ARCO Construction – Sunset Ridge at Manchester

ArcoARCO Construction completed a senior living facility in St. Louis after overcoming difficult building conditions. 

By Stephanie Crets

ARCO Construction is a design/build general contractor with a client-centered, process-driven focus on every project. Founded in 1992, the company is headquartered in St. Louis with offices across the United States including Kansas City, Indianapolis, Chicago, Atlanta, Cincinnati, Philadelphia, Dallas, Tampa and Houston.

Having completed more than $4 billion in finished projects in 24 years, ARCO Construction is committed to providing clients with the complete design/build package and exceeding expectations through successful planning, design and construction. “We work with our customers hand-in-hand from design and conception to completion of the project,” Senior Project Manager Kyle Darnell says. This reason alone is likely why nearly three-fourths of the company’s revenue is from repeat clients.Arco info box

Darnell has been with Arco Construction for 10 years, and the latest project he managed was an assisted living and memory care project for a repeat customer, Provision Living. The first step in developing this new, 30-acre highly sought after real estate in unincorporated St. Louis County was to navigate the construction requirements on what was an old rock quarry. The site was zoned for a mixed-used development that also included a 254-unit luxury apartment complex, a 211-room Marriott Residence Inn and Courtyard Hotel, a bank and a 50,000-square-foot office building.

ARCO Construction worked with Casemark Development in developing the land and determining out the various requirements. “We looked at how to develop this valuable piece of ground,” Darnell explains. “We knew there was a major infrastructure piece that needed to happen as part of the master-planning for the site. We helped assemble all the puzzle pieces together from utility and infrastructure, simultaneously working with all the other pieces potentially master-planned for the site.”

Piecing Together

Sunset Ridge at Manchester infrastructure development and subsequent construction for the senior living facility began in September 2015 and was completed in October 2016. The project, formerly known as The Quarry, is now known as Sunset Ridge at Manchester.

The quarry site was vacant since 1985, and in the early 2000s, it became a fill site for other construction projects, making the soil conditions both difficult and not fully known. It required ARCO Construction to perform ground improvement and remediation. Lightweight construction practices were used for the senior living facility including lightweight concrete, and backfill while everything vertical was wood construction.

For all the different projects, there were more than 150 workers on site on any given day. Most subcontractors were hired locally, which created temporary jobs in the St. Louis community. However, having that many workers on a high-traffic area was also a challenge from a safety standpoint.

The company is dedicated not only to making the construction process enjoyable and beneficial, but also ensuring safe and injury-free working environments for its associates, subcontractors and clients. At Sunset Ridge, ARCO Construction had safety personnel on site, along with equipping everyone with hard hats, safety glasses, and ensuring high visibility attire and coordinated jobsite signage. “We also had ensure maintaining traffic flow, and maintaining public access around the improvements while limiting public access during construction,” Darnell adds.

With ARCO Construction’s phase of the Sunset Ridge project complete, the company is proud of developing something that will have a major impact on the metropolitan area, while also promoting pedestrian connections. “We’ve created a new destination development that will be nice for years to come,” Darnell says. “We learned so much on this project – from how to go through due diligence of a complicated site with a lot of different municipalities and utility providers that we’re working with, to uncovering the unknowns on the site. It was a really great experience.”

Now, ARCO Construction and Darnell continue to work with their existing customers and new opportunities across the country for the next slate of projects. “We’re getting ready to start on a handful of new senior living and multi-family projects including some skilled nursing facilities in California,” he says. “We have a lot going on across the country. I’m excited about the opportunity to continue to do work and spread the ARCO experience to new customers across the country on new senior living and multi-family facilities.”

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