CCC was contracted by General Motors to construct a 92,000-square-foot building addition to accommodate a new state-of-the-art tryout press for their North Stamping Plant in Pontiac, Michigan.

CCC’s scope of work on this design/build project began with relocation of all Underground utilities to accommodate the expansion, including reworking the existing truck route and constructing a new cooling tower and demolishing the old to make way for the new building. Next CCC performed the excavation for the new building foundations, press pit (170’L x 90’W x 25’D) and scrap tunnel. CCC self-performed the concrete for the building foundation, press pit, scrap tunnel, miscellaneous pits, slab-on-grade and exterior architectural concrete work. Mechanical, electrical and plumbing sub-contracts were involved with design using a design/assist approach to minimize construction cost and maximize value. CCC managed MEP subs who were responsible for fabricating and installing new fire protection, compressed air, waterlines, Industrial Water lines, electrical drops and a new electrical substation to support the new press equipment and process for the entire building addition.

CCC also self-performed the rigging for the new electrical substation installation; and installation of metal stubs, drywall, ceilings and trim for new locker rooms and offices.

UNIQUE FEATURES AND CHALLENGES

• Despite the aggressive schedule, difficult site conditions, and numerous changes, CCC had the facility ready for press installation in 9 months
• CCC self-performed all site exterior concrete, building foundations, press pit concrete, scrap tunnel concrete, interior slab-on-grade concrete, rigging for new electrical substation, installation of metal studs, drywall, ceilings and trim for new locker rooms and offices.
• Relocating underground fire water, sanitary lines and domestic water lines without shutting down or interrupting the existing operations.
• As-built drawings were inaccurate leading to unexpected removal of caisson caps in the location of the new scrap tunnel and lots of exploratory digging to locate existing underground utilities.
• The design of the press changed several times once our design was finished and construction had begun. Quick decisions were required by the project team to maintain schedule.