MWAA Rail Yard and Maintenance Facility

The Metropolitan Washington Airports Authority (MWAA) Rail Yard and Maintenance Facility in Dulles, VA is part of the Silver Line Corridor project. In 2015, The Shockey Precast Group (SPG) was contracted by Hensel Phelps Construction to design, manufacture, and erect approximately 180,000 SF of precast insulated wall panels for the project. The scope of work was comprised of six steel buildings with precast concrete wall panels and flat slabs utilized as the main lateral force-resisting system, and one total precast storage building for the Metro Silver Line extension.

SPG played an integral role in the overall building design, serving as the precast engineer of record for this design-build project, with drawings issued to MWAA, WMATA, and Loudoun County for final permit approval. The project’s high-efficiency, LEED-certified design included insulated precast wall panels that incorporated multiple architectural mixes, with a variety of finishes throughout the project. A charcoal-based color was selected as the primary color for the precast wall panels, with contrasting white highlights and sandblast finishes to accent windows and other openings. Most of the wall panels featured an acid-etched finish to accentuate the natural aesthetics of the concrete.

The project’s tight original sequence of design, production, and erection presented numerous challenges, including an aggressive erection schedule that forced precast production to begin before full design approval. Production variances related to insulation reveals were identified early in the project and successfully resolved in the field post-erection. Additionally, SPG utilized multiple types of insulation and connections to account for the variety of panel loading conditions. Further, erection progress proceeded more slowly than expected due to unforeseen challenges. These unexpected issues presented SPG with the opportunity to develop a deeper understanding of the customer’s end-use and intent regarding specific design features, and provided growth opportunities in working closely with the Owner and GC to achieve the Architect’s vision. Through innovative thinking, collaboration with other trades, and open communication with the project team, SPG helped bring the MWAA Rail Yard and Maintenance Facility to successful fruition, delivering a project that met the Owner’s needs and schedule, and fulfilled the Architect’s aesthetic vision.

Location: Dulles, VA
Owner: Metropolitan Washington Airports Authority
Architect: Giuliani and Associates Architects
General Contractor: Hensel Phelps Construction
Size: 180,000 SF
Completed: 2017




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