Castro Valley, California
Driven by state-mandated seismic code deadlines, Sutter Health faced an unparalleled challenge in the development of their new acute care and patient-centered facility: the 231,000-square-foot, 130-bed hospital had to be planned, designed, permitted, built, and opened two years faster than any other comparable project. Beyond the aggressive schedule, the project’s success depended on 100% certainty of meeting its budget without compromising its operational and sustainability goals.
In a groundbreaking move, Sutter decided to use a heightened form of integrated project delivery, executing an 11-party IPD agreement between the owner, architect, engineers, general contractor, and specialty contractors. As the 11th team member, Ghafari was tasked with providing overall design and pre-construction management and lean project planning to deliver a high-performing facility on time and on budget.
Our job was to lead design and pre-construction management, including overall project information flow management and process mapping. We facilitated design and detailed constructability review meetings using 3D models, allowing all team members, including trade contractors, to have input at the earliest stages. This ultimately reduced the amount of field labor required during the installation of the facility systems.
We also employed laser scanning during construction as a quality control method to verify that field installation was proceeding according to the fully coordinated 3D model.
Under our guidance, the integrated team used a sequenced decision-making approach, ensuring that later design decisions did not create any rework. The result was an effective overlap of design and construction activities. Thanks to careful management, the project was completed $2 million under budget and one month ahead of schedule. Working together through all phases of this complex project, our team delivered a hospital that supports a “no compromises” approach to patient-centered care.