Nestlé , the world’s largest food and beverage company was looking to relocate its USA headquarters from Glendale, CA, to the Washington, DC, metro area. The new location of the headquarters was determined to be 1812 N. Moore St, a 34-story commercial building located in Arlington, VA. To accommodate the new tenant, the building owner was tasked with performing modifications to the existing building layout.

One of the requested alterations was to install a large stair tower from floors 26 to 33 with the goal of creating an open space spanning eight floors. In order to achieve this request, large openings (approx. 23’ x 28’) were created in the slab.

General Contractor

Davis Construction
Subcontractor

Freyssinet, Inc.
Owner

Nestlé
Project Duration

August 2017-December 2017
Location

Arlington, Virginia

Freyssinet's Scope of Work

Freyssinet was contracted to provide structural strengthening to account for the loss in strength resulting from the openings without the need for additional steel reinforcement. Ultimately, the project objective was to maximize the ceiling heights and maintain the open space concept requested by Nestlé.

The scope of work for this project consisted of installing 5,000 SF of CFRP on the underside of the slab around the openings on floors 26 through 33.

Our first step was providing the necessary dust containment enclosure to adhere to the OSHA Silica standards in addition to providing a safe work zone to other workers in the vicinity. One of the challenges encountered was primarily caused by the fact that this project took place in a commercial building with very limited airflow. Additionally, windows could not be opened to ventilate the work area. As a result, Freyssinet was responsible for installing tightly sealed enclosures on floors 26 through 33 to perform shot blasting operations.

Freyssinet used a reusable rubber blasting medium, which is designed to help minimize dust creation resulting from blasting operations. Air scrubbing and filtration equipment were also put in place to minimize silica dust exposure.

Freyssinet Installs CFRP and Repairs Nestle Headquarters in 2017

CFRP Surface Preparation at Nestlé Headquarters

The concrete surface needed to be prepared to a CSP-3 profile to ensure an optimum bond between the CFRP and the concrete. This was achieved using sandblasting, which was difficult to facilitate in the occupied commercial environment on the 30th floor with no ventilation.

In order to overcome this challenge, Freyssinet procured a 900 cfm air compressor for the duration of the project. Freyssinet crews then had to run approximately 400 linear feet of hoses from the compressor up 33 floors to access each work area. Crews had to safely secure the hoses up the stairwells, while still providing means of egress in case of emergency. The hoses had to be taken down at the end of each work day and re-installed the following day.

Once the required surface profile was achieved, Freyssinet proceeded with the CFRP application process, following the manufacturer’s recommended application methods. The job site was then thoroughly cleaned prior to demobilization.

Project Completion

Freyssinet completed the work on time and according to schedule, despite challenges, within a 4-month timeframe from the time of award to demobilization.

Nestle Headquarters CFRP Application

Building Solutions

Building maintenance presents ongoing challenges for operators. As a specialist main contractor, Freyssinet helps refine structural maintenance strategies and delivers customized solutions to repair, strengthen, and protect your building.

Discover Our Solutions

Structural Strengthening

Through Freyssinet's Foreva® solutions and turnkey services, we enhance the structural strengthening of your assets—improving safety, durability, and long-term maintainability.

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Building Solutions

Discover Our Solutions

Structural Strengthening

Through Freyssinet's Foreva® solutions and turnkey services, we enhance the structural strengthening of your assets—improving safety, durability, and long-term maintainability.

Learn More

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