Fourth District Court of Appeal
Gate Precast Company

Involved Companies

Background

The client requested a modern courthouse with a large courtroom being the central focus. The site selected was an existing surface parking lot in the center of downtown. The façade of the courthouse is a combination of precast concrete, cast stone, and precast concrete 40-foot architectural columns. The three-story courthouse building includes a secure public lobby; one courtroom, 14 judicial suites, and a courtyard on the second floor located directly above the courtroom. Parking is provided in the new parking garage (100,742 sf) located behind the courthouse.

The architect originally planned for the entire building’s façade to be constructed with precast concrete for its high-quality appearance and durability. The project is pursuing LEED Silver Certification.

Schedule

The project was completed on time and on budget despite two hurricanes during its 18 months of construction. Hurricane Irma hit Palm Beach County in September 2017; about 11 months after Hurricane Matthew impacted the area in October 2016.

The interior lobby columns were installed first due to their position under the structure. The installation of the exterior columns followed. The adjacent parking garage and courthouse were constructed simultaneously. Each had to be sequenced so the main crane and truck road could be shared without any construction interruption to others. Reduced access limited crane size. The crane had to be positioned on the north side for the installation of components on the north half of the project and positioned on the south side for the south half. The crane had to travel back and forth from south to north then north to south as column halves were erected from east to west, inside to outside.

Once columns were placed, steel framing was completed and roof joists installed. The precast concrete pediment pieces followed in the erection sequence.

Design Challenges

The 40-foot architectural precast column covers were challenging to install due to overhead power lines bordering the public entrance.

While the project shell was being constructed, precast column cover erection was choreographed with the structural steel erection. Steel columns cantilevered from the foundation and were braced east to west to structural framing. X-bracing provided stability north to south. Steel framing and bracing needed a minimalistic approach as 40’ tall x 5’-6 wide columns were threaded through and around framing and rotated into position.

The installation of the interior/understructure lobby columns was challenging as well. These heavy, awkward, coped pieces were carefully placed.

Another key design challenge was to make components as large as possible to minimize joints and to conceal all connections behind the precast or within precast joints.

Meeting the design requirement to maintain building tolerances within ¼” was critical. The glass for the gable end of the pediment was ordered ahead of time and had to fit the rough opening precisely.

Innovations/Accomplishments

Utilizing innovative construction techniques, the courthouse’s massive columns were placed carefully to avoid hitting the power lines or poles. Each column was hoisted above the pre-built steel superstructure protruding from the building before lowering each column into position. The method of installing the interior columns was unique. The columns were rolled in with large carts and erected with cables threaded through the upper floor and rendered into position with chain falls supported on stanchions supported on the upper floor.