total site development

Site Development

Construction projects are complex, detailed endeavors. Castle can streamline the process with turnkey civil site development services. This means we manage and contract all scopes of work and subcontractors associated with the site -- think of us as a general contractor for the site only. Castle will also coordinate with project stakeholders and self-perform earthwork and utilities to ensure quality control.

In addition, our in-house, civil design-build services provide team continuity and project understanding from site selection and conceptual design through construction and delivery of a pad-ready site. We can help reduce risk due to unknowns on site, lower costs, and get your project started while you finalize building details.

  • Wide range of self-perform capabilities
  • Civil design-build services
  • Preconstruction budgeting
  • Expedited schedule and communications planning

IKEA Properties, Inc.

IKEA Store — St. Louis, MO

Situation and Challenges:

The 380,000-square-foot IKEA retail store and 1,300-space parking lot site preparation included 40,000 cubic yards of earthwork, clearing and demolition, soil remediation, storm and sanitary sewers, fire and domestic water service, MEP civil for underslab rough-in, and 20,000 cubic yards of bio-retention. The development of the complex urban site came with numerous challenges to overcome in order to keep the project on schedule for the secured grand opening of the IKEA store. Castle:

  • Rerouted 1,100 linear feet of an existing 144-inch live combination sewer line around the proposed IKEA store location.
  • Set 135 pieces of precast concrete pipe, each weighing 56,000 pounds, utilizing a 240,000-pound excavator.
  • Operated round-the-clock bypass pumping, utilizing two 36-inch pumps, moving 40,000 gallons per minute, 24 hours a day for three weeks.
  • Built CIP concrete junction chambers over existing active sewer in two locations, while building the rerouted section, to provide two independent tie-in locations.
  • Installed 2,100 linear feet of new 66-inch separated storm sewer adjacent to combination line.

Results:

Castle engaged early with the general contractor and owner to assist with establishing budgets for the high-risk, complicated sitework. To maximize collaboration, Castle project team members were embedded in the general contractor’s on-site trailers to enhance communication, orchestrate the sitework and be available for real-time decision-making. The collaborative efforts were critical to project success, as utilities were threaded throughout the site and work coincided with vertical construction. 

 

I wanted to thank all of you for the great work you did on our St. Louis store. Constructing this project came with its share of challenges. Whether it was the relocation of the 12’ diameter CSO, heavy utility infrastructure relocation, contaminated/poor soils, demolition of 10+ building structures, phased construction, road improvement work, bio-retention, poor weather, etc. This is all in addition to a 380,000-square-foot raised level IKEA retail facility. You met these challenges head-on while coming to the table with ideas and solutions.

Jim Hartzel, Construction Project Manager
IKEA Property, Inc.

Taubman Prestige Outlets Chesterfield LLC

Taubman Prestige Outlets — Chesterfield, MO

Situation and Challenges:

Castle acted as site general contractor, managing multiple subcontractors as site general contractor for the preparation of the 49-acre, 310,000-square-foot outlet mall and parking. Scope included grading, 100,000 cubic yards of cut and fill, dual box culvert, water line, ductbank, manholes, drainage channel with fabric and rip rap, storm and sanitary sewer, lift station and associated deep piping, bio-basins, widening of North Outer Forty Road and the interstate off-ramp, installation of plaza drains and micro bio-basins for stormwater, and retaining wall construction. Taubman required an aggressive schedule to help them open by the end-of-year holiday season in 2013. Construction work began in June 2012 and the sitework was compressed into three months. 

Results:

Castle proposed the concept of a bundled sitework package, essentially combining all site scopes – earthwork, utilities and miscellaneous site MEP work. The team also utilized “tradestacking,” or working on multiple components simultaneously, which required exceptional daily communication to execute successfully. In addition, the double-barrel box culvert system was approved swiftly due to thorough understanding of MSD requirements and quality installation, which prevented jurisdictional delays. Because of the approach, the total cost for the premium time associated with the three-month fast-track schedule, or 20 percent acceleration, was valuable to the owner so the outlet mall could open in time for the holiday season.

Great Rivers Greenway

Great Rivers Greenway (Multiple Pedestrian Trails) — St. Louis, MO

Situation and Challenges

The River Des Peres Greenway Trail project is a 3.1-mile span of ADA-compliant trail from Lansdowne to Gravois along River Des Peres Boulevard in St. Louis County. The trail scope included a full concrete trail, connector spurs, drainage, earthwork and excavation, a living retaining wall system, erosion control, storm water Best Management Practices (BMPs), landscaping, site furnishings, traffic signal modifications, lighting system, utilities, striping, signage and monuments with stone veneer and cast stone accents.

Castle deployed 11 crews over the three-mile length of the trail, carefully sequencing the project to complete on time. Crews worked three stages (site removals and excavation, concrete trail and drainage, and finishing) for three sections at miles 1, 2 and 3 and coordinated the work between them to create an efficient process that maximized productivity and time. The most challenging aspect was the cold weather concrete pours. At a given time, concrete blankets covered 2,500 lineal feet of concrete to maintain concrete quality without affecting schedule.

Results:

Castle’s team safely executed the project while working in tight spaces along a busy four-lane road using traffic control for the length of the trail, advanced planning with traffic experts, and input from the community. Safety measures included signage and lane closures, pedestrian controls and reroutes. There were no safety incidents with construction crews or the public. This was partially due to the communications plan Castle developed that included input from the local community and trail users. Castle adjusted schedules on a weekly basis, communicated the information to all project stakeholders and coordinated the work.

ICL Performance Products

ICL Specialty Solutions Addition, Webster Groves Technical Center — Webster Groves, MO

Situation and Challenges:

Castle was engaged to provide a pad-ready site for a 12,500-square-foot addition with offices, labs, meeting and support spaces, and a new main entrance to the existing ICL facility. Castle presented conceptual designs with parking and building placement scenarios up front, giving the client multiple layout options. Castle established budgets for all options presented providing the client with choices while staying on/under budget. The ICL facility is located within a larger office campus and abuts a railroad and creek, which presented challenges to stormwater outfall and management.

Results:

By providing civil design-build services, Castle enhanced value to the campus owner by looking at the overall campus and addressing future development needs, providing a master plan for achieving stormwater quality and quantity within the watershed that met sewer district requirements and reduced costs. Stormwater management included rainwater gardens, detention ponds, and channel protection that helps the site hold a larger volume of stormwater over a 24-hour period. Castle was able to phase the site into packages to incorporate time for design reviews and long-lead permits into the schedule, while also allowing site construction for the building pad to begin before architectural design was completed. This shaved almost a year off the schedule. By utilizing design-build to deliver the site, the owner was able to competitively bid and evaluate the vertical construction component to obtain the best value and expedite the project.

GBT Realty Corp.

The Shoppes at Mid Rivers — St. Peters, MO

Situation and Challenges:

The $7.6 million, 28-acre site development project supported construction of a $54 million, 270,000-square-foot shopping center with 14 buildings located at the interchange of Interstate 70 and Mid Rivers Mall Drive. The project was fast-tracked to meet the goal of completing work by Fall 2017, so the facility would be open for the holiday season. 

 Castle self-performed:

  • Installation of 8,835 linear feet of silt fence.
  • Clearing and grubbing.
  • 44,000 cubic yards of grading.
  • Import of 38,800 cubic yards of structural fill.
  • 138,284 square yards of fine grading for building/ parking areas.

Subcontracted scope included building demolition, retaining walls, site concrete, asphalt pavement, traffic signals, site lighting, landscaping and irrigation.

Results:

Castle was integral in keeping the project on schedule, enabling vertical work to begin in February 2017 after breaking ground in November 2016. In four months, Castle delivered a pad-ready site and brought all major infrastructure to the site within five feet of the building, including installation of 5,700 linear feet of water main, 1,400 linear feet of water/ fire service, 9,039 linear feet of storm pipe and 57 storm structures, 4,462 linear feet of PVC main, 20 manholes, 930-foot laterals, four grease traps and 11,000 linear feet of dry utility conduit. Scope also included pavement removal and grading at North Outer Road for road widening project. Work was completed with zero incidents on over 26,000 self-perform hours on the job.

Contact

Aaron Retherford
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