Value Engineering Is About Building Smarter, Not Just Cutting Costs
When people hear the term value engineering, they often assume it means cutting costs by removing material or simplifying a design. In my experience, that's only a small part of the story.
The best value engineering happens when the design and construction teams work together to challenge assumptions, explore alternatives, and identify solutions that improve not only the project budget but also constructability, schedule, and long-term performance.
One project I recently managed reminded me exactly why collaboration is one of the most valuable engineering tools we have.
Project Background
As the Project Manager and Structural EOR, I had the opportunity to lead the structural design of a large mixed-use development consisting of a six-story post-tensioned concrete building, an adjacent residential component, and a two-level underground parking garage totaling more than 400,000 square feet.
Our original design utilized isolated footings supported by aggregate geopier soil improvement, along with post-tensioned slabs from the first elevated parking level through the roof. Based on the geotechnical report, the improved soil was expected to provide an allowable bearing capacity of 6,000 psf, while unimproved soil was limited to a net allowable bearing capacity of 3,000 psf.
As construction planning progressed, the general contractor recognized there might be opportunities to improve constructability and reduce costs. They approached our team to explore alternative structural solutions.
One of the advantages of serving as the Engineer of Record is that you understand not only what was designed, but also why it was designed that way. Because our team had developed the original structural system, we were able to evaluate each proposed change holistically rather than as an isolated revision.
Instead of asking, "How can we make this less expensive?" we asked, "How can we make this project perform better while also making it easier and more economical to build?"
That shift in mindset led to a comprehensive value engineering effort that ultimately improved the entire structural system.
Rather than making isolated modifications, my team and I re-evaluated the project's foundation system, framing strategy, and construction sequencing as an integrated structural solution.
Working closely with the contractor and concrete subcontractor, we analyzed how changes in one portion of the structure would affect the rest of the building. This collaborative process allowed us to optimize the design while maintaining the project's safety, durability, and long-term performance objectives.
The redesigned structural system ultimately included several significant improvements:
Our Approach
Post-Tensioned Hydrostatic Mat Foundation
The isolated footings and aggregate geopier soil improvement were replaced with a post-tensioned hydrostatic mat foundation, eliminating the need for ground improvement while simplifying the foundation system and providing a more efficient load distribution.
Hydrostatic Uplift Resistance
The mat foundation was designed to resist groundwater uplift resulting from approximately 6 feet of hydrostatic head, helping protect the structure against flotation and long-term hydrostatic pressures.
Three-dimensional analytical models of the post-tensioned hydrostatic mat foundation developed in ADAPT-Builder during the structural design process.
Improved Construction Sequencing
The basement parking level (P1) was redesigned from a post-tensioned slab to a conventionally reinforced concrete slab. This modification allowed the basement walls and slab construction to proceed simultaneously, improving construction sequencing and reducing schedule impacts.
More Efficient Load Path
At the ground level, transfer girders were extended to cantilever and support column loads, significantly reducing the number of isolated footings required. This created a more efficient structural load path while reducing excavation, concrete placement, and reinforcing steel.
Building the future
Aspen at Greenleigh demonstrates what is possible when innovative construction methods are paired with strong engineering leadership. As North America's largest ICF project, Aspen at Greenleigh serves as a showcase not only for the capabilities of Insulated Concrete Form construction but also for the collaborative leadership, technical excellence, and dedication that define KLINE's engineering approach.
For KLINE, the project represents more than a structural achievement; it reflects our commitment to advancing the industry through innovation, technical expertise, and the development of future engineering leaders.
Project Partners
Aspen at Greenleigh is the result of a collaborative effort among an exceptional team of owners, developers, designers, and builders. KLINE is grateful for the opportunity to contribute to a project that is helping redefine the possibilities of large-scale ICF construction.
Read more about the project’s recent groundbreaking announcement here
The KLINE Team Behind the Project
While Aspen at Greenleigh is notable for its scale and technical complexity, it is equally a testament to the strength of the team delivering it.
The project is led by KLINE’s Vice President of Operations and Principal, Katherine Farley, PE, who serves as Project Executive alongside Project Manager Estefania Ramirez. Together, they have guided the structural design and coordination efforts for the largest ICF project in North America.
Notably, Aspen at Greenleigh is led by a team of accomplished women engineers whose leadership has been instrumental to the project's success. From structural design and project management to construction administration and coordination, Katherine Farley, PE, Estefania Ramirez, and Yuriko Reátegui have played central roles in delivering North America's largest ICF project.
Under their leadership, a talented team of emerging engineers and design professionals, including Joseph Diaz, Mohamad Asad, Nicholas Owusu, and BIM Lead Christian Queirolo, has contributed to the project's design and development. Their collective efforts reflect KLINE's commitment to fostering the next generation of engineering talent while delivering innovative and technically demanding projects.
Katherine Farley, P.E.
Project Executive
Provides strategic leadership and technical oversight for Aspen at Greenleigh, helping guide the delivery of North America's largest ICF project. Her experience and vision continue to support the project's success through every phase of development.
Estefania Ramirez
Project Manager
Leads project coordination and structural design efforts, working closely with the team and project partners to advance this landmark development. Her dedication and attention to detail help drive the project forward every day.
Yuriko Reategui
Structural Engineer II
Leads KLINE's construction administration efforts, working closely with the field team to maintain design continuity and support successful project execution. Her proactive approach helps keep this complex project moving forward with confidence.