School is back in session for Sundt as we return to California State University, Fullerton for a new student housing project. Eight months ago, the team began construction on the $130 million Jewel Plummer Cobb Student Housing project after completing an award-winning housing expansion for the university in 2022. The project adds 512 beds to campus, increasing its on-campus housing capacity to over 2,600. Located beside the Arboretum and Botanical Garden, the new space focuses on wellness – offering outdoor seating and a relaxing courtyard where students can de-stress or bring their studies into nature.

With its opening, Cal State Fullerton will launch a new affordable housing initiative that includes 390 subsidized beds specifically for students. These units are offered below standard rental rates, making them more accessible to students who face financial barriers or burdens.

Jewel Plummer Cobb Student Housing will be 155,000 square feet and six stories of apartment-style housing for upperclassmen and includes laundry area, mail room, and market.

 

 

Making the Grade with Concrete Self-Performance

With a team of 43 skilled craft professionals, Sundt is self-performing the concrete scope of the project. To date, the team has poured 9,783 cubic yards of concrete. Along with subcontractor CMC Steel Fabrications, the team has used 1,250 tons of rebar and 286,000 linear feet of post-tensioned cable.

The team began pouring foundations in December 2024, before moving to level one vertical elements in January, the slab at the end of February and the level two deck in March. To date, they have completed 26 concrete pours.

 

 

Why Concrete?

Thoughtful material selection in the planning phase is key to achieving a project’s long-term goals.

Concrete’s resistance to rot, mold, termites, and moisture makes it an optimal choice for long-lasting structures. It also offers lower maintenance costs over time when compared to traditional wood framing. In regions like Southern California, where fire safety is a critical concern, concrete’s noncombustible nature adds an important layer of protection for residents. Beyond its structural benefits, concrete helps create a more peaceful living environment. It reduces noise and wall vibrations, minimizing disruptions from neighbors and enhancing the overall student lifestyle.

 

 

Overcoming Roadblocks with Innovative Solutions

Leveraging new technologies, skilled team members and additional support, the team has delivered unique solutions to challenges encountered throughout construction, proactively mitigating potential issues.

While working in Southern California comes with its perks, the team had to strategize around one of the region’s downsides: traffic. The team carefully planned around Southern California rush hour, ensuring that the trucks delivering supplies and concrete wouldn’t be backed up due to heavy traffic.

 

 

“Our placements are at 2 a.m. and the pours usually last three and a half hours. By the time traffic starts picking up, we are basically wrapping up our placements,” said Gerardo Lopez, Project Superintendent for Sundt’s Concrete Division. “By the time it cures around 9 a.m., we’re able to let our vertical crew on the deck so we can start setting vertical.”

 

 

Another aid in avoiding schedule delays was the team’s use of new and improved SmartRock sensors. These sensors were incorporated to assist in checking concrete temperatures and PSI.

“This [SmartRock Sensors] helps the team monitor the strength of the deck, and it gives us an early indication of when we can stress the decks,” said Nicholas Aguilar, project manager. This early accuracy enabled the team to move on to the next cycle faster, keeping the project on schedule.

Additionally, Cemex, the concrete supplier, had a full-time quality control technician at the plant and on the jobsite to monitor the concrete as it arrived on site. These extra precautions ensured concrete work met plan specifications and quality standards.

Using Sundt’s in-house technology also helped identify and address issues before they occurred. Virtual Construction Senior Engineer Adrian Juarez captured detailed photos of the concrete decks with a drone before the concrete pour.

“In the event we need to post anchor any bolts or screws, we can identify where the rebar and the post-tension cables are located with one-eighth of an inch,” said Aguilar.

Sundt’s self-perform concrete team uses innovative approaches to deliver high-quality, long-lasting structures for higher-education and student housing. With a skilled team working together, the Cal State Fullerton Campus Jewel Plummer Cobb Student Housing project continues on schedule and trending under budget. Learn more about how we build student housing for the future.