Corning Distribution Center is a built-to-suit Design-Build regional facility in Tarboro, NC. The project includes 750,000 SF of warehouse space with a 30,000-SF office upfit.

With multiple loading conditions, deeply evaluating the subgrade reactions for Corning's distribution center was critical in ensuring long-term performance of the slab. Originally designed as a 7-inch-thick slab based on preliminary reviews, upon more in-depth study with the geotechnical and structural engineer, Choate determined the floor slab thickness really needed to be a reinforced 9-inch-thick slab.

A solid understanding of the soil types was critical to that game-changing review. The soil in Rocky Mount appears to have good bearing (3,000psf) and good blow counts (15-20). But look a little deeper, past the upper 15 feet of soil, and you'll find blow counts decreased dramatically (to 2-4). Combining that intel with Corning's future loading conditions, the real (k) value became apparent.

Without the extra two inches, bringing the slab thickness to 9 inches, stress cracks were imminent.

Getting the correct (k) value was critical in leading the team to the correct design for the floor.

Thoughtful Warehouse Design & Construction

To accommodate the client’s specialized manufacturing needs, the facility features 40′ clear heights, 70′ speed bays, racking loads, and order picker traffic. To ensure receiving and shipping efficiency, the warehouse is cross docked.

The warehouse is constructed of load bearing tilt-wall panels and reinforced slabs to account for concrete shrinkage and floor flatness.

Welcoming Employee Areas

Employee wellbeing and satisfaction is valued at Corning, evident in the amenities and finishes found both in the office space and warehouse. In the office, glass storefront and sleek wood accents create a contemporary space that rivals any Class A office. A cafe and dining area provide opportunities for employees to take a break inside while a covered patio with an aluminum fans, crisp lighting and ceiling fans provide a festive outdoor area.

Showers and a mother’s room are available for employees, but even external visitors are not forgotten. Corning set up rest stations within the warehouse for visiting truck drivers, providing a convenient space to unwind, use the restroom, or grab a bite to eat.

Maximizing Site Efficiency

Storm water management is key to maximizing this site’s possibilities including retention, discharge, mitigation.