Top 3 Challenges in Architectural Builds: Insights from BuildNZ at ASB Showgrounds – Gaia Forest ECE

At the recent BuildNZ event, Sanjesh Lal shared valuable insights into the construction of the Gaia Forest Early Childhood Education (ECE) Centre. Early in the project, we implemented value engineering, saving the client $380,000. This project, designed with a Gaia Earth-based approach and inspired by biomimicry, faced several challenges, from complex design elements to logistical issues. The project required precise planning and coordination to address both aesthetic and functional requirements while navigating multiple technical hurdles. The dedication and innovation demonstrated throughout the project were recognised when we won a Silver Award at the 2023 NZ Commercial Project Awards, highlighting the project’s outstanding achievement in the commercial construction sector.

One of the major challenges was the complex design and execution of the building, which was uniquely shaped like a leaf. This design required the careful placement of 240 timber piles to ensure structural integrity. Additionally, there were significant site challenges, including asbestos contamination that required removal, as well as weak ground conditions that necessitated deeper piles for the foundation. The project also had an oversized roof that created access issues for installation and maintenance, and the carpark redesign was required due to tree root zones, complicating the layout and adding further engineering challenges.

Sustainability was a core principle for the project, and environmental integration posed its own set of difficulties. The building was designed to incorporate eco-friendly features such as rainwater harvesting, underfloor heating, smart ventilation, and planned solar panels. Integrating these systems without compromising the building’s design was a complex task. Furthermore, the project was located near one of Auckland’s last ancient forest systems, requiring careful environmental considerations to blend the structure seamlessly into the natural surroundings.

Logistical and supply chain issues further complicated the project. We faced COVID-19 delays, which pushed the project timeline by over two years. Cost escalation driven by the pandemic and other market pressures added to the financial burden. The fires in New South Wales during the 2019/20 fire season caused disruptions in the supply of essential materials like glulam beams, further delaying the project. Additionally, the project’s location presented unique challenges, such as the need to extend services and navigate around the tree canopy for local utility installations, which required coordination with various stakeholders and authorities.

Value engineering is possible in even the most difficult scenarios, including those exacerbated by the COVID-19 pandemic. By reassessing the project’s design, materials, and approach, we identified opportunities to reduce costs without compromising quality. We implemented value engineering solutions that helped mitigate costs while maintaining the project’s integrity. Changes to the design included switching from wire to timber balustrades, altering the roof specifications, changing the decking material to pine, and updating the flooring specification. These adjustments helped deliver the project at a reduced cost, achieving savings of $380,000 for the client. These value engineering measures were crucial in keeping the project within budget despite the external pressures.

Check out Sanjeshs’s case study.

For more insights into this project and others like it, stay tuned to our blog and follow our journey as we continue to push the boundaries of architectural excellence.
Remember, “Be more human.”