Where Robotics Meets the Coast: Building for Resilience
MBARI’s new 30,000-sf Instrumentation Integration and Testing Facility combines advanced robotics research capabilities with resilient, environmentally sensitive coastal construction. Image: Garry Belinsky—Garry Belinsky Photography
The Monterey Bay Aquarium Research Institute (MBARI) in Moss Landing, CA, has unveiled a facility designed to change the way scientists and engineers explore the ocean. The new 30,000-sf Instrumentation Integration and Testing Facility, built by McCarthy Building Companies in collaboration with Flad Architects, expands MBARI’s capacity to develop advanced robotic technology to better understand and protect marine ecosystems.
More than just a building, the project represents the intersection of science, architecture, and environmental stewardship—an achievement that required creativity, technical skill, and a deep respect for the coastal setting in which it now stands.
Tackling coastal site challenges
Constructing a major research facility along California’s shoreline is no small task. The sandy soils, high water tables, and tidal surges at Moss Landing created an unstable building environment that required specialized solutions.
“Building on a coastal site with high water tables and sandy soil led to challenges that required creative problem-solving and strict schedule management. The sandy ground lacked stability, making it difficult to build the structure,” explains Kris Barr, senior vice president, McCarthy Building Companies.
To manage the challenges of working so close to the shoreline, the construction team implemented a method known as backforming, which involved shaping the sand to prevent it from encroaching on the concrete during pours. While this approach required some adjustment early on, it ultimately improved efficiency on site. The project also had to account for King Tides, which meant concrete placement had to be carefully scheduled and often wrapped up by early afternoon to avoid rising water levels. The ability to self-perform concrete work provided the contractor with greater flexibility and adaptability in navigating these unique coastal conditions.
King Tides, in particular, introduced a layer of unpredictability that demanded agility from the team. Pour schedules often shifted at the last minute, requiring extra manpower and careful sequencing. For other builders facing similar conditions, this project underscores the value of planning for tidal cycles early in scheduling and maintaining contingencies for environmental disruptions.
Innovative engineering solutions
Given the tight footprint and coastal constraints, traditional methods simply weren’t possible. “Due to the tight site constraints, traditional methods weren’t possible,” says said Barr. “The team used a reverse forming system with sand to cast panels creatively on-site. Since there was no room to brace walls from the outside, the slab had to be redesigned and reinforced to support everything from the inside. This required precise coordination. It was a unique, out-of-the-box solution that combined smart engineering and collaboration to make the project work in a very limited space.”
This approach also highlights a broader lesson: on constrained sites, design flexibility must be built into both structure and process. Instead of relying on textbook methods, the team combined creative formwork design, adaptive slab engineering, and close coordination among trades to make the project possible.
McCarthy’s decision to self-perform the board form concrete walls further improved quality control and schedule reliability. Self-performing not only gave the team direct oversight but also allowed adjustments in real time as unexpected conditions arose. For labs and other high-performance buildings, having the ability to adapt construction techniques in-house can mean the difference between delays and timely delivery.
Designing for resilience and longevity
The project also prioritized environmental protection and long-term durability. “Every piece of this project considered environmental impact and long-term resilience. We wanted to ensure that the building would persist in a unique environment and stand the test of time. For example, concrete walls are utilized to ensure longevity and stainless-steel grade nuts, bolts, and screws to resist rust. Additionally, sensitive areas were blocked off and it was emphasized that these areas be left alone,” says Barr.
These details—down to the grade of stainless steel—underscore how material choices are magnified in coastal environments. What may be “standard” in inland projects requires rethinking when salt spray and marine air become factors. The design team carefully vetted every finish and fastener to minimize corrosion risks and long-term maintenance costs.
Smart water management for sensitive habitats
Stormwater posed another major challenge. “To manage stormwater while protecting nearby dune and marine habitats, the team designed a system that accounted for king tides and site-specific conditions. They used permeable pavers to let water percolate naturally, reducing runoff and minimizing impact on the surrounding environment. This thoughtful approach balanced resilience and sustainability in a sensitive coastal setting,” Barr says.
Unlike conventional stormwater systems that direct runoff into municipal systems or waterways, MBARI’s facility is designed to mimic natural hydrology. Rainwater infiltrates through permeable pavers and bioretention planters, recharging the ground and limiting pollutants. Overflow only occurs in extreme weather events, reducing routine discharge into Monterey Bay.
This strategy provides a valuable takeaway for other labs near sensitive ecosystems: water management must be viewed not only as an engineering requirement but also as a form of ecological stewardship.
Protecting wildlife and nature with technology
The project team piloted several creative measures to balance building performance with wildlife protection. As Barr explains, “Two notable features of this project reflect a strong consideration for local wildlife.”
To minimize the impact of stormwater runoff, the site was designed to capture water from both the street and on-site drainage. Stormwater is directed into bioretention planters, while permeable pavers allow water absorption rather than surface discharge. “As a result, stormwater discharge to the bay functions only as an overflow system, not the primary outlet,” Barr notes. For this approach to work, the subgrade had to remain permeable—native sand sufficed, while a compacted aggregate base would not.
Nesting seagulls presented another challenge. The roof peaks were outfitted with a bird deterrent system that uses compressed air manifolds and nylon hoses to mimic the motion of inflatable tube men, discouraging birds from nesting. Each manifold is connected to a timer that periodically releases compressed air. “A key lesson learned was trimming the hoses to be long enough to move freely, but short enough to avoid getting caught under roof tiles,” Barr says.
For other builders, this provides a clear lesson: pilot systems should be tested for both performance and practicality. The bird deterrent system, though effective, required fine-tuning—a reminder that even innovative solutions benefit from iteration and real-world adjustment.
The facility’s coastal location also meant construction overlapped with fragile dune ecosystems. “Part of the site was located within sand dunes designated for environmental preservation, which made logistics more challenging. Incorporating environmental protection measures into our site orientation was a mandatory requirement. In some cases, we encountered protected insect species, and had to ensure work in those specific areas was not performed until the insects naturally vacated, luckily there were no impacts to work on these occasions,” Barr says.
Close coordination with local dune conservation biologists ensured proper fencing, exclusion zones, and monitoring were in place. For project teams elsewhere, MBARI’s approach underscores the importance of early stakeholder engagement with environmental experts to anticipate potential disruptions before they affect schedules.
Practical takeaways for future projects
The MBARI lab illustrates key lessons for project teams working in coastal or environmentally sensitive areas:
Schedule flexibility is essential — tidal cycles, wildlife activity, and weather can all affect work windows.
Material durability should be prioritized — every fastener, seal, and finish must be corrosion-resistant to ensure longevity.
Collaboration with environmental experts reduces risk — early input prevents costly rework and ensures compliance.
On constrained sites, innovation matters — reverse forming, reinforced slabs, and adaptive construction techniques allowed this project to succeed despite limited space.
Pilot and refine new systems — both the bird deterrent system and permeable paver installation required testing and adjustment before reaching optimal performance.
A model for coastal construction
By blending smart engineering, environmental sensitivity, and community collaboration, the Instrumentation Integration and Testing Facility demonstrates what is possible in one of the most challenging construction environments. “Every piece of this project considered environmental impact and long-term resilience,” Barr says. “We wanted to ensure that the building would persist in a unique environment and stand the test of time.”
The result is a building that will not only expand MBARI’s scientific capabilities but also stand as a model for sustainable, resilient construction in sensitive coastal settings—offering a roadmap for how research facilities can thrive at the intersection of innovation and environmental responsibility.
