A Bold Build Begins: From Concept to Completion in 11 Months
In December 2018, STIHL set out to expand its footprint in Western Canada with a brand-new distribution warehouse and office in Acheson, Alberta. The challenge? Deliver a 64,770 sq. ft. facility combining operational scale with modern design within a tight timeline and a fixed budget. With Scott Builders leading the design-build delivery and Laviolette Engineering as the consulting engineer, the team brought STIHL’s vision to life ahead of winter’s deadlines and operational expectations.
Executive Summary: Strategic Build, Seamless Delivery
Scott Builders successfully delivered the STIHL warehouse and office project with a scope that included:
- Facility Size: 61,270 sq. ft. warehouse and 3,500 sq. ft. office
- Site Development: 7.6-acre parcel in Acheson, Alberta
- Contract Model: Design-build contract (CCDC #14) with Laviolette Engineering
- Project Timeline: February 2019 to November 2019
- Construction Budget: $7.5M original | $7.8M final
Despite the winter start and site complexities, the team completed the facility on time and within expectations, delivering a durable, high-performance space that now serves as a cornerstone for STIHL’s regional logistics.
Building for Growth: A Distribution Hub with Office Integration
The facility was designed to streamline STIHL’s operations in Alberta and beyond. The design-build warehouse features high-bay racking, heavy-duty floor systems, and multiple dock doors to accommodate inventory movement and shipping. The 3,500 sq. ft. office provides a polished space for staff, complete with branded interiors and direct connectivity to the warehouse.
As the design-builder, Scott Builders coordinated closely with Laviolette Engineering to optimize every square foot. From the pre-engineered steel structure of the warehouse to low-maintenance finishes in the office, the entire facility was planned to meet STIHL’s current and future needs — with room to grow.
Meeting the Moment: How the Team Tackled Winter, Scale, and Speed
Several critical factors shaped the project’s complexity:
- Winter Conditions: Groundwork began in December, requiring heated enclosures, concrete protection, and adjusted site logistics.
- Tight Turnaround: With an 11-month schedule, decisions had to be streamlined and site execution carefully phased.
- Large-site Coordination: Managing utilities, two distinct building programs (warehouse and office), and site paving across 7.6 acres demanded exceptional planning.
- Durability Demands: Heavy equipment use required specialized slab design, floor flatness control, and enhanced envelope performance.
- Mid-project Adjustments: Scope additions, such as interior layout changes, had to be incorporated quickly, without slowing momentum.
Built to Perform: Design-Build Solutions That Delivered
Scott Builders' solutions-focused approach made the difference:
- Design-Build Synergy: By overlapping the design and construction phases, the team saved time and increased flexibility. Early site grading began while interior plans were still being finalized.
- Cold-Weather Readiness: The team used ground thaw systems, heated tents, and strategic scheduling to maintain progress through freezing conditions.
- Dedicated Site Management: Superintendent Henry Oomen ran a lean, well-coordinated site, with daily check-ins and lookahead scheduling across crews and trades.
- Cost Control with Transparency: Despite a small increase to $7.8M, all changes were value-added and tracked with client approval.
- Fit-for-Purpose Construction: Reinforced slab design, energy-efficient LED lighting, and thoughtful interior detailing created a durable, professional space aligned with STIHL’s operations and brand.
“This project was the definition of teamwork and adaptability,” says Dan O’Hara, Project Manager. “From sub-zero temperatures to evolving client needs, we worked as one team to keep the project on time and aligned with STIHL’s goals.”
Results That Speak: On Time, On Brand, and Built to Last
By November 2019, the project was turned over and fully operational. Highlights include:
- On-Time Turnover: Delivered in 11 months despite a winter start.
- Functional Efficiency: The layout, racking readiness, and dock configuration were tailored to STIHL’s logistics model.
- Branded Space: The office interior reflects STIHL’s identity, creating cohesion across client visits and employee experience.
- Satisfied Client: STIHL expressed full satisfaction with both the quality and pace of delivery, an outcome made possible by open communication and clear expectations from start to finish.
More Than a Building: A Lasting Partnership
The STIHL warehouse and office project is a prime example of Scott Builders’ ability to deliver design-build solutions with speed, quality, and care. It also reflects a commitment to long-term client relationships. From navigating design decisions to managing winter build constraints, the project was a masterclass in collaboration.
Let’s Build Your Next Success
Whether you’re launching a logistics hub, industrial facility, or office build, Scott Builders is ready to partner with you. Our design-build team brings experience, transparency, and results to every project — just ask STIHL.
Contact us today to learn how we can help bring your next project to life.