REACHING New Heights - Layton Construction

Summer 2012A Quarterly Publicationfrom Layton Construction Companywww.laytonconstruction.com

2 | Nuts & BoltsLayton in the News

10 | Subcontractor ProfileReynolds Excavation Demolition & Utilities

REACHINGNew HeightsATK Aircraft Commercial Center of Excellence | Page 4

12 | The Last WordA Composite Approach

David S. Layton

2 | FOUNDATION | Layton Construction Company

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Surprise

Crashing into the Pac-12Layton teams with Utah Utes to build a new conference legacy

Kyle Whittingham, the head football coach at the University of Utah, took the controls of demolition equipment to signal the start of construction of the new Dee Glen Smith Athletic Center at the university. Entering its second year as a member of the Pac-12, new

football training facilities at the university are critical to compete with conference powerhouse schools. The $27 million, 132,000-square-foot facility will include state-of-the-art sports medicine and rehabilita-tion areas, a team auditorium, a players’ lounge, team position

group meeting rooms, a multi-purpose dining hall, a team locker room, aerobic equipment, hydrotherapy pools and coach and staff offices. New outdoor practice fields are also part of the construction package. The new football center will be complete for the 2013 football season.

A Reputation Built in ConcreteLayton’s excellence in concrete recognized in two similarly named projects

The Larry H. Miller Group knows what it takes to win. As owners of the NBA’s Utah Jazz,

the company understands it takes communication, dedication and a team-first approach to find success. The same principles apply to the auto dealerships the LHM Group operates in Utah, Arizona, Colo-rado, Idaho, New Mexico, Oregon and Washington. With the company opening a new 60,000 square-foot Chrysler Jeep Dodge dealership in Surprise, Ariz., LHM Group called the number of a trusted teammate by awarding the construction project to Layton Construction. Layton also partners with the Larry H. Miller Group in other community-based causes including sponsorship of the Million Miles at Miller biking event to benefit Special Olympics of Utah.

Featured Project

The James L. Sorenson Molecular Biotechnology Building — a USTAR Innovation Center (Salt Lake City) and the J. L. Sorenson Recreation Center (Herriman, Utah) share more than a namesake. Layton Construction received 2012 Excellence in Concrete Awards by the Intermountain Chapter of the American Concrete Institute for its work on the two buildings. Both facilities received generous contributions from the Soren-son family for the buildings’ construction. Durability is key for the popular and heavily used recreation

center, which features stamped colored concrete floors and pool decks. Architectural concrete stairways were chosen instead of steel to weather the humid pool environment. The USTAR facility houses high-tech nanofabrication and microscopy equipment. The concrete structure was designed and built with stringent vibration performance criteria to minimize the effects of shaking upon the very sensitive equipment that has little tolerance for movement. Both facilities are LEED® Gold certified.

Larry H. Miller Group knows a winning team in Layton

Layton and LHM Group are famil-iar partners throughout the West.

Utah Utes football coach Kyle Whittingham helped demolish the previous football facility to make way for top-notch facilities fit for a Pac-12 member school.

Layton Construction Company | FOUNDATION | 3

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Hospital joins the family in Harker Heights, Texas Expectant parents anticipate smooth deliveries and so do healthcare management groups who build hospitals. Layton Construction delivered the Seton Medical Center Harker Heights (Texas) under adverse conditions and an almost un-

heard of schedule. Construction workers battled record-setting heat and drought while doing site work, pouring concrete foot-ings and foundations, and erect-ing steel, in the summer of 2011. The green field site also neces-sitated the installation of all site

utilities as well as electrical and mechanical equipment. The 83-bed, 192,400-square-foot facility was completed in little more than 12 months. Materials staging and subcontractor coordination had to be nearly flawless to meet such a tight schedule.

General Contractors/Construction Managers/Engineer-Constructors Outlook Now and Looking Forward

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Construction Industry Confidence Index (CICI)

Declining Stable Improving

Industry Trends

Layton Construction was named the 44th largest builder in the country on Engineering News-Record (ENR) magazine’s “Top 50 in Domestic General Build-ing Revenue” list. The general building category includes office buildings, educational structures, health care fa-cilities, hospitality projects and manufacturing. Layton is also recognized as the 85th largest commercial construction company on the overall ENR 2012 slate of Top 400 Contractors. “Is the construction industry finally coming out of the recession?” asks ENR Senior Editor Gary J. Tulacz. He says work in the manufacturing sector is picking up, but in the public infrastructure and buildings markets, contractors are scrambling to get their share of a diminished yet stable workload. In markets served by Layton Construction, the economy is showing signs of improvement, and the company is well positioned to continue to serve and strengthen its customer base.

Smooth Delivery#44

Custom-designed accounting software receives recognition from industry leader Layton Construction’s excel-lence goes beyond concrete work and building techniques. The company’s accounting team developed a unique soft-ware program to automate the company’s American Express® workflow process, earning the 2011 North American CMiC Innovation Award. CMiC is the leading provider of advanced technologically open enterprise-wide software solutions for the construction industry. Faster processing times and lower overhead costs result in lower business costs for Layton, savings that can be passed on to its customers. Layton donated the award prize money to the Maliheh Free Clinic in Salt Lake City, a provider of charitable health care services.

Patients at Seton Medical Center Harker Heights (Texas) will receive high-quality service under all kinds of circumstances, just like Layton provided the hospital during construction.

HEIGHTSREACHING NEW


ATK Aircraft Commercial Center of ExcellenceClearfield, Utah

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Layton completes plant for leading aerospace manufacturer ATK

STORY BY GREG BENNETT

magine you have to construct a

600,000-square-foot, state-of-the-art

manufacturing facility — complete with

clean rooms, customized, proprietary equipment

and daily design changes.

Now, imagine you were creating this facility in a

building that was a vacant distribution center.

Add a tight six-month schedule and you have the

complicated job Layton completed for ATK Aero-

space Structures in Clearfield, Utah.

Layton’s Interior Construction Specialists built

out this manufacturing operation that allows for

some of the world’s best aircraft components to be

designed, constructed and shipped. > > >

PHOTOS BY ATK AEROSPACE


[ Project Profile ]

This AUIS-7 ultrasonic inspection machine uses sophis-ticated phased array ultrasonic technology, employing

water as a transmitter of sound, to certify within minutes that ATK’s composite products are defect-free.

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New contract = new building In May 2010, ATK Aerospace began designing the plant, which was built to manufacture compos-ite components used in the con-struction of the core airframe for the Airbus A350 — a commercial airliner with an expected roll-out date of 2014. ATK’s 50 years of experience and expertise in composite technology coupled with the company’s ability to automate the manufacturing process through proprietary design and engineering enabled the com-pany to get the contract.


The DetailsStart Date

December 2010

ConstructionCompletion Date

July 2011

Total Square Footage615,000

ArchitectsCase Lowe and Hart

Ogden, Utah

> > > “Layton was the one that had the

best presentation and plan for getting

this job done in the time we had.”Gary A. Pestotnik, P.E.

senior manager, facilities engineering, ATK Aerospace Structures

“The process is complicated, so our ability to automate made things less expensive, which makes all the difference in the competi-tive aerospace industry,” says Gary A. Pestotnik, senior manager of facilities engineering for ATK’s Clearfield composite structures facilities.

Getting the job done With a construction start date of December 2010 and a deadline of July 15, 2011, Gary and his team members knew they would need to rely on a quality contractor that had the manpower and experi-ence to get the job done in a tight window.

[ Project Profile ]

“We didn’t have every contractor around bid on this job,” Gary says. “We selected the best in the valley and Layton was the one that had the best presentation and plan for getting this job done in the time we had.” Layton came to the table with a schedule, a plan for some of the more complicated parts of the job and the idea to finish different parts of the plant at different times, enabling ATK work to begin in some areas while other parts were still being completed. The competitive price was an added bonus.

ATK pre-ordered long-lead materials to expedite the tight con-struction schedule. The company also kept engineers on the site at all times to answer questions and keep the process moving. “This was an extremely technical job that had a lot of little details,” says Scott Bradford, Layton’s superintendent on the job. “It was a pleasure to have the engineers on site to answer our questions almost immediately.”

A moving target Another unique aspect to this project arose because the machines


Acoustic Ceilings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Acoustico, Inc.Concrete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Iron Horse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Koyal Concrete. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Alta View ConcreteConcrete Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . C & L CoatingsDemolition and Saw Cutting . . . . . . . . . . .Total Interior DemolitionDoors and Frames . . . . . . . . . . . . . . .Architectural Building SupplyElectrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cache Valley ElectricGlass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Murray GlassMasonry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Allen’s MasonryMechanical . . . . . . . . . . . . . . . . . . . . . . . . . .United Team MechanicalOverhead Doors . . . . . . . . . . . . . . . . . . . . Bountiful Overhead DoorPainting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Greg Brown PaintingPlumbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reliable PlumbingSteel Erection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rocket SteelSteel Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-D SteelWood Framing . . . . . . . . . . . . . . . . . . . . Ron Peterson Construction

Key Subcontractors

One of the positive-pressure clean

rooms is large enough to house an en-

tire soccer field within its walls.

These pressurized autoclaves are used to compact and cure the com-posite material so the individual layers are properly fused together. The

autoclaves use a combination of heat and pressure to uniformly cure diverse structures with complex composite geometries.

Constructing large flat walls is dif-ficult because imperfections are so visible. These walls show attention to fine detail.

the building would house were be-ing designed and built at the same time the building was renovated. This meant there were tweaks to the plans based on new engineering needs. Obviously, good communication was essential.

“Beside the engineers being on the floor every day, we would have formal communication meetings once a week,” Gary says. “But, informally, we would speak every day about what needed to be done. We kept purchasing around so we didn’t have to wait for formal

change orders.” It was a process that allowed for the massive interior construction project to be completed in about six months.

High visibility area The Clearfield facility equates to

a significant investment for ATK’s corporate headquarters, so it was no surprise that company leaders would visit the job site frequently. Layton didn’t disappoint. “The CEO would come monthly and would often bring executives from our partner companies,” Gary

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All of the machinery in the plant was custom designed by ATK engineers on site. Because these machines were still being invented and

finalized during construction, adjustments to the building were ongoing throughout the

entire construction process.

[ Project Profile ]


“Overall, we’re extremely pleased with the building.

We’ve had many positive comments. As far as work-

ing relationships go, it was great. We would defi-

nitely give Layton a chance to do other work for us.”

Gary A. Pestotnik, P.E.senior manager, facilities engineering, ATK Aerospace Structures

says. “They were always amazed at the progress.” For example, on one occasion, an executive from Airbus was visiting. Layton was cutting out part of the floor. When the executive came back from lunch, the concrete was already replaced. In his experience, that replacement would come on another day — not a few hours later. Because of the anticipated economic impact, the project was also highly visible for the city of Clearfield. City officials and inspectors worked with Layton and

ATK to keep the process moving. Of course, it helped that ATK had a great relationship with the city.

Mission accomplished Despite the tight window, recur-ring changes and high-visibility of the project, it was completed on schedule and has been well received. “This was a team effort where everyone did what they needed to do to get the right outcome,” Gary says. “We worked through issues together and have the facility we need.”

ATK Aerospace Man-

ufacturing Facility

By the Numbers

The building uses 10 MW of electricity, enough to power 3,000 to 5,000 single-fam-ily residences or 10 Super Walmart stores.

There are 16 fire-supression risers and 2,400 light fixtures.

The autoclaves used in produc-tion are 13-feet in diameter and are 60-feet long. They cure ma-terials at approximately 350° F.

The facility was originally built in 1973 as a General Electric Distribution Center. Now, ATK uses the facility to manufac-ture parts for General Electric jet engines.

740 individual components are produced for Airbus at this facility.

The positive feelings come from the Layton side, too. “This was a great team effort,” Scott says. “We had to have the right people in the right place to make sure we got things done the right way. We worked together to get things done.”

Onward and upward In the coming years, air travelers will enjoy the strength and efficien-cies of an airplane built with com-posite components manufactured in and shipped from this amazing facility in Utah.

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ATK Aerospace manufactures composite materials used to assemble the fuselage of

the new Airbus A350. The structure is made from composite material that is one-fifth the

weight of steel but is twice as strong.

In 1945, the Reynolds brothers from Salt Lake City started a company that dug basements

and driveways for local homebuild-ers. Reynolds Brothers Excavation grew steadily for the next 45 years when the original owners sold the company to Gary Reynolds and Rob Reynolds — first cousins and sons of two of the founders of the company. That’s when the growth into larger construction projects — and more of a relationship with Layton Construction — began to form. “In business, if you aren’t moving forward, you’re moving backward,” Gary says. “We invested in equip-ment than made it so we could expand what we were able to do.”

FOUNDED1945

TYPE OF WORKExcavatingDemolitionUtilities

EMPLOYEES

HIGH-PROFILE JOBS WITH LAYTON

-lar Biotechnology Building — a USTAR Innovation Center, Salt Lake City

Utah

Salt Lake City

Peak Hospital, Draper, Utah

CONTACT INFORMATION89 W. 13490 SouthDraper, UT 84020(801) 566-2110www.reynoldsbrothers.com

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That expansion led them to be one of the area’s leaders in excavat-ing, demolition and utilities. By the time Gary and Rob sold Reynolds to Staker Parson in 2010, the company had grown to revenues that were 30 times larger than when the pair of cousins bought the business in 1990. That growth, according to Gary, came from who he worked with. “We try to hire the best people for every area of our business,” he says. “We wanted to expand demo and utilities, so we hired the best men in town to oversee it for us. These are the people that make us successful.” Tim Brown, is a general manager at Reynolds, and will be one of the people to carry Reynolds into the future. He runs the day-to-day

operations — while mentoring with Rob and Gary — and continues to preach the values that have brought the company success. He is also working to make sure Reynolds continues to be a valued partner on Layton’s projects. “Just in the time I’ve been here, I’ve already worked with Layton on Herriman High School, USTAR and now the Dee Glen (Smith Ath-letic Center),” Tim says. “I’ve appre-ciated the clear, concise directives I get from Layton’s project managers. When they say something, they mean it.” Staker Parson’s purchase of Reynolds has enabled the company to benefit from the size of its parent company and has them poised for future growth and development.

Reynolds Excavation Demolition & Utilities

From the Ground UpReynolds gets started right with digging Layton counts on

Gary Reynolds (left), Tim Brown (center) and Jim Marsden (right) are part of the team that has brought more than

65 years of growth and success to Reynolds Excavation, Demolition & Utilities in Draper, Utah.

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Ed Izatt has always been good at putting out fires — literally and figuratively. When he was a young man grow-ing up in rural Idaho, he became a certified EMT. The area he lived in was remote and he saw a need that needed to be filled, so he filled it. Eventually, his training as an EMT got him interested in becoming a firefighter and he spent most of his career work-

ing for Layton Construction during the day and as a firefighter at night. “The two jobs go hand-in-hand,” Ed says. “You have to think on your feet and make important decisions.” Ed has worked on numerous Layton projects including the Great Salt Lake pumping project and the Ely (Nev.) maximum security prison. But it’s his work on buildings designed to serve those in need

that he’s most proud of. “Working on Primary Children’s (Medical Center) has been one of the big highlights for me,” he says. “They do such great work there.” He also notes the purpose of the Bishop’s Central Storehouse in Salt Lake City, which he helped build, which sends aid around the world through the LDS Church’s humani-tarian service.

Ed Izatt | 26 years


Employee Focus

Just a Moment, PleaseUtah’s seismic concerns require creative, cost-saving solutions

Layton Construction is build-ing the HCA Mountain Star Lone Peak Hospital, a

four-story facility in Draper, Utah, which is located in an area of high seismicity. To help understand seismic con-siderations, it’s important to know that a “moment” is a physics term, which describes the measure of a force, specifically the lateral move-ment or torque on a structure. A moment frame is a box-shaped frame in a building that allows the facility to flex as necessary to maintain structural integrity. The lateral (side-to-side move-ment) load resisting system for the Draper hospital consists of “Special Steel Moment Frames” with Side-Plate® connections between the horizontal moment frame beams and vertical columns. The poor quality of the native soils dictated the use of shal-low spread footings bearing on GeoPiers®. The patented process consists of deep vertical columns drilled in the earth, which are then filled with compacted aggregate and capped with concrete. The GeoPiers® and spread footings support the building’s primary columns. The combination of poor soil conditions and high seismic forces at the interface between the columns and foundation elements

also presented a challenge for an economical foundation design. Either very large footings or grade beams running below ground be-tween the columns were necessary to resist the seismic moments at the base of the columns. Resisting these forces by the footings alone would have increased not only the size of the footings but also the cost of the ground improvements. The most cost-effective solution was the use of steel beams between

the column bases with patented Side-Plate® connections. The concrete-grade beam encase-ment of the steel moment frame beams simplified the construc-tion process and proved to be the most cost-effective solution with regard to both steel and concrete. These concrete-encased beams significantly reduced reinforcing requirements. Otherwise, “Special Concrete Moment Frame” beams would have been tightly spaced

and heavily reinforced — costly from both material and labor perspectives. Literally from the ground up, the engineering design and construction of the Lone Peak Hospital will save HCA money and time. When the ground shakes at the Lone Peak Hospital, odds are greatly increased that the hospital will be standing so its profession-als can provide life-saving services when needed most.

Steel grade beams will be encased in concrete to further strengthen and in-crease the ability to endure the heavy

side-to-side shaking of an earthquake.

Ed Izatt

A composite approachBuilding layer upon layer, Layton adds strength and flexibility

LaytonConstructionCompanyArea Offices

Salt Lake City9090 S. Sandy ParkwaySandy, UT 84070(801) 568-9090

Phoenix4686 E. Van BurenSuite 100Phoenix, AZ 85008(602) 840-8655

Irvine8001 Irvine Center Drive 4th FloorIrvine, CA 92618(949) 453-8300

Orlando5401 S. Kirkman RoadSuite 310Orlando, FL 32819(407) 681-0185

Hawaii4370 Kukui Grove StreetSuite 202Lihue, HI 96766(808) 245-8680

Boise1444 S. Entertainment Ave.Suite 300Boise, ID 83709(208) 429-6740

Nashville5409 Maryland Way Suite 100Brentwood, TN 37027(615) 376-6217

A publication of theLayton Construction Companymarketing department:

Alan Rindlisbacher, Director

Chris Knoles, Manager

Loni Morrey, Coordinator

www.laytonconstruction.com


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ATK has a long history

in the aerospace and defense industries, pro-viding propulsion systems that have

put man into space for decades. Layton’s connection with the aerospace group dates back to the ‘80s when our team built the solid rocket motor booster test firing facility at Promontory, Utah. ATK is nimble and changes with the times and technology. The space shuttle program is now part of aero-space history, but ATK continues to look ahead to new opportunities as it continues to be a leader of propulsion systems and compos-ite structures. Similarly, Layton has moved forward, relegating some equipment to the tool shed, adapting to electronic and digital technology, adopting sustainable

building practices, improving safety values and programs and putting iPads with construction apps in the hands of site superintendents. ATK’s new Aircraft Commercial Center of Excellence (ACCE) facil-ity in Clearfield, Utah houses the world’s most advanced composites manufacturing technologies. Air-craft manufacturers are tenacious to replace heavy steel with light-weight composites, which are five times stronger but half the weight. Composite structures are carefully built by putting down layer upon layer of carbon fibers, criss-crossed again and again until the specified size and strength of the component is achieved. Like our work in the construc-tion industry, we carefully lay down plans, specs, designs, models, pricing and value engineering to secure contracts. Our teams continue to work with customers in regular construction coordina-

tion meetings, communicating and orchestrating construction with many subcontractors. Upon completion we can then declare our work strong and whole. The ACCE facility was an ex-ceptional design-build experience. ATK’s contracts with the likes of Airbus, General Electric and Rolls-Royce drove them to push us on this fast-paced build-out. Timing was critical. Their engineers on site helped us immediately evaluate and approve construction elements. Our team laid it on the line. ATK now lays down composites in their state-of-the-art facilities to fill com-mercial aircraft component orders exceeding a billion dollars. And just as ATK excels in build-ing strong composite structures, Layton’s teams continue to meet the exacting needs of our many customers by constructing noteworthy facilities and building strong lasting relationships.

David S. Layton

Taking each step one at a time — and working with clients along the way — brings stron-ger relationships and better results to each Layton project.

REACHING New Heights - Layton Construction

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