The Yaphank Correctional Facility project consisted of: 1) clearing and preparation of 29 acres for site staging of a precast concrete production and storage yard; and 2) precasting 360 high security prison cells. The project was mandated by the Governor of New York State and had an aggressive time schedule to meet the executive order.

Because of the executive order mandating immediate construction, procurement for this project was greatly expedited. Therefore, the project had not been completely engineered and designed. Concrete precasting, usually done in an indoor controlled environment, had to be done on the site. Due to a short construction season, we had to mobilize very rapidly and expedite a detailed analysis of required resources and a quality control plan. This was the only way to ensure perfect production of precast materials under these uncontrolled conditions.

Posillico set up three main production areas, one for each phase of precasting: 1) the fabrication preparation area; 2) the forming and pouring area; and 3) the finish and staging area. Each area required a detailed pre-planned layout that anticipated each of the complex requirements of each phase. Just before the clearing and preparation of these areas, Posillico began mass excavation of the building area. This area consisted of thousands of yards of unsuitable fill that needed to be stabilized or replaced to eliminate impact to these soils once they were exposed to poor winter conditions. By training and implementing an aggressive project control methodology, which focused on workers safety, Posillico was able to successfully complete the precasting process and site construction ahead of schedule.