GAP/Old Navy Distribution Center
Fishkill, New York In February of 1999, Clayco Construction Company was awarded one of the largest contracts in its 15-year history. The Gap turned to Clayco to construct its 1.5 million-square-foot warehouse/distribution facility for The Gap/Old Navy.

Phase I of the project included the main distribution bulk storage facility and the associated office components. Future phases include two additional stand-alone buildings set on a master plan campus design in Fishkill, N.Y.

Clayco provided an alternate to The Gap to construct the entire facility with its load bearing tilt-up concrete exterior skin technology. The building also contains more total square-footage of MFL walls than perimeter wall. The facility contains eight specific fire zones, each bounded by firewalls. These zones contain high-bay rack storage, combination rack storage and pick and multi-level pick modules, receiving dock areas, and sorting and shipping. The material handling and racking systems included within this facility are state-of-the-art and one of the most complex and intricate systems Clayco has coordinated with in its 15-year history.

The accelerated schedule provided an additional challenge for the Clayco design and construction team. The project included an excess of 750,000 cubic yards of rock blasting prior to the start of foundations.

This facility services approximately 350 Old Navy stores in the northeastern region of the United States.