Meeting a project deadline is one thing. Meeting it four
months early is another. Especially when that allowed the project, a new tower
at Harrah's Cherokee Casino & Hotel, to open in time for the profitable New
Year's Day holiday. But that is just part of the reason why Turner Construction
Co. of Charlotte won the 2011 GC Project of the Year recently in the 2011
Excellence in Construction Awards competition presented by The Associated
Builders and Contractors of the Carolinas (ABCC).
The winning general contractor effort was a 21-story,
532-room, 459,509-square-foot hotel tower that included 78 suites, 454 guest
rooms and a sky bridge connecting it to two existing hotel towers. . Turner, a
national construction company that has Carolina
offices in Charlotte, Raleigh
and Charleston,
began construction on this $120 million hotel in July 2009. The hotel is just a
portion of the $633 million expansion program going on at Harrah’s Cherokee
Casino and Hotel. Among the obstacles it faced was a "no-excuses"
deadline, the need to get the tower occupied as soon as possible, and the unrelenting
winters in western North Carolina.
To meet the challenges of the tower project, Turner used
LEAN scheduling and principles, building-information modeling and integrated
project delivery with its subcontractors and design team. All contractors had
to produce weekly work plans that defined workflows, and Turner had a full-time
scheduling engineer on site, who spoke with foremen for contractors and
subcontractors every day to monitor progress.
In addition, Turner monitored activity on other projects at
the site, including a general contractor who was building two parking decks. It
held weekly meetings with the other contractors and Harrah's staff to go over
site logistics, to make sure everyone knew what would be going on everyday and
could plan accordingly so as not to negatively affect other work or Harrah's
guests. LEAN principles used included: anticipating problems as soon as
possible, slowing down when necessary to get quality right the first time,
stopping to fix problems, analyzing the situation constantly, and empowering
employees to identify problems.
“One of our key challenges was to erect this concrete frame
building in a remote, mountainous location through a very harsh winter of rain
and snow,” said Robert Thompson, operations manager of Baker Concrete
Construction. “We were able to use the pre-construction period to carefully
plan for a just-in-time delivery of materials. The planning and coordination
paid off. The concrete floors were placed averaging one floor per week. This
enabled us to meet the target for the expedited schedule.”
Despite the accelerated pace, the company also stressed
safety during the project, according to Thompson. "As important as
schedule and revenue are to a project, nothing is more important than safety,”
he said. Working under Turner's safety program, Baker was able to erect this
21-story hotel without a single lost time injury.
“About 17% of the contract value was awarded to
subcontractors and vendors certified by the Tribal Employment Rights Office,
providing additional work for members of the Eastern Band of Cherokee Indians.
That didn't go unnoticed. Scott Robertson, area director of design and
construction for Harrah's Entertainment, says Turner was easy to work with.
"They have performed with excellence in both preconstruction and
construction," Robertson says. "We challenged them to meet an
aggressive and expedited schedule. Their achievement enabled Harrah's Cherokee
to market the Creek
Tower for our busiest
weekend of the year." He praised the company's use of cutting edge
technology. It "ensured our expectations were met and our revenue
maximized," Robertson says.
Ultimately, it set a standard for the hotel complex.
"This is the first time of the Harrah's Cherokee history that any major
project was delivered on time," says Ray Rose, project manager for
Harrah’s/Eastern Band of Cherokee Indians. "Turner delivered on their
promise."
The company also lived up to expectations in working with
tribe members. "Turner has embraced the TERO program and … provided many
contracting and employment successes, says Curtis Wildcatt, compliance office
for the program. "Turner has made great efforts to ensure the Cherokee
people benefit from this employment and economic opportunity and has cooperated
well above all my expectations."
That's not the only way the company worked with the tribe.
During a topping-off ceremony in April 2010, it began the day with a
traditional prayer to the seven spiritual directions of the Cherokee, offered
by a tribal elder. Jim Owle, chairman of the tribal council, praised other
efforts by the company to become part of the community. "Turner partnered
with the Tribe to create the Madison Hornbuckle Children's Cancer Foundation,
which raised more than $100,000 in its inaugural year," he says.
Turner brought together companies from around the country
for the project. It was designed by The Cuningham Group, an architectural firm
based in Minnesota, while the mechanical and
electrical design engineers, Xn-th, are located in Las
Vegas and Orlando,
Fla. The team used electronic
submissions and requests for information to keep everyone looped in during the
construction process. "This was our first opportunity to work
together," says Michael Strand, AIA principal at The Cuningham Group,
"and during that time, I have developed a high regard for their ability to
manage the construction of this complicated, multifaceted project, and I was
struck by their ability to understand the complexity of our design."
And it was complex. The tower featured a waving roof form
designed to complement the surrounding mountain
view. Other features included a VIP check-in area,
fire lounges, a café/bakery area and floor of "super suites." Custom
light features hang throughout the main lobbies, and one of them uses fiber
optics that can be customized to change colors.
The building is a post-tensioned concrete structure with
structural steel on the 21st floor and lower porte cochere, which rests on
pilecaps and auger-cast piles. Exterior finishes include stone, stucco, trespa
panels, and a curtain wall system. Floors one and two contain the main lobbies
for the tower, along with stores, a café, a fire lounge and an arcade.
The porte cochere provides the main entry and valet for the
entire hotel complex. Floors three through twenty contain rooms and two-bay
suites, while the top floor consists of
eight themed suites and two "super" suites, which all have exterior
balconies overlooking the dramatic views outside.
Turner also has won a $100 million contract to expand the
Harrah’s Cherokee casino. The project, which is scheduled for completion in
January 2013, will add 110,000 square feet of gaming-floor area to casino while
renovating the existing 130,000 square feet. It also will provide new modern
bars, restaurants and entertainment stages to the casino and hotel, add a
70-foot interior waterfall and a rotunda that will change lighting and sounds
with the seasons.