A Total Precast Solution
Sanderson Farms, Inc., a Fortune 1000 food company and poultry processor, required a building solution for a new facility (170,000 SF total) to support a wide range of specialized equipment and discreet processes. Precast offered the ideal solution for the complex project with the opportunity to achieve early occupancy with sanitary design elements, inherent fire resistance, clean, smooth, non-porous surfaces necessary for a food processing environment and structural support for large equipment and utility systems.
Precast was designed as the thermal envelope for the variety of room temperatures within the facility from administrative areas to processing and finished product storage areas.
Tindall’s total precast building package and single source responsibility included the technical services and expertise to design, fabricate and deliver a complete precast building system that addressed all of the project requirements from exterior architectural finishes, thermal performance, interior food safety and sanitation design and structural framing systems.
Owner: Sanderson Farms Inc.
Architect: Chas. N. Clark Associates Ltd.
Engineer: Walter P. Moore and Associates
Developer: Sanderson Farms, Inc.
General Contractor: Vaughn Construction
Location: Palestine, Texas
The single source turnkey precast project approach provided many advantages for the project delivery. Tindall's ability to provide the engineering, fabrication, logistics and erection of the total precast structure reduced the number of trades necessary to coordinate the many different design requirements and limited the on-site labor that would otherwise have been required. With an accelerated design and fabrication process, the project benefited by having a single trade that incorporated exterior architectural finishes, thermal building envelope, fire resistance, sanitary design and finishes in process areas, structural support for process piping and equipment in the fabricated precast elements, including insulated wall panels, double tees,beams and columns.
- In addition to the numerous load bearing precast building components, 284 insulated panels were used for the exterior walls.
- Precast erection started on March 19, 2014 and was completed July 8, 2014. Operational date: February 2015.
The exterior architectural design included insulated precast concrete wall panels with an exposed aggregate finish. The insulated precast concrete wall system was used throughout the project in all areas of the facility including the Hatchery, Feed Mill and Processing and Storage areas to achieve a consistant exterior architectural theme while providing the proper thermal properties and interior surface treatments for the variety of room occupancies in the facility including critical sanitary areas for food processing.
The structural system was designed to support suspended loads from ceiling mounted conveyors and pipe systems in addition to large roof supported mechanical and hygienic refrigeration equipment in addition to the code required building loads. The total precast structure system design utilized wall panels as load bearing elements where feasible and all structural elements exposed to process areas were designed with no ledges or voids to provide a clean and sanitary design.
Tindall's in-house engineering team was able to quickly address and incorporate all of the complex building design requirments into the final engineering documents on an accelerated schedule which supported an agressive precast fabrication and erection schedule for the project.