ASCENT CASE STUDY

Auto Dealerships Sold On Precast Concrete Structures

pci.org
Click for more

Multistory precast concrete designs save real estate, provide protection and create secure storage while boosting sales for auto dealers around the country

20

utomobile dealerships around the country are understanding the marketing advantage that Bev Smith Ford in Lake Park, Fla., gains from being able to tout its Four Floors of Fords! The boast results from the dealer building a four-story precast concrete parking structure adjacent to the showroom that provides more storage in a small space. Other dealers have expanded that concept a step further by creating multistory showrooms from precast concrete components, putting display space and the parts department on the first floor and using upper floors for inventory and added showroom space. The design concept offers significant advantages by allowing better use of real estate, providing weather protection, securing inventory better and offering expanded showroom space thats flexible and energy efficient. Dealers both above and below the Mason Dixon line are finding that precast concrete structures make sense in their geographic locations. It was the best investment we have made, says Joe Pepe, owner of Pepe Motors in White Plains, N.Y. The dealership created a precast concrete parking facility on its tight sight that saves the company considerable manpower and time each winter. It protects inventoried Mercedes-Benz and Infiniti autos from snow and salt while keeping them nearby for customer viewing. That cuts waiting times and makes the dealership more efficient. It makes perfect sense to keep cars under cover in the Northeast.

The total-precast concrete structure was designed with pretopped double tees, columns, spandrels, inverted tee beams, horizontal lite walls, shear walls and stair risers. About 267 components were used, including a solid precast wall

It was the best investment we have made.

that was built along the property line to allow the facility to be built up to the line. Unistress Corp. in Pittsfield, Mass., produced the components. More dealers are realizing the benefits all the time, says John Tice, principal at Winningham, Bundy & Tice, Architects in Fort Lauderdale, Fla. Weve done quite a number of these, using precast double-tee systems, he says. They usually include the showroom, parts department, service department, everything. Often, the upper floors, which are designed essentially as a parking structure, feature brighter lighting levels and more finish detail to create an extended showroom space. Customers can take the elevator up to the appropriate location to view the desired car. The format saves time compared to storing vehicles off-site and having them delivered by a staff person when needed, quickly connecting customer and car. Autobuilders General Contracting Service in West Palm Beach, Fla., which constructed the Bev Smith project,

ASCENT, SPRING 2004

The three-story total-precast concrete building constructed for Pepe Motors in White Plains, N.Y., provides inventory space for up to 500 Mercedes-Benz and Infiniti automobiles. The building reduces waiting time for cars to arrive and provides year-round weather protection.

specializes in this type of construction. The company recently finished six such projects and has four more being designed, says J.J. Wolfe, executive vice president. All of the dealerships we build now use this format. The company works closely with Coreslab Structures (MIAMI) Inc. in Miami, Fla., to create the precast concrete designs.

Better Use Of Space

Existing dealerships are running out of room and need space to expand, he explains. The precast concrete structure can be erected on a tight site, dramatically increasing the storage space

Wayne Akers Ford in Lake Worth, Fla., features a 70,000-square-foot total-precast concrete design that includes the showroom, parts department and service center with 43 service bays. The design was created by Popper & Associates Automotive Facilities Consultants Inc., with precast concrete components provided by Coreslab Structures (MIAMI) Inc.

available. But even more advantages are gained when the designs are planned from initial construction, he notes. If you incorporate this type of structure when youre first planning a dealership, you dont need to figure on needing so many acres of land for cars. In some cases, dealers even are designing precast concrete structures with an eye toward further expansion, says Freddy Lee, architectural designer with Popper & Associates Automotive Facilities Consultants Inc. in West Palm Beach, Fla. One project currently on the boards will feature a service and parts departments on the first floor with inventory storage overhead. But the columns and double tees on the roof are being designed so additional floors can be added later. In addition, inverted tee beams are being notched to provide ledges for further horizontal expansion if desired. Its easier to build horizontally, because you can quickly add another square next to the existing one, he says. But its not always possible to have that much land available.

Protection Is Key Benefit

The benefits these designs provide dealers are substantial. Foremost is protection from the elements, whether in the north or south. The ability to house autos within the showroom building out of the weather is very handy, says Tice. In the south,

protection from rain is important, as is shade from the bright sun to help keep the car finishes from fading, says Wolfe. Protection from theft and vandalism also is enhanced by storing them in a secured, durable structure. Some local municipalities, in fact, have instituted

Nobody can tell me that a steel-frame building is better.

Knoxville, Tenn., for instance, double tees were deepened to 32 inches from the standard 24 inches to meet the fire codes. Tindall Corp. in Spartanburg, S.C., provided the precast components for that 152,524-square-foot, threestory project. Precast concretes durability is a significant point in its favor, especially in Florida, where building owners worry about hurricanes, notes Poppers Lee. Nobody can tell me that a steel-frame building is better, he says. They are more costly, and they cant withstand the airborne-debris [hurricane] the way precast concrete can.

21

West Side Honda in Knoxville, Tenn., used a total-precast concrete structural system to design its showroom, which includes storage space and a service center on the first floor. The 152,524square-foot building features a parts department on a mezzanine level.

ASCENT, SPRING 2004

You can more easily secure your inventory in a precast concrete structure.

ordinances against storing autos in large, open spaces, notes Tice. Security measures are becoming more important today, he says. And you can more easily secure your inventory in a precast concrete structure. Fire safety also is enhanced by the precast structure, notes Wolfe. Precasts inherent fire resistance ensures it wont contribute to a fire spreading. Double tees also can easily provide the required fire separation between upper auto-storage levels and lowerlevel showroom and service areas. At the total-precast concrete design used for West Side Honda dealership in

Lexus of Watertown in Watertown, Mass., constructed a three-story precast concrete structure on a 3.6-acre site to provide sales, service and storage facilities for its inventory of cars. Northeast Concrete Products LLC in Plainville, Mass., produced the precast components.

Precast Aids Design

The ability to produce long, clear spans also aids design flexibility when using precast concrete components, architects say. For the Lexus of Watertown dealership in Watertown, Mass., for instance, Regent Associates Inc. architects used two 70-foot-long double tees to create a 140-foot-wide space that allowed for the long spans required for a vehicle service facility. This was a more complicated building than the usual type that dealerships often build, says designer Mark Regent, principal in the Worcester, Mass.-based design firm. But where real estate is at a premium, and storage space cant be found, incorporating a parking structure offers a real solution.

Lou Bachrodt Chevrolet in Coconut Creek, Fla., features a 207,480-square-foot total precast concrete structure to house 400 cars, as well as offices and a parts department, 45 service bays and a car wash. Coreslab Structures (MIAMI) Inc. provided the components for the project, which was designed by Popper & Associates Automotive Facilities Consultants Inc. in West Palm Beach, Fla.

Fairbanks Chrysler/Jeep/Dodge in Tamarac, Fla., was designed to feature a two-tone showroom across its front (with display vehicles overhead) and an expansive space for inventorying vehicles stretching out behind it. The three-story facility includes additional parking on its roof. The total-precast concrete design was constructed by Autobuilders Inc., with precast concrete components provided by Coreslab Structures (MIAMI) Inc.

Au t o b u i l d e r s Wo l f e a g r e e s . These buildings are designed for cost effectiveness and efficiency. His company uses designs that incorporate external speed ramps, which open up higher-level interiors and ensure flat, easily accessible space throughout the building. We often create 75-foot open spaces using double tees, he says. They ensure there are no layout issues. Energy efficiency also is enhanced with the precast concrete system, Wolfe notes. By adding more levels above the showroom and parts departments, we dont have the sun beating down on the showroom roof, he explains. That allows some dealers to more easily air-condition their service and parts departments, which works as a marketing tool to hire mechanics and other service people easier. Other dealers are beginning to catch onto this and air-condition their spaces to compete for top employees, but the

The Pines Auto Plaza in Pembroke Pines, Fla., includes Lexus and GMC dealerships along with a detached body shop and car wash. The service and body-shop portions feature precast concrete joists, which allow parking on the body-shop roof. The project was designed by Winningham, Bundy & Tice Architects, with Autobuilders serving as general contractor. Photo: Aerial Photography, Inc.

costs are higher without that added overhead protection, he says. Even one-story structures benefit, designers say. By designing with precast concrete components, the roof can be used for parking autos, including employee cars. The design frees up real estate, making more efficient use of every square foot. If youre creating even a one-story building and using only the ground level, youre wasting space, says Poppers Lee.

Speed To Market Helps

One of the most critical factors in favor of precast concrete structures is their speed to market, all agree. The ability to cast components as site work, approvals and drawings progress allows the precast structure to begin erection as soon as everything else is ready. Everybody loves the speed, says Tice. Dealers are always on a tight schedule and want their showrooms to be generating revenue. Wolfe agrees. Precast is way faster than any other type of concrete, he says. In the south, the companies work as fast as they can through the winter to beat the summer rains, and precast ensures that happens. It also helps enclose the structure quickly, speeding the timetable by

which interior trades can begin work, which aids the process even more. We cant lay carpet, do interior finishes or start drywall if its raining every day and we dont have the roof on yet, Wolfe says. We need that roof, and precast concrete encloses the space quickly so we dont have to worry about that. Precast concretes speed is an allimportant factor for us. Tice agrees. Its a real benefit to get that structural shell up so others have something to work inside of.

panels hung on a steel frame. But when the estimates came in, there was no real advantages, especially with the longterm maintenance needs that would have been required, such as keeping the steel painted, says Regent.

Many Finish Options

A wide range of finish options help precast concrete structures blend with any existing buildings or create a dramatic, attention-grabbing appearance. Stone, brick and other finishes can be replicated easily. We use a variety of finishes, and its never a problem, says Tice. Ironically, precast panels even can be designed to replicate exterior insulation finish systems (EIFS), such as the one used on the Lexus of Watertown showroom, which is mandated by Lexus. This must be the first time that a precast concrete finish had to replicate the look of EIFS, Regent says. A buff cement was used in the mix to create the needed warm, gray tone that Lexus dealerships feature. Autobuilders has used a variety of finish designs, particularly on the firstfloor showroom space, which sets the tone for visitors. Weve tried other materials, but they dont work as well,

23

Weve tried other materials, but they dont work as well, so now were using precast concrete panels as often as possible.
Long-range maintenance needs also help boost precast structural systems, reducing costs over the life of the building. Designers on the Lexus of Watertown project, for instance, briefly considered a hybrid design, with precast

ASCENT, SPRING 2004

Central Florida Chrysler/Jeep/Dodge in Orlando, Fla., features an elaborate four-story design plus additional parking on the roof, using a total-precast concrete structural system. The design was constructed by Autobuilders Inc. with precast concrete components provided by Coreslab Structures (MIAMI) Inc.

24

so now were using precast concrete panels as often as possible, Wolfe says. Speed and appearance are the deciding factors. Using precast panels on the first floor speeds up the process and ensures a consistent look throughout the building. Using another material on the first floor that has to be matched to upper spandrels produces unsatisfactory results, he says. The need to paint and keep repainting complicates the project, especially when we can achieve the look we want with precast panels. The range of options ensures design flexibility, notes Seymour Gage, principal at G.A.L. Associates in Pleasantville, N.Y., the architectural and structural engineering firm for the Pepe Motors project. His firm recently completed a dealership in Schenectady, N.Y., that featured thin-brick insets on the wall panels. You can achieve the same appearance with precast concrete as with other materials, so aesthetically theyre comparable. And precasts ability to panelize the masonry ensures a uniform, attractive look that is quickly erected without labor congestion on the site.

Receiving all materials from a single source of supply not only enhances appearance consistency and minimizes site congestion, but it ensures fewer field adjustments and a faster process overall, designers note. With one supplier providing the manufacturing, delivery and erection, the precaster offered everything from top to bottom, except for the foundation and mechanicals, says Gage. It really eliminates a lot of the complexity that comes with these projects.

level work as a showroom and service center. This requires taller ceilings, typically at least 14 feet, than a standard parking structure with retail or office space on the first floor, explains Tice. As a result, ramps to the second and upper floors must be longer. Marrying this variety of functions together takes more design work than a traditional showroom or parking structure would require, says Tice. Poppers Lee embraces the added height. He increases that minimum a little further and creates a mezzanine or split-floor design in first-floor areas that dont require the extensive height of the service department. The other key concern is ensuring the open environment of the upper parking levels doesnt create a problem for the lower contained floors. You have to ensure that its watertight, but that can be achieved easily with topping and caulking, says Lee. Weve never had a problem with a precast concrete structure. They wont leak. At West Side Honda, factory-topped double tees were used, with the joints caulked and waterproofed, essentially creating a sealed rooftop for the lower floor. Upper floors also were sloped more than is typical to provide faster drainage. The advantages provided by these systems have more dealers examining the potential, say designers. Dealers are beginning to see a precast design in their area, and they want their own just like it, Lee says. Theres a great potential to do more of them. We definitely expect to do more in the future. Adds Wolfe, People are paying attention now, so there are absolutely more being done. Craig A. Shutt

ASCENT, SPRING 2004

Minimal Design Challenges

There are some design challenges that must be considered when creating these structures, architects pointed out. Foremost is the need to make the first

pci.org Click For More

For additional information on this story, visit www.pci.org/pdf/knowledgebank/ dealerships04.pdf. (Adobe Acrobat version 4 or greater required.) To learn more about total-precast concrete structural systems, visit the Designers Knowledge Bank by clicking on the DKB icon at www.pci.org or at your local precasters Web site.