Web Exclusive: Unique Construction Features Add Value to Community

In recent years, mixed-use communities have been springing up all over the country — and for good reason. Live-work-play communities create a sense of belonging, promote a healthier lifestyle, and embrace the latest sustainable principles.

One such project is Dos Lagos in Corona, Calif., a 534-acre mixed use community that incorporates residential properties, offices, a retail center, and large central park/gathering area, which serves as the heart of the community.

Previously having been an abandoned silica quarry, the process of redeveloping the area into a showcase community began with vision and foresight of Ali Sahabi, owner of SE Corporation, the master developer of Dos Lagos. Sahabi's dream was to create a community that would set the standards for sustainability and livability. Having achieved that vision, Dos Lagos is being admired and studied by developers across the U.S. who see it as a model for redevelopment practices.

The process of developing Dos Lagos began with careful environmental testing and treatment. After the site had been declared environmentally sound, Sahabi commissioned Consolidating Contracting Services, Inc. to put into motion the planned 10-acre park, referred to as the community's "heart" and a crown jewel for the development.

The strategically designed, sustainable elements of the lake area create a sense of community and address the environmental, social and economic aspects of life. The project’s use of natural materials and water features add to its basic appeal.

Designed by renowned architect Norberto Nardi of Nardi Associates LLP, the heart includes two 4-acre, heart-shaped manmade lakes with a built-in biological filter to keep the lakes clean. A central 9-foot-high waterfall, which is illuminated by fiber-optic lighting at nighttime, flows below the steel and bamboo bridge, anchoring the lakes. A circular pedestrian walkway, which is representative of the city of Corona’s distinct and historic Grand Avenue circle, is lined with park benches and leads visitors to a 440-seat outdoor amphitheater.

Perhaps Dos Lagos’ most interesting feature, and arguably the most challenging to construct, is its undulating armature walkway, which is covered by a 750-by-16-foot garden trellis of bamboo, concrete and rolled steel beams. The artistic armature divides the two signature lake halves and bridges the foot of the waterfall, creating a breathtaking panorama of the developer’s vision — combining nature with community. Dos Lagos’ distinctive bridge took months of planning, construction and assistance from around the world. Following are some of the construction challenges Consolidated Contracting encountered while managing the massive project:

Custom Cold-Rolled Steel I-Beams

The biggest challenge of the armature’s trellis was constructing its 200 steel I-beams. These particular beams required special attention in their manufacturing and fabrication. After being individually cold-rolled in Chicago, they were then taken to Montana for fabrication.

Each and every beam had to be detailed on a 3-D model, ensuring it would fit perfectly within the design of the winding walkway — much like piecing together a puzzle. After the structure’s fabrication in Montana, it was shipped down to California in pieces and assembled on site at Dos Lagos. The steel ribs were covered with a faux metallic paint to give them the appearance and feel of rusting metal.

Distinctive Bamboo Trellis

To create the look and feel of a trellis and contribute to the sustainability of the project, horizontal bamboo members were erected to connect the vertical I-beams. After the construction team discovered that bamboo with adequate durability and size needed for the project was not available in the States, they decided to have the materials specially imported from Vietnam.

On its way to the States, the bamboo had to go through customs, and was quarantined — a process that took nearly three months from beginning to end. Then, to ensure the bamboo would be able to weather the elements, each piece had to be hand oiled. When the bamboo was finally ready to be put into place, the construction team had to determine how best to attach it to the steel beams. After several mock ups and some trial and error, they came to a solution using metal straps to secure the bamboo in place.

Poured-in-Place Pile

In order to secure the bridge into place, the construction team installed several 50-foot-deep poured-in-place piles, ensuring the structure will remain stabilized for years to come. The piles then were connected by a 20-by-16-inch, 100-foot-long, hot-galvanized steel tube. I-beams and a metal pan deck filled with concrete complete the bridge. Radius saw cuts and multi-colored concrete stain put the finishing touches on the structure’s artistic design.

During the construction of the "Heart Park" at Dos Lagos, the team at Consolidated Contracting Services learned that building a 900-foot undulating structure isn’t just a walk in the park. Careful planning, trial and error, and outside resources all combined to make the project a success — one that will be enjoyed by visitors and the residents of Corona for years to come.