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Manhard Consulting Designs Site Plan for Construction of World’s Largest Yogurt Production Facility

Manhard Consulting Designs Site Plan for Construction of World’s Largest Yogurt Production Facility
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Manhard Consulting Designs Site Plan for Construction of World’s Largest Yogurt Production Facility - 1

Advancing Infrastructure Project Summary Organization: Manhard Consulting, Ltd. Solution: Land Development Location: Twin Falls, Idaho, United States Project Objective: • Improve site infrastructure for 200 acres of land to support the world's largest yogurt production plant. • Minimize time and costs associated with earthworks analysis and site grading. • Meet the aggressive schedule imposed by client. Products used: SITEOPS Manhard Consulting Designs Site Plan for Construction f World's Largest Yogurt Production Facility Bentley SITEOPS® Facilitates Project Delivery within an Unprecedented Time Frame Fast Facts • Chobani invested USD 450 million to build its yogurt production facility in Twin Falls, Idaho. • Manhard used SITEOPS to develop the 200 acres of sloping terrain to accommodate the 939,000 square-foot building pad. • SITEOPS facilitated collaboration and enhanced decision making between Manhard and the general contractor, optimizing optioneering. Using SITEOPS reduced the schedule from ground-break to building pad delivery to an unprecedented 326 days, requiring 2,000 workers and 1.7 million resource hours to build. SITEOPS provided a solution that kept earthworks and grading costs to a minimum. The new Chobani production facility created over 300 jobs and continues to promote economic growth in Twin Falls, with a USD 1 million expansion recently announced. Aggressive Design-build Schedule Headquartered in Norwich, New York, Chobani, LLC is best known for suppling its number-one-selling Greek yogurt to millions of people across America. When its New Berlin facility reached maximum production capacity due to increasing consumer demand, the company had to instate additional manufacturing space to capitalize on "Without the power of Bentley SITEOPS, the critical site planning decisions never could have been made at such an accelerated pace." — Frederick Thaete, Director of Engineering, Manhard Consulting the momentum of the Chobani brand. Chobani contracted Tippmann Construction to design and construct a nearly 1 million square-foot facility production and distribution plant to be located in Twin Falls, Idaho. The contractor turned to Manhard Consulting, a full-service civil engineering and surveying firm, to assist with the land development phase of the project and complete a site design under the aggressive schedule mandated by Chobani. To deliver a site master plan for this fast-track USD 450 million project, which included grading and earthworks analysis, infrastructure design, and stormwater management, Manhard relied on the conceptual design capabilities of Bentley SITEOPS. The innovative use of Bentley's civil site design software enabled project engineers to produce site designs faster, and provide more land development options to the general contractor, creating an informed project lifecycle. Working with Terrain Constraints Faced with 200 acres of sloping Idaho terrain that would impact the site layout and ground elevations linked to a 939,000 square-foot building pad, Manhard needed to work closely with Tippmann to make decisions quickly and accurately. The abbreviated timeline imposed by Chobani together with an aggressive design-build schedule required close coordination between the Manhard team, Tippmann, and various other consultants involved in the design of the production facility building. With all grading constraints associated with the logistics of arriving milk supply trucks, finished product truck maneuvering, truck docks, and other support services, a traditional approach to site layout and grading would take too long and would likely throw the project off schedule, resulting in an ineffective solution. Furthermore, stormwater drainage also needed to be considered to minimize the total area of ground disturbance. Employing a traditional iterative process would have required Manhard's project engineers to design a grading scheme and perform earthwork analysis, which would likely add weeks to the project schedule. Based on the analysis results, the engineers would then have to modify the grading design and perform a separate analysis to achieve the desired work balance condition. To accommodate these challenges and provide viable options to its client, Manhard required an innovative, integrated design approach. Optioneering and Collaboration The exact placement of the facility on the site was highly variable. With each modification the grading design, earthwork balance, and ultimately amount of time needed

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Manhard Consulting Designs Site Plan for Construction of World’s Largest Yogurt Production Facility - 2

“The mission of delivering the project within the unprecedented time frame requested by the client would have been virtually impossible without utilizing SITEOPS.” – rederick Thaete, F Director of Engineering at Manhard Find out about Bentley at: www.bentley.com to complete the earth-moving operations was in flux. Using SITEOPS, Manhard analyzed earthworks and generated multiple site design options with associated costs in a matter of days, as opposed to months. The ability to work in real time with Bentley’s conceptual design software streamlined collaboration, enabling the teams to sit...

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