Build and Learn: Underpinning & Shoring at the Kennett Creamery

At BPGS Construction, our Build and Learn sessions reflect our commitment to continuous improvement and technical excellence. Recently, our team came together to examine the complex structural challenges encountered at the historic Kennett Creamery.

Originally constructed in 1902, the building has served multiple industrial uses over the past century. Preserving and stabilizing a structure of that age requires more than standard practice—it demands thoughtful sequencing, adaptive engineering, and real-time problem solving.

Even minor miscalculations in underpinning or shoring can lead to settlement, safety concerns, or schedule disruption. Success depends on meticulous coordination and a deep understanding of how historic materials interact with modern structural requirements.

Structural Strategy at Kennett Creamery

Stabilizing the existing structure while preparing it for new uses required a targeted approach:

• Mass Concrete Underpinning
  Foundations were deepened below the 30-inch frost line to support new ramps and increased structural loads while maintaining the integrity of the original building.
• Tower Shoring
  Temporary tower shoring systems supported roof trusses during removal of legacy steel beams, ensuring safe demolition without compromising structural stability.
• Wall Bracing
  Historic stone walls were braced to resist lateral soil pressure during excavation until permanent structural elements were installed.

Coordination and Adaptation

Underpinning and shoring demand disciplined sequencing. At Kennett Creamery, work progressed in a structured “A-B-C” 7-day cycle to maintain continuous structural support. Building Information Modeling (BIM) was used to verify pier placement and sequencing, while third-party inspections confirmed proper installation and curing before load transfer.

When crews uncovered that a primary venue wall rested on loose, unmortared stone, traditional underpinning methods were deemed unsafe. The team adapted quickly, designing and pouring a reinforced concrete retaining wall against the existing stone foundation. This solution secured the historic wall while accommodating the new grade and structural requirements.

Lessons from the Field

Projects like Kennett Creamery reinforce key principles that guide our work:

• Safety-first sequencing – Confirm shoring before demolition begins.

• Proactive water management – Drain open trenches to prevent soil softening.

• Strategic procurement – Evaluate long-term shoring rentals versus purchase.

• Adaptability in the field – Anticipate unexpected conditions, especially in historic structures.

• Clear scope definition – Confirm shoring and specialty footings early to prevent cost impacts.

Building Knowledge, Strengthening Teams

Our Build and Learn sessions are more than project recaps. They are opportunities to share lessons, refine best practices, and strengthen our collective expertise.

Historic renovations demand precision, flexibility, and leadership. At Kennett Creamery, the team demonstrated how disciplined planning and adaptive execution can transform structural challenges into long-term stability.

If you’re passionate about collaboration, technical growth, and building with purpose, explore opportunities to grow with BPGS Construction.

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