Cottrell, Inc. Manufacturing Plant

The first step in this monumental project was readying the ground for the development. Due to the client’s delivery goals, wetland permitting, and the location of the project atop a mountain, the team developed a phased approach to the extensive earthmoving and grading required to reshape the mountain terrain and ensure a schedule with no delays. Starting in 2022 – one of the wettest winters in Gainesville’s history – the team cut the mountain in half and began the massive grading needed for Cottrell’s new manufacturing facility. In the end, more than 1,800,000 CY of dirt and rock was moved, but not removed.

Rather than remove the graded earth from the site, the team chose an innovative approach and reused 35% of the blasted rock for soil stabilization, with the remainder repurposed across the site. This undertaking required 30 graders to work simultaneously for nearly 40 weeks, saving the project more than $2 million. Through a detailed site analysis, the Choate team guided trade partners in the cut-and-fill process (up to 60 feet for both) to adjust the final contours and create a balanced site for long-term stability.

What began as a 400,000-SF rectangular structure evolved into a 545,000-SF manufacturing plant with a layout uniquely designed to optimize Cottrell’s equipment assembly and production flow. The design of the 522,000-SF assembly space and 23,000-SF office space customized to maximize the production process, given the size and unloading requirements of Cottrell’s finished trailers.

With the help of Choate’s virtual design and construction department, VirtualWorks, the team used VR technology to provide walkthrough models for the client to showcase precisely how recommendations and design adjustments could help build efficiencies for production and maximize the client’s bottom line.

Beyond serving as the general contracting partner for this project, the Choate team became the facilitator and guiding point at every facet of this new business venture for Cottrell, building a deep level of trust to execute a successful project and ultimately deliver a product that will alter the course of the manufacturer’s future and solidifying its industry-leading position for decades. Helping the client navigate uncharted waters, including introductions to the design community and process engineering experts, the project team’s innovation, thoughtful project management approach, transparent communication, and ingenuity ensured the client’s vision became a reality.