SAFETY ONSITE
In addition to routine safety precautions, building an aquarium also required flotation devices, life vests and other life-safety equipment that was staged nearby to protect individuals suspended over water- filled exhibits. Other safety measures included controlling silica dust during the large-scale interior demolition and excavation, ensuring safe access to confined tank spaces and maintaining consistent indoor environmental quality.
Temporary bracing was erected to support the existing structure while individual sections were demolished and replaced with a new self-supporting structure. On the second level, the use of lightweight aerial lifts with outriggers ensured weight remained under loading limits.
A separate safety plan developed for the rockwork/theming contractor emphasized the safe use of high-VOC products. Installation of above-and-beyond air exchangers helped ventilate workspaces during the application of specialty coatings on tanks and themed features.
Minimal use of gas/propane-powered equipment and the strategic placement of fans ensured exhaust rose above work areas, mitigating carbon-monoxide risk throughout the interior environment. The team also followed meticulous procedures for moving trucks in and out of the site to protect pedestrians in the high-traffic, urban area outside the fence.
TECHNOLOGY TRANSFORMED HISTORICAL ARCHITECTURE
Laser scanning of the entire aquarium footprint within the existing building enabled the team to identify various columns, walls and foundation conditions that did not match as-built drawings so they could be adjusted on the design documents before negatively impacting the project.
McCarthy’s subsurface utility mapping group used an electromagnetic locator, Sonde camera and acoustic pipe locator to gain a better understanding of the existing underground infrastructure and proactive- ly address subsurface concerns to mitigate project changes and risk. Utility location data collected by an onsite total station was subsequently developed into a BIM deliverable for use in BIM coordination with other trades.
McCarthy’s virtual design and construction (VDC) team then worked closely with the company’s subsurface utility mapping professionals to model existing underground utilities to accurately coordinate subsurface conditions with other new utilities prior to the installation of new foundations and piers.
Throughout the design and construction phases, early design team collaboration and 3D building systems coordination was key to keeping the project on schedule and helped facilitate owner buy-in of the aquarium’s complex MEP/FP systems prior to fabrication and installation, ensuring long-term maintenance and accessibility.
Laser scanning of all acrylic panel installations created 3D models of the frames with thousands of data points that could be compared to the manufacturers’ 3D models to detect any physical abnormalities before installation. This process enabled McCarthy’s field team to identify—and correct—a minor discrepancy on the aquarium’s largest glass panel, which weighs nearly 14,000 pounds, before installation.
The 3D modeling of concrete lift drawings for field coordination with McCarthy’s self-perform concrete team saved time and potential rework by combining all information into a streamlined, coordinated set of graphical, easy-to-understand drawings.
CONSTRUCTION QUALITY AND CRAFTSMANSHIP
McCarthy created mockups to authenticate the optimal concrete placement method for the 1,145 cubic yards of aquatic concrete that form the walls of each exhibit habitat. The 4,000 to 5,000 psi specialty concrete included antimicrobial and moisture-mitigating admixtures.
Photos: McCarthy Building Cos. Inc.