to Miller Industries before, during and after completion of the project.

Year Completed

Number of Blocks Cut

Months to Complete

Amazing Result

BIM Highlights

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Monorail

The new monorail was designed completely in Revit.

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100% Robotic Layout

To ensure maximum equipment efficiency & placement inside the new facility.

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Equipment Coordination

Allowing Wesex and Miller Industries to completely understand where and how equipment would be placed.

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CCL Container Hermitage

CCL Container Hermitage

CCL Container – Hermitage, PA

The Challenge

Wesex has done quite a bit of work on CCL’s Hermitage facility over the years, but perhaps one aspect stands out as our most interesting challenge at this facility. CCL acquired a neighboring property off the back of their existing space, requiring an expansion to combine the two facilities into one, functioning space. The existing space required substantial improvements, the connection piece involved two different finish floor elevations which needed a transition that would be safe for traffic, and the front office area was in major need of a facelift – both inside and out.

The total project also required the addition of a small expansion for Hazardous storage, upgrading their safety protocols and helping to keep employees safer. All of this work, particularly the office renovation/addition, needed to be carefully planned around maintaining facility operations and minimizing time office employees would need to spend in temporary space while their renovation was being completed.

The Solution

Wesex provided Design-Build, Development, Program Management and Self-Performed General Construction services for CCL Container’s latest expansion and renovation project. This project involves a 5,000 square foot office expansion, 15,000 square foot office renovation, a 93,000 square foot renovation (including a 50,000 square foot manufacturing facility addition, a 38,000 square foot warehouse addition, and 5,000 square feet of office renovations), loading dock expansion, and the addition of a hazardous storage room with deflagration venting. 

In addition to work on this facility, Wesex has done a number of other projects with CCL, including a brand new container facility in New Albany, OH and the company’s design facility in Strongsville, Ohio.

Year Completed

Seperate Projects Here

Total Square Feet

Amazing Result

BIM Highlights

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Automated Layout

All additions, including sprinkler drops, were laid out using the Revit model and our GPS system.

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Existing Facility Management

The entire existing facility was field verified and included in the Revit model to provide the owner with an accurate model of their entire facility at completion.

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Sight Line Studies

The owner was concerned about the view from building approach due to the addition of the hazardous storage space on the front of the facility. We were able to provide them with accurate sight line renderings to make sure their expectations were aligned with reality.

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