Duke Energy high-rise erected in record time with prompt special inspections and materials testing

Client

Duke Energy

Location

Charlotte, N.C.

Challenge

When you’re building a new 40-story headquarters and parking deck in just over a year for one of America’s largest energy companies — and the company leaders can observe the structure develop from their current offices across the street — assembling a highly competent, trusted team is job No. 1. 

Duke Energy Plaza’s design called for a high-strength, post-tensioned reinforced concrete tower and incorporating a pre-cast “double T” floor system with a lightweight concrete topping slab. The top of the tower featured a structural steel framed penthouse with a glass facade to highlight the Duke Energy signature logo. 

While the unique “double T” system had proved successful and cost-effective in erecting Duke Energy’s current tower, it requires prompt materials testing and special inspections to stay on schedule. Each level had to meet certain structural requirements before the next floor could be placed. In addition, a connected seven-level post-tensioned reinforced concrete parking deck and conference center was to be built concurrently.

Solution

Our project manager’s experience with the construction and development on Duke Energy’s previous tower, which had a similar design, as well as our experience with other high-rises and high-strength concrete, made us an obvious choice to provide construction materials testing and special inspections. The availability of a team of certified, experienced technicians and special inspectors to be on site full-time was another big advantage and contributed to the success of the project. 

Providing the contractor with real-time data was crucial for the project to continue with its scheduled construction sequence. Terracon’s project manager was in constant communication with the contractor’s team, providing data each morning and throughout the day. Terracon utilized its proprietary electronic reporting system to deliver materials testing and special inspection reports daily.

Because the parking deck was being built at the same time, our team prioritized clear communication amongst themselves and with the contractor to confirm the right people were in the right place at the right time.

Results

The Duke Energy Center and parking deck core and shell structures were completed on time in just 14 months. It’s the fifth largest building in Charlotte and an iconic part of the city’s skyline.