SEI Takes on a Fast-Track Costco Build in Newport News

When you build a Costco warehouse on the site of a former corporate headquarters, it takes more than a standard construction plan. In Newport News, Virginia, SEI and Project Manager Paiden Easley are leading a fast-track project that began with a major transformation: turning the former Ferguson headquarters campus into a new Costco Wholesale warehouse site.

Before the team could focus on the 162,457 SF. warehouse itself, there was plenty of work to do below and around the 38.30-acre future building pad. Three large structures, including a five-story building, had to be demolished. Acres of trees were cleared. Existing utilities had to be located, traced, and removed. Concrete was crushed. And once crews got into the ground, they found clay, organics, and unsuitable soils that had to be hauled off before the site could move forward.

“It was a fully established prior facility, with utilities running everywhere,” Easley said. “We were chasing utility lines, demoing them, and then dealing with a lot of clay. The demo was one of the biggest hallmarks of the project.”

The site conditions were only part of the challenge. SEI was already working with a schedule that had been reduced by two months. Then, after jurisdictional permitting took longer than expected, Costco asked the team to accelerate again so the warehouse could open before November. In all, four months were compressed from the schedule, with the team still working toward a projected November 19 delivery.

Newport News also brought a high level of environmental oversight. The city’s environmental department was on-site regularly, paying close attention to erosion control, inlet protection, and overall site practices. Even with that added scrutiny, Easley said the team was able to keep the project moving while building a strong working relationship with the environmental monitor.

For Easley, the project reflects the value of preparation, communication, and a strong team. His prior Costco experience helped him understand the pace and expectations of a warehouse opening, but he said the success in Newport News has come from the people around him. “The site guys and leadership team have been phenomenal,” Easley said. “We have a great site team, and we couldn’t do it all without them.