Director of Engineering at PERI USA
“That was the starting point where one question kept us all up at night: Is this construction even buildable?”
Head of the Middle East and Africa Engineering Competence Center
“Our collaboration on the project went on for about 1.5-2 years. The total number of hours shows how much engineering work went into it, namely an incredible 1,800 hours!”
Execution phase: Our engineers deep dive into solutions
Once all the tasks were assigned, the most complicated and the most exciting phase began. Why complicated? Because during this step it became clear whether the Ocean Pavilion could actually be built or not. And why exciting? Because there were a series of challenges that made the work all the more interesting.
Major focus 1: Finding a formwork and scaffolding that made the complex geometry work.
Easier said than done. For this job, the teams needed to communicate a lot with everyone involved and they had to be extremely creative to come up with great individual solutions. But the close cooperation between the transnational PERI offices made it possible! To accommodate the difficult shapes, a foam system was used in combination with our formwork system. Our engineers therefore had to calculate the exact size of the formwork panels so that the foam could be cut accordingly. Otherwise, everything would have to be redone, which would have been very time-consuming.
Major focus 2: Calculating the correct concrete pressure.
That was probably one of the biggest challenges during the whole project. Tim explains why: “The problem was that we didn't know at the beginning whether our formwork could withstand the pressure of the concrete. Since the concrete is liquid at first and hardens later, we had to calculate the correct concrete pressure. And that was a difficult task to solve.”
Major focus 3: Including a roadway in the construction site in the short term.
Short-term changes are normal on construction sites, but this one had it all! Much of the work on the site had already been completed, but then the road which runs adjacent to the site had to be incorporated to enable a continuous traffic flow. That created a lot of extra work for the team at the last minute. They eventually found a creative and out-of-the-box solution together. PERI UP scaffolding was used here, which enabled us to span the roadway cost-effectively and with the highest safety requirements.
Assembly phase: With precision to success
The next step on the construction site was to get to the heart of the matter: the assembly phase.
Major focus: Delivering the right material at the right time.
Due to the tight storage capacity, not everything could be delivered at once. So, while the systems were gradually engineered, the finished system parts were delivered and assembled one after the other. To make sure that everything went smoothly here, the team in the USA triple-checked the quantities of all systems. Because accuracy is our strength! And with the last delivery, the whole team did an amazing job.
Client expectations? Exceeded!
Although the project won’t be finished until early 2024, we’ve already exceeded the expectations of our client. “Turner Construction was really really happy with us. Be it the approach we took, how we collaborated or how we dealt with all the challenges. In the beginning, we weren’t even sure if we could manage a complex project like this, but we made it – and I’m really proud of us”, says Tim.
Kyle can only agree: “Turner was even so impressed that PERI USA got a whole lot of return work after that.”
Despite a project as complex as the expansion of the Seattle Aquarium, we are happy to have found the right solutions. And all thanks to our expertise, our courage to think out-of-the-box and the close collaboration with our client. We can’t wait to see the final result!