Foundation of Excellence
Throughout the CAT Lehigh Valley project, the Wohlsen team faced a series of complex challenges but turned each obstacle into a triumph through collaboration, expertise, and meticulous planning. The project site, an existing uncontrolled fill area, presented numerous unknowns that were uncovered through extensive geotechnical testing. To create a stable foundation, the team executed dynamic compaction, utilizing a ten-ton weight dropped from 50 feet in the air, repeating the process over 800 times across the site in a grid-like pattern. Additional soil treatments, including soil cementing and lime stabilization, were applied where necessary to ensure optimal conditions for construction. Beyond the challenges of the site itself, the team adeptly managed the installation of critical site utilities, including drilling a well and setting up an on-site septic system, all while navigating the complexities of vendor coordination for owner-provided equipment. By proactively aligning schedules and ensuring the site was prepared for every phase, the Wohlsen team delivered a successful project despite the hurdles encountered along the way.
Lean-Driven Milestones
This project was brought to Wohlsen in January 2022 with a construction start date in October of 2022, and a completion date of December 2023. This timeline offered the team a ten month turnaround from preconstruction to postconstruction, therefore requiring a quick start to meet the teamâs goals. Weekly meetings with the design team and client allowed Wohlsen to obtain all approvals and the permit to break ground in October of 2022. The use of Lean construction principles allowed our trade partners to collaborate and plan the scheduled activities. The team could also identify and adjust the schedule to meet or exceed milestone dates by scheduling and looking ahead six weeks out. Despite material delays and extensive lead times, the Wohlsen team collaborated with the owner to pre-release critical packages so the materials, such as the roofing insulation, would be on site well before they were needed. The team worked adamantly to install owner-furnished equipment, such as the generator and automatic transfer switch, as soon as possible to ensure these items would not hold up other critical milestones.
Visual Management Implementation
Visual Management played a crucial role in this project, fostering a shared understanding of key information among the team. Using Procore’s collaborative software, the team effectively visualized schedule productivity and sequencing, ensuring that everyone remained informed of daily progress. Wohlsen’s superintendent meticulously tracked on-site personnel, documenting their locations and tasks, while daily huddles maintained open communication, enabling timely issue resolution. The continuous coordination with subcontractors boosted productivity, enhanced scheduling, and elevated the project’s overall quality. With Foley’s priority on operationalizing their parts area swiftly, the team strategically prioritized and adjusted manpower to meet equipment installation timelines, ensuring the project stayed on track.
