Total Precast
Caledonia Community Schools Athletic Complex
Overview
The Caledonia Community Schools Athletic Complex is a major new community hub located approximately 20 miles southeast of downtown Grand Rapids, Michigan. At approximately 47,000 square feet, this modern two-story facility brings a diverse set of wellness, recreation, and educational amenities under one roof. The project required a durable structural solution capable of performing in a high-moisture natatorium environment while meeting budget and schedule expectations.
2026 PCI Award: School (K-12) Honorable Mention
2026 PCI Award: BIM Award Honorable Mention
Project Details:
General Contractor
Rockford Construction
Architect
Stantec Architecture Inc.
Erector
Assemblers Precast & Steel Services, Inc.
The Calplex is an athletic facility is a joint venture between the Caledonia Public Schools and the YMCA.
From a full-size gym and indoor walking track to a community aquatics center with an eight-lane competition pool and seating for 175 spectators, the complex was designed from the start to serve students and residents.
Problem
The original building design relied on a structural steel frame with insulated metal panels. As the project progressed, rising material costs, schedule risk, and long-term maintenance concerns prompted the project team to re-evaluate the structural system.
The natatorium, in particular, required a solution that could withstand constant exposure to moisture and corrosive conditions while minimizing future upkeep. The team needed an alternative that balanced performance, durability, and constructability without compromising the architectural vision.
Solution
Fabcon partnered early with Stantec Architecture and the owner to develop a precast concrete solution using BIM to ensure seamless integration with the building’s layout and systems. Over the natatorium, 12 foot-wide, 96’-0” long, precast double tees replaced a traditional steel roof, creating a clean, fully open, non-corrosive structure all while reducing long-term maintenance.
Insulated precast wall panels were designed to act as both the building envelope and a continuous vapor barrier, controlling condensation and improving thermal performance. A corrosion-inhibiting admixture further enhanced durability and extended the facility’s service life.
Results
The transition to a precast concrete structural system delivered measurable benefits across durability, performance, cost, and schedule. The use of long-span double tee members over the pool eliminated a traditional steel roof system, reducing corrosion risk and ongoing maintenance in the natatorium. Insulated wall panels with an integrated vapor barrier effectively managed moisture and condensation, improving overall building performance.
Off-site fabrication and coordinated BIM modeling supported efficient installation, helping the project remain on schedule and within budget. The completed athletic complex provides Caledonia Community Schools with a resilient, low-maintenance facility designed to serve students and the community for decades.
”Precast offered several key advantages, including reduced long-term maintenance in the high-humidity, corrosive pool environment, an issue that would have required special marine coatings on traditional structural steel. It enabled an accelerated construction timeline to enclose the building quickly. This helped reduce costs and lead times compared to conventional structural joists, ultimately bringing the project within budget.
Ed Bloom, Vice President of EducationRockford Construction
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