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February 24th, 2009 WOBURN, MA. Tocci is well into construction of Crate and Barrel’s exciting new store at General Growth Properties’ Natick Collection the world-class retail destination located on Route 9 in Natick, MA. Given the new Crate and Barrel’s proximity to other ongoing property improvement projects, exceptionally detailed and well coordinated logistics planning was required. In addition, construction needed to take place during the busy Christmas shopping season requiring a high degree of traffic and pedestrian safety.

The Building Information Model (BIM) was key to our logistics strategy; we utilized a time-infused model to carefully plan each phase of the project. The Project Manager worked closely with the Virtual Construction Coordinator to continually update the schedule and logistics based on the visualizations they created.

Construction Logistics February 2009

Tocci’s Logistics Model

A rendering from the logistics model

We began site excavation and steel erection in the late fall of 2008 to maximize the time and space available to the construction team before the busy holiday season. GGP requested that Tocci and major subcontractors demobilize the construction site to minimal activities and reduce the foot print to maximize parking availability.

Through the use of the BIM Tocci was able to clear the site for minimal activities, reduce the footprint down to 35% of its original size, and free up additional parking. We also produced visual renderings of how the site would look and feel during the demobilization as well as give exact dimensions for fence relocation and coordination.

GGP, Crate and Barrel, and Tocci successfully executed a full site demobilization; reconfiguration; and reduction for 3 Months. After the holidays were over we were to resume work immediately and bring construction up to full speed.

The Crate&Barrel site demobilized for the holidays

February 24th, 2009 WOBURN, MA. Tocci’s Crate and Barrel project at Natick Collection is well underway. Half of the new two story modernist design store extends into the existing parking lot and half takes over space from former tenants and their interior frontage. This configuration provided an irresistible opportunity for Tocci’s graphics staff to use our advanced VDC capabilities for a purely artistic marketing experiment. Of course!

Our designer posed the thought that the large, temporary barrier wall to be erected at the future storefront location to protect mall customers from the ongoing construction was really a canvas for an exciting interactive customer display.

Tocci took views directly from the Building Information Model (BIM), as seen at eye level. We hid the outside walls and exported an image that reveals an accurate view of what they’ll see in a few months. From there Tocci, working in collaboration with Crate and Barrel’s own great graphics staff, added interesting construction statistics such as exact steel tonnage and cubic footage of concrete and so on. And voila! – a blank plywood wall is transformed into an attractive and educational event and a window for loyal and future customers into a small part of the effort that goes into bringing their new Crate and Barrel store to life.

Head over to the Natick Mall in May and see the banner installed!

February 24th, 2009 WOBURN, MA. Crate and Barrel Natick was our first opportunity to leverage direct-from-model fabrication, working with the architect: Teng Associates and The steel fabricator, SteelFab. Because Teng utilized Revit to design the project, SteelFab was able to bring geometry into a program called Tekla for detailing. The model based workflow allowed all parties involved to quickly review issues.

To better understand SteelFab’s workflow, the entire team, Teng included, visited their fabrication facility in Charlotte, NC. SteelFab’s use of Tekla enables them to take advantage of direct to CNC exports. After CNC fabrication, SteelFab utilizes a coding system to keep track of each piece of steel for the project.

This workflow more than reduced review time; it also eliminated field issues, resulting in efficient field execution.

Steel Fabrication Model

Steel Fabrication Facility

Steel Fabrication Installation

The credit crunch is stifling markets, shrinking our workforce, and preventing scores of projects from being built. The irony of our crisis is that opportunity abounds if you know where to look. Market statistics reveal a window of opportunity to radically reduce construction costs for any project that starts by Q3 2009. With swift action we can build your project for up to 15% less and 8% faster than 2008 if we build now.

Tocci is ready to work with you to get your projects “shovel-ready” and in the ground by September 2009. Why then? Do you really think this downturn will be over by then? Nope, but by then we, and more importantly, major construction economists believe the surge of construction orders resulting from unprecedented public sector stimulus spending will result in a dramatic correction – and then a surge in construction commodity pricing. The window is quite likely to literally slam shut. Until then opportunity knocks…

Declining material prices (2009 average with best pricing advantages in Q1 and Q2)

Increased labor availability
Construction jobless rate is approaching 16%. 111,000 construction jobs were lost in January 2009 and over 1M have been lost since the start of the recession. So what’s so good about this? Because in times like these merit based builders and subcontractors pare staff but hold onto their smartest and most productive workers. Studies show overall crew productivity increases 12-18% during significant downturns

Increased advantage of open shop labor
Despite the layoffs and downturn union labor wages will rise 3% on average, according the Department of Labor and the Bureau of Labor Statistics. Inflexible work rules remain in place and neutralize most economy-driven incentive to relax apprentice ratios and increase productivity. In the open shop sector wages are holding but folks are simply appreciating their current jobs more and swinging hammers harder. In addition employers reduce markups to keep their best people on board. The 20% – 35% project savings that have been previously realized through open sourcing construction trades is increasing in this economic climate.

Pent up demand
It’s important to remember the construction downturn is a result of the credit crunch not overbuilding. When the U.S. emerges from this recession basic demand for buildings will also recover. Those clients who start now will enjoy the ripening fruit. Those who can’t or don’t will, wistfully reminisce; “if only I bought my job back in 09…”