Old Navy Distribution Center, NY
Advance Testing, a SOCOTEC Company provided construction materials testing and special inspection services for the $78 million, 1.5 million-square-foot Gap/Old Navy distribution facility and warehouse development in Fishkill, New York.
Key Information
Project Name: Old Navy Distribution Center
Client: Clayco Corporation
Location: Fishkill, NY
Services Provided: Construction Materials Testing, Laboratory Testing, Building Code Special Inspections
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The Challenge
Building a Distribution Center at an Unprecedented Scale
Clayco Corporation was tasked with delivering an industrial project of exceptional scale: a $78 million distribution and warehouse complex spanning 1.5 million square feet across a 200-acre site for Gap/Old Navy. The scope was substantial from the outset, encompassing:
- A 50,000-square-foot, two-story office building integrated with the main distribution facility
- A 1.5-million-square-foot distribution zone
- Plans for two additional structures — a 300,000-square-foot building and a 700,000-square-foot facility
Site preparation alone required over 800,000 cubic yards of rock to be blasted, crushed, and moved, while construction called for 67,000 cubic yards of concrete and more than 650,000 square feet of tilt-up wall panels — a volume that made this the largest tilt-up concrete project on record at the time.
With a build of this magnitude, every phase — from earthwork to structural steel to finished floor slabs — carried significant risk. Consistent, code-compliant quality assurance was essential to keep the project safe, structurally sound, and on schedule.
The Solution
Comprehensive Testing and Special Inspections
Advance Testing, a SOCOTEC Company was contracted by Clayco/Old Navy to provide inspection and testing services throughout the project.
A significant component of the assignment involved the inspection of all cast-in-place concrete on site. This work resulted in more than 2,500 concrete cylinders being tested through Advance Testing, a SOCOTEC Company, supporting the project's extensive concrete construction program.
Beyond concrete testing and inspection, the team provided a broad range of field, laboratory, and special inspection services to address different stages and components of construction.
Services included:
- Utility installation inspection
- Asphalt field testing and inspection
- Reinforcing steel inspection
- Concrete testing and inspection
- Floor flatness testing
- Bolting inspection
- Visual welding inspection
- Ultrasonic weld testing
- Fireproofing inspection
- Laboratory testing
- Building Code Special Inspections
By bringing these capabilities together, Advance Testing supported Clayco/Old Navy with testing and inspection services across a project characterized by substantial quantities of concrete, structural components, and site development work.
Advance Testing, a SOCOTEC Company was contracted by Clayco/Old Navy to provide inspection and testing services throughout the project.
A significant component of the assignment involved the inspection of all cast-in-place concrete on site. This work resulted in more than 2,500 concrete cylinders being tested through Advance Testing, a SOCOTEC Company, supporting the project's extensive concrete construction program.
Beyond concrete testing and inspection, the team provided a broad range of field, laboratory, and special inspection services to address different stages and components of construction.
Services included:
- Utility installation inspection
- Asphalt field testing and inspection
- Reinforcing steel inspection
- Concrete testing and inspection
- Floor flatness testing
- Bolting inspection
- Visual welding inspection
- Ultrasonic weld testing
- Fireproofing inspection
- Laboratory testing
- Building Code Special Inspections
By bringing these capabilities together, Advance Testing supported Clayco/Old Navy with testing and inspection services across a project characterized by substantial quantities of concrete, structural components, and site development work.
The Results
Testing at the Scale of the Project
Advance Testing, a SOCOTEC Company, delivered construction materials testing and special inspection services across multiple disciplines throughout the project.
More than 2,500 concrete cylinders were tested through Advance Testing, a SOCOTEC Company, providing extensive laboratory support for the project’s concrete program.
The team’s involvement also covered reinforcing steel, asphalt, bolting, welding, fireproofing, utilities, and other construction elements, providing coordinated quality assurance support across key phases of construction.
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