Toyota Logistics Center Vehicle Distribution Center at the Port of Long Beach

90th Anniversary Case Studies

June 21, 2022 – Oltmans Construction Co. announces the completion of the new LEED Gold, Toyota Vehicle Processing and Distribution Center (VDC).

The city of Long Beach was home to Toyota’s first North American manufacturing plant established in 1972. Since then, Toyota has gone from producing 2 million vehicles to 10 million in 2020. When it came time to consolidate and rebuild their vehicle processing and distribution center to meet today’s current market demand, Toyota and R.A. Vezzuto Consulting underwent a rigorous vetting process before selecting Oltmans Construction Co. as the most qualified contractor for the project.

The partnership was a hit from the get go, and it’s no surprise after learning that both companies were founded in the 1930s and have stayed committed to strong family values. Remarkably, to this day the leadership of both companies continues to include direct family members of the original founders.

Toyota LS

After 22 months of demolition, construction, and a phased move-in, the collaboration has offered the project team a unique opportunity to establish even deeper connections with the city and port of Long Beach. The campus includes Toyota’s LEED Gold 155,000 s.f. post-production building, 5,200 s.f. car wash building, and a 3,500 s.f. fuel island with hydrogen refueling capabilities. The new campus is constructed on a 21% smaller footprint than the previous facility within the original 144-acre lot. The new design creates a more efficient workflow, reduces vehicle movement and emissions, increases site safety, and raises the seismic integrity of the facility. A robust electrical infrastructure was also added to support the increasing number of EV chargers anticipated as demand for electric vehicles increases.

Part of the redevelopment also included a renewable energy fuel cell power plant that converts natural gas into water and electricity. The electricity is used to supply power to Toyota’s operations and the water is pumped to the car wash to be reused.

Toyota LS

Getting engaged on the project early Oltmans was able to work with the design team to provide preconstruction services and subcontractor input through Oltmans’ in-house estimating, project management, and field operations teams. The team provided budgeting, value engineering, scheduling, and constructability validation throughout the design process.

Due to Toyota’s land lease agreement with the port of Long Beach, the project site bisects both the cities of Los Angeles and Long Beach. During preconstruction, the building was shifted into the City of Long Beach which reduced the anticipated permitting and plan check timeframes associated with the dual jurisdictions and allowed the construction team to engage with the city of Long Beach building relationships that proved invaluable throughout construction.

Early engagement with the subcontracting community during preconstruction also produced value engineering that resulted in significant savings. The electrical subcontractor, Gregg Electric Inc. provided constructability and feasibility inputs that were vetted by Oltmans’ preconstruction team and shared with Toyota and P2S, the project electrical engineer. During construction, Gregg Electric went on to assist with adding an electrical bus duct system throughout the production areas that provide Toyota’s operations team maximum flexibility in modifying their ever-changing processing requirements.

Toyota LS

Toyota LS

Trust and transparency were integral to successfully complying with all the safety and security measures in place at the port. A few important components included navigating the extensive existing infrastructure of underground utilities, and managing the high groundwater and hazardous soil at the port. Approximately 2-1/2 miles of underground utilities were installed with three of the four most sensitive connections made directly to a one-hundred-year-old sewer main located 15 feet below ground. To manage the high water table and hazardous soil, continuous dewatering was required and over 3,000 cubic yards of hazardous dirt was hauled to an offsite disposal facility. The processed and filtered water was reused on-site for dust control.

During construction, specialized employee screening was required through the Transportation Security Administration (TSA). All oversight personnel on the project were required to carry a Transportation Worker Identification Credential (TWIC) as required by the Maritime Transportation Security Act. Oltmans worked alongside the U.S. Coast Guard to ensure that proper compliance was met and the expectation that random security checks would and did occur was communicated.

Initial COVID-19 shutdowns also affected the project’s ability to procure piles causing significant delays. To mitigate time lost, the team reconfigured the construction sequence to keep the project moving forward.

Toyota LS

Toyota LS

Oltmans Concrete Division self-performed the entirety of the concrete scope of the project. Over the course of fifteen months, 10,550 yards of concrete was poured. A typical concrete slab is seven inches with one layer of rebar but due to the site’s liquefaction and strict seismic requirements, twelve inch slabs with doublemat, two layers of rebar were required to mitigate settlement.

Controlling a field force of over 300 carpenters, Oltmans Concrete was able to exert strategic control of the schedule and meet manpower requirements despite a severely constrained labor force due to the pandemic. With the implementation of proper State and CDC COVID guidelines the project team was able to avoid schedule disruptions and delivered the project on time.

Vince Ruesch Superintendent

The new Toyota Logistics System VDC marks the continued expansion of the port of Long Beach and the importance of the city to Southern California’s logistics infrastructure for generations to come.

Project Team:

Summary of Links: