OCTOBER 2012
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CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012 5
CONTENTS
THE UAW / CHRYSLER WORLD CLASS MANUFACTURING ACADEMY
FALL 2012 SPECIAL ISSUE
FROM
12
elcome to the 17th edition of CAM Magazine’s Special Issue. These 12 honored projects show great diversity and an interesting cross-section of the types of projects that are going on in Michigan’s construction industry today.
C.S. Mott Children’s Hospital & Von Voigtlander Women’s Hospital U-M’s Big Hospital for “Little Victors”
18
BAE Systems Sterling Heights Facility Leaning Forward Into Battle
24
Wayne State University, Chemistry Building Addition & Renovation A World-Class Facility
30
THE
EDITOR
W
As you read through these projects, you will see many positive indicators: progress with environmental consciousness; value engineering; LEED certifications; use of Building Information Modeling (BIM); wind developments; alternative energies; bringing global industry to Michigan; cutting-edge technology; Crime Prevention Through Environmental Design (CPTED); revitalizing the Great Lakes tourism market; along with many challenges and achievements. We would like to thank our members for their continued support of CAM, CAM Magazine, and this annual Special Issue. Enjoy.
Berman Center for the Performing Arts Playing Against Type
36
The University of Michigan Player Development Center for Intercollegiate Basketball
Amanda Tackett Amanda Tackett Editor
Home Court Advantage
6 CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012
“Voice Of The Construction Industry”®
Expanded Opportunities
Available online at www.cammagazineonline.com
CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012 7
CONTENTS
THE M@DISON BUILDING
FALL 2012 SPECIAL ISSUE 42
Detroit/Wayne County Port Authority Public Dock and Terminal Port of Call on the Riverfront
52
86
Michigan State University, Molecular Plant Sciences Building Expansion A New Breed of Building for MSU
92
Project Subcontractor Lists
The M@dison Building Detroit’s Tech Incubator
70
Mackenzie Pre K – 8 School Building Design Focuses on Student Safety
H-Project Battery Manufacturing Facility Jumpstarting a New Industry
62
82
Chrysler / UAW World Class Manufacturing Academy
CAM MAGAZINE IS ONLINE S U B S C R I B E F R E E T O D AY !
Built for Success
76
Gratiot County Wind Project A Bumper Crop of Wind Turbines
www.cammagazineonline.com 8 CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012
“Voice Of The Construction Industry”®
American Beauty
The XLERATOR® hand dryer is the new industry standard. The XLERATOR dries hands completely in 10–15 seconds, uses 80 percent less energy, saves 95% versus paper towels and reduces your carbon footprint by 70%. It is the only hand dryer that is MADE in USA CERTIFIED™ and the first hand dryer to be GreenSpec® listed. It also helps facilities qualify for LEED® credits. All with a state-of-the-art, efficient design.
TIME TO THROW IN THE TOWEL PROUDLY REPRESENTED BY CAM MEMBER: DUKER-REILLY-MCPHERSON & ASSOCIATES, INC. 877.376.2863 • www.duker-reilly.com Available online at www.cammagazineonline.com
BORN IN THE U.S.A.
CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012 9
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PUBLISHER EDITOR
Kevin N. Koehler Amanda M. Tackett
ASSOCIATE EDITOR
Mary E. Kremposky
PRODUCTION DIRECTOR GRAPHIC DESIGN DIRECTOR OF MARKETING ACCOUNT EXECUTIVE
Matthew J. Austermann Marci L. Christian Gregg A. Montowski Cathy A. Jones
DIRECTORS OFFICERS Chairman
Frank G. Nehr, Jr. Davis Iron Works
Vice Chairman
James Brennan Broadcast Design & Construction, Inc.
Vice Chairman
Donald J. Purdie, Jr. Detroit Elevator Company
Treasurer
Gregory Andrzejewski
President
Kevin N. Koehler
PPG Industries
DIRECTORS
Larry S. Brinker, Jr. The Brinker Group
Roofing and and Wall Wall Systems Systems in in Many Many Profiles Profiles from from •• Roofing Different Manufacturers Different Manuafacturers
Kevin French Poncraft Door Company
Todd W. Hill Ventcon, Inc.
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Beaver Tile & Stone
Donielle Wunderlich George W. Auch Company
CAM MAGAZINE EDITORIAL ADVISORY COMMITTEE
William L. Borch, Jr. Ironworkers Local Union 25
Gary Boyajian Universal Glass and Metals, Inc.
Stevan Bratic Bratic Enterprises, LLC
Marty Burnstein Law Office of Marty Burnstein
George Dobrowitsky Walbridge
Daniel Englehart Peter Basso and Associates, Inc.
Chris Hippler Capital Letters
Dennis King Harley Ellis Devereaux
Nancy Marshall Aluminum Supply Company
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CAM Magazine (ISSN08837880) is published monthly by the Construction Association of Michigan, 43636 Woodward Ave., P.O. Box 3204, Bloomfield Hills, MI 48302-3204 (248) 972-1000. $24.00 of annual membership dues is allocated to a subscription to CAM Magazine. Additional subscriptions $40.00 annually. Periodical postage paid at Bloomfield Hills, MI and additional mailing offices. POSTMASTER, SEND ADDRESS CHANGES TO: CAM MAGAZINE, 43636 WOODWARD AVE., BLOOMFIELD HILLS, MI 48302-3204. For editorial comment or more information: magazine@cam-online.com For reprints or to sell CAM Magazine: 248-972-1000 Copyright © 2012 Construction Association of Michigan. All rights reserved. Reproduction in whole or part without permission is prohibited. CAM Magazine is a registered trademark of the Construction Association of Michigan.
10 CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012
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With fossil patterns on the floor and washes of LED light above, the lobby has a natural feel with a touch of Disney magic.
By Mary E. Kremposky, Associate Editor he new C.S. Mott Children’s Hospital is a place with a child’s fingerprints all over it in the best way possible. Past and present patients crafted over 1,600 colorful tiles scattered throughout this leading pediatric hospital. “We took a picture of each child when they made the tiles, and we held a special event for all of them,” said Associate Hospital Director Loree Collett, RN, BSN, MSBA, C.S. Mott Children’s Hospital, Von Voigtlander Women’s Hospital. The hands of hundreds of skilled tradespeople left their own mark on the new C.S. Mott Children’s Hospital and the Von Voigtlander Women’s Hospital, a hospital within a hospital located on the ninth floor and directly paired with a new birthing center. At over 1.1 million square feet, this amazing facility was the largest construction project in Michigan at the time of its construction. Barton
T
Malow Company, Southfield, orchestrated the construction of this massive project teaming with an average of 600 construction workers daily. “It was like building a city,” said Associate Director Mary L. Krasny, Hospital Design & Construction, University of Michigan Architecture, Engineering and Construction. Barton Malow began construction in February 2007, and 10,500 tons of steel and 1.3 million sheets of drywall later, the four main entrances to this new hospital swung open in December 2011. Designed by Dallas-based HKS, Inc., the new $754 million dollar facility is already delivering the next generation in the birthing center’s 50 private maternity rooms. Stitched into the University of Michigan Health System’s (UMHS) main medical campus in Ann Arbor, the new facility supports the work of approximately 4,500 employees, virtually creating a small town within a larger
12 CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012
Photography by Brad Feinknopf medical complex. Despite its massive size, this house of healing never loses its personal touch. Photos of children who were once babies in the Neonatal Intensive Care Unit (NICU) grace a display wall near the new NICU’s 46 private rooms. At C.S. Mott, a child can select the LED wall color and play character of their choice in the hospital’s new open-field MRI, a much less confining MRI than its conventional, narrow tube counterpart. The 348-bed hospital also never loses its visual connection to the natural world. Housed in two broad curves, the 12-story inpatient wing rises on the leafy fringes of Ann Arbor’s Nichols Arboretum, an oasis of woodlands, gardens and fields along the Huron River. The nine-story outpatient wing offers expansive windows adorned with nature-based artwork. The building’s undulations – a series of concave and convex arcs - are calculated to fit “Voice Of The Construction Industry”®
this massive building on an incredibly tight site, all while offering every inpatient room a view of this natural oasis, affectionately called The Arb. “The primary driver for the design of the building had to do with its relationship to the arboretum across the street,” said Senior Vice President John Bienko, AIA, associate principal at HKS, Inc., the architectural firm whose health care group and pediatric studio designed the facility, as well as at least 50 other children’s hospitals across the globe. Beyond a wonderful natural view, the University injected sustainability into the very fabric of the building, ultimately achieving LEED Silver certification. From a 100,000-square-foot green roof to several detention tanks below the building, this new development manages its own stormwater and protects The Arb from any negative impact. With a rooftop helipad designed to take the fierce winds generated by a Black Hawk helicopter, Barton Malow established the sedum roof two years prior to occupancy to ensure a secure, well-established installation, said Senior Superintendent Brad Smith, Barton Malow. Inspired by the University and the Ann Arbor community, the project team opted for LEED registration in the very beginning of schematic design. Barton Malow stepped up to the plate to go the distance for LEED certification, diverting 86 percent of waste from a landfill, using all biodiesel fuel in construction equipment, securing 84 percent of wood products certified by the Forest Stewardship Council, and completing extensive documentation. “I have to give Barton Malow credit,” said Krasny. “Because of their ability to document the materials going into the building, we were able to get LEED points that we weren’t really expecting to get, which brought us so close to LEED Silver we went for it.” The grand, two-story lobby reflects the community’s respect for the natural world. Referencing a tree, the lobby’s main columns “grow” from a floor marked with fossil patterns. In another area, a high wall is host to a burst of blue metal butterflies composed of recycled Arizona Ice Tea cans, each cut, stamped and painted by an artist who transformed potential trash into a fluttering wall collage. “The contractors drank Arizona Ice Tea while they were building the hospital, and the artist was able to recycle and reuse the 800 cans,” said Collett. The inviting lobby and interior is filled with colorful floor patterns, delicate washes of LED lighting and greeting stations clad in Pewabic tile. Beneath these appealing finishes are the colossal steel “bones” of a building capable of supporting 17-foot-high, floor-to-floor heights. “At 195 feet, the overall height of the building is equivalent to a 15- to 18-story structure rather than the actual 12 stories,” said Senior Vice President Penny Wright, AIA, CCA, LEED AP, associate principal, HKS, Inc. Available online at www.cammagazineonline.com
The University prescribed greater floor-tofloor heights to provide a sense of openness and to create a flexible space for the latest medical technologies and MEP systems. “Most of our hospitals do not have this type of floorto-floor height, but the U-M standard requires this height in order to have a larger plenum space for increased flexibility of systems,” said Bienko. With increased infrastructure space, the new hospital has the power to offer best practices in healthcare, including 16 operating rooms with robotic surgery capabilities and the first intraoperative MRI in Michigan and one of the few in the country. With 4.4 million feet of wire for electrical, communications and fire alarm, C.S. Mott has a Get Well Network, an education and entertainment network bringing on demand patient education, movies and games to a flat screen panel at the foot of every child’s bed. In addition, the hospital has 100 percent HEPA filtration throughout the building, allowing the adult Bone Marrow Transplant Unit to provide a high level of protection to its patient population and permitting children with certain disorders to avoid being confined to only designated areas. Recently, C.S. Mott, Von Voigtlander hospitals have been ranked among the top 100 most innovative and inspiring infrastructure projects in the world by KPMG, an audit, tax and advisory firm with a Global Infrastructure Practice. In 2012, U.S. News & World Report placed C.S. Mott, Von Voigtlander among the nation’s top hospitals in all 10 categories. In line with such an accomplished client,
Barton Malow used best practices in construction management to build this leading hospital, including employing BIM for coordinating both overhead systems and inwall construction. As part of managing this fast-track project, Barton Malow used two tower cranes that were completely unattached to the building. “We used two 330-foot-tall tower cranes that were among the tallest independent tower cranes used in Michigan,” said Vice President Don Davis, Barton Malow. Barton Malow devised a schedule and phasing plan that essentially broke this galactic project down into manageable pieces. Outside of the original project timeline, Barton Malow even completed 125,000 square feet of shell space scattered in 22 different locations throughout the building, said Associate Project Director Mary Pinegar-Koster, U-M Architecture, Engineering and Construction. At the end of the day, Barton Malow delivered this miracle project a year earlier than anticipated and 10 percent under budget. “I think everybody who worked on the project did a phenomenal job,” said Krasny. “We were all together for many years, and there was a great deal of cooperation between not only Barton Malow and HKS but also Horizon Engineering Associates, Novi, our commissioning group, as well as the University’s interiors and capital equipment team.” FAMILY VALUES High demand and an outdated facility ultimately drove the development of this stateof-the-art hospital. “At the old hospital, we were
The building’s massing was calculated to fit this 1.1-million-square-foot hospital on an incredibly tight site. CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012 13
very close to 90 percent occupancy at all times,” said Collett. “We had demand and a proven business case. About five percent of our patients come from outside Michigan and even from around the world.” Originally built in 1969, the former hospital was outdated both in its ability to incorporate new technologies and in its level of accommodations. The before picture: Cramped accommodations with four pediatric patients sharing one bathroom, and sleeping arrangements for only one family in a semiprivate room. More frequent patient transfer was required to create semi-private rooms with patients of the same sex. The after picture: 300square-foot private rooms with sleeping space for parents and even a personal refrigerator. The new C.S. Mott also includes decentralized nursing stations, duplicate headwalls in every patient room and a personal medicine cabinet. Respite areas at the end of every floor offer seating areas and a view of the rolling hills enveloping Ann Arbor. Family centers, complete with showers, laundry facilities and Internet access, are available to help parents more comfortably stay with an ill child. A COLLABORATIVE CULTURE The University approved the development of the new hospital in 2005, beginning the search for the best project team. The University wanted an architect and contractor with previous experience working with an academic medical center and prior experience on a fasttrack project. But one “soft” skill trumped the others: the ability to communicate and work collaboratively. “Even though a company may have had individuals with healthcare experience, we wanted to see if they had worked together successfully on the same project,” said Krasny. “Also, the consultant team on this project was huge. We needed firms that could work in a collaborative culture.” Sharp communication tools were a must for this immense undertaking. Over 400 people in the Mott community took part in focus meetings in the design phase alone. A small army of University personnel, project consultants and trade contractors built the new 855,000-square-foot inpatient wing and the linked 245,000-square-foot pediatric clinic and medical office wing. “Not only is the building big, but the entire organization was big,” said Krasny. “The University had an unprecedented number of staff dedicated to this project. Overall, seven project managers were assigned to the team full-time, plus myself as project director to provide design and construction management for the University.” The architect maintained an average of three full-time field reps on site for five years. Barton Malow managed its own battalion of construction forces. “On the dayshift, we hit 780 people at peak, and that was for about seven months,” said General Superintendent John
Pierman, Barton Malow. Because of the tight site, Barton Malow even bused construction workers in daily from a parking lot near Plymouth Road and US 23. BREAKING GROUND October 6, 2006 marked the official groundbreaking ceremony, but February 2007 was the actual launch of this herculean effort. This postage stamp of a tight site was a simple surface parking lot – a blank slate of asphalt with minimal utilities snaking through the soil below. Because of the site’s fine sugar sand, the project team opted to install continuous rows of overlapping auger cast piles as the earth retention system. “With this running sand and a typical beam and lagging retention system, there might be a great deal of settling through the beam boards and above at the surface,” said Smith. In addition, installing auger cast piles is a “quiet, fast and smooth operation” that reduces vibration on a tight site in close proximity to University Hospital and directly along the perimeter of a main roadway, said Pierman. Auger cast piles with pile caps were chosen for foundations, as well. The auger cast piles are 80 to 120 feet deep, with some piles hitting a shelf of clay hardpan at 80 feet. “Where the clay hardpan drops off to an area of deep sand, the auger cast pile foundations had to go to a significant depth of 120 feet,” said PinegarKoster. A STEEL COLOSSUS After “planting” foundations in the glacial soil, Barton Malow began installing the monumental structural steel frame. “Some of the pieces were ordered from Belgium, because there was no mill in the United States that could make the large beams that are in the lowerlevel loading dock,” said Krasny. Bienko explains, “A floor-to-floor steel truss creates a 150-foot clear span on the back side of the loading dock to facilitate truck movement. The large steel columns are sized to support that steel truss.” Another reason for ordering stout pieces of steel was changing shear walls from poured-inplace concrete to steel frame. “We chose that direction because it helped the overall construction schedule,” said Pierman. Large steel pieces also support the building’s large bay sizes and the 17-foot-high, floor-tofloor height, added Wright. This height is dwarfed by the 38-foot-high, floor-to-floor height in the fifth- and sixth-floor mechanical rooms. One thing was even higher than the mechanical rooms: the sky-high price of steel at the time of the project. High prices and uncertain availability of some of the building’s unique steel sizes led the project team to order much of the steel in design development. “At that time, we only had a short window, as little
14 CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012
as 20 days, to order certain sizes of steel,” said Krasny. Overall, four orders of steel were issued in design development, roughly 8 to 10 months ahead of time. Clearly, the early bird gets the worm and at the best available price, too. “By doing this, we were locking in steel pricing,” said Pinegar-Koster. Barton Malow enlisted the services of Midwest Steel, Inc., Detroit, as steel trade manager to handle the detailing that would almost certainly be needed. “We knew that ordering during design development was going to create the need for some changes as the rest of the design caught up,” said Krasny, “but at least we had the major pieces ordered and on the way.” The actual design is “structural gravity framing (gravity loads are vertical loads bearing straight down) with composite steel beams and a lightweight concrete deck,” said Wright. “The lateral system for managing wind and seismic loads is a combination of moment frames and braced frames.” Bienko added, “With such a high building, we had to really take wind loads into consideration.” Midwest Steel began installation in November 2007 and topped out in December 2008. During steel erection, Barton Malow constructed a temporary interior staircase to ease access. “As the structural steel went up, the steel-framed stairs went up with them,” said Smith. “We had access to each floor as it was erected.” Ultimately, construction access included the use of four of the 21 elevators now providing vertical circulation throughout the facility. WORKING INSIDE OUT Building enclosure spanned from October 2008 to October 2009. Barton Malow masterminded the building enclosure – part precast panels and part glass curtain wall - for maximum efficiency and minimum site congestion. “There are over 1,150 precast panels and some of the panels are upwards of 30,000 to 40,000 lbs.,” said Smith. “With only two panels per truckload, and with the goal of putting up 10 to 12 a day, it meant a great deal of trucking in and out of the tight site.” Barton Malow orchestrated a complex flow of materials and manpower on the tight site as an aid in precast installation and for the entire project. “We had seven gates to the property, which gave us the ability to maintain the flow of materials and trucks in and out of the site without the vehicles having to turn around constantly,” said Pierman. “We had a full-time person on the loading dock and sometimes even two full-time people.” Barton Malow also broke the precast installation into four different building areas and used tower cranes to hoist the heavyweight panels. Being unattached to the building, “the two independent tower cranes “Voice Of The Construction Industry”®
didn’t interrupt the installation of the building’s exterior skin,” said Davis. Barton Malow used two internal buck hoists for the same reason. “The interior buck hoists allowed enclosure to go on without leaving 12story holes open in the building face that had to be filled in later,” said Pierman. For curtain wall installation, the massive tower cranes gave way to a small crane called a Geko. The unitized glazing system was fabricated off site, shipped to the jobsite and loaded into the building interior. “We actually erected the curtain wall from the inside out,” said Smith. “We didn’t have to take up any valuable site space occupied by other jobsite activities.” The Geko was used for this novel approach. “It is a small crane that can actually fit through a door opening and hoist weights of up to 2,500 lbs. for curtain wall and similar types of exterior components,” said Smith. CALCULATED PHASING Overall, the building was divided into four sections and constructed from east to west. Work on different components occurred simultaneously under Barton Malow’s phasing plan. “At one point, steel was being set on one side of the building, concrete deck was being placed in the center, and the enclosure of precast panels and finally curtain wall was being installed at the other end,” said Smith. The two independent tower cranes - set on 30-foot square and 10-foot deep concrete foundations - were pivotal to this multi-tasking maneuver. “The booms overlapped each other, giving us the full reach of the entire building,” said Pierman. Divide and conquer was used on the interior, as well. “We grouped the floors into threes due to the size of the floors and the amount of work,” said Smith. “But at 100,000 square feet, each individual floor essentially had its own separate crew and supervisors. Almost every floor was handled as a small project.” Ultimately, construction was in full swing on all floors. “We staggered the start of the floors, sequencing three floors at a time, but at one point we had all the floors going,” said Pierman. “In some cases, we even broke each floor down further, so we could resolve issues more quickly instead of having to potentially stop for any reason.” MEP MAGIC With its clash detection magic, BIM was used to coordinate the vast labyrinth of MEP systems snaking through the interior. BIM coordination took well over a year to complete in the model - actually longer than conventional overhead coordination - but “the payoff in speed of construction more than made up for it,” said Pinegar-Koster. Krasny added, “Once work began in the field, it progressed relatively unimpeded by questions and RFIs.” Available online at www.cammagazineonline.com
Barton Malow used the BIM model to launch construction of each floor. The foremen of each MEP contractor met together and viewed the model to gain control of the installation sequence in the field. The sequence differed from floor to floor and even within each floor, making BIM the best tool in the tool belt for efficiency and schedule. “It really paid off in the big mechanical rooms, because they contain layer after layer of ductwork, conduit and pipe,” said Pierman. “Without that 3D model,
installation would have been much slower.” The project is a first for Barton Malow in using BIM for in-wall coordination. Essentially, “BIM was used to coordinate all the electrical, telephone, data, and mechanical outlets in the walls,” explained Krasny. “It was a way to make sure we weren’t missing outlets or installing anything unnecessarily back-to-back.” For accuracy, a headwall template was used for outlet installation to ensure uniformity in every patient room. For further efficiency,
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Barton Malow also enlisted the services of Dee Cramer, Inc., Holly, as a trade manager for dryside mechanical. With some trade contracts larger than most projects, several of the larger MEP contracts were split into more manageable pieces. Four major electrical contractors handled different aspects of this gargantuan project. Barton Malow issued two separate HVAC contracts with the mains and the equipment in one contract and all the branch lines as a separate contract. “This approach made it more manageable for the trade contractors, both manpower wise and financially in terms of bonding capacity,” said Pierman. PLAYING A SHELL GAME By 2010, Barton Malow had shepherded this complex project through four years of complex site logistics, work sequencing and the daily game of problem-solving on a nine-figure construction project. The University then decided to finish most of the shell space scattered throughout the new complex. “At first, we thought finishing the shell space was going to add an additional year to the project,” said Krasny. Barton Malow completed the requested shell space a year earlier, managing an additional $30
million in construction by assigning a separate group to complete this unexpected assignment. Success also hinged on State of Michigan inspection and approval of the fire alarm system for both the main base building and the shell at the same time. “The work was sequenced in a way that the fire alarm for both projects could be tested together,” said Krasny. “The State of Michigan went along with the plan. The testing was intense but it got done, and it was the piece of the puzzle that allowed this all to come together.” The doors still would not have opened on that December day without the continual presence of the State of Michigan health inspector throughout the entire job. “The inspector came to the site at very regular intervals, so when it came down to what would be the formal inspection for occupancy, our list was miniscule,” said Pinegar-Koster. Barton Malow made continual adjustments based on the inspector’s regular visits throughout the project. “We were comparing notes with one of our sister institutions out East that had a hospital at the same point as ours,” recalled Krasny. “They were resolving a notebook full of adjustments called for by state inspections. On our job, we had a very short list of open issues that needed to be addressed.”
A WELCOMING LIGHT The end result of this truly monumental effort is a new, improved and enlarged version of this leading hospital, including a Trauma I pediatric emergency department and even a Regional Infectious Containment Unit (RICU) for high-level infection control on the top floor. HKS created key adjacencies linking all of the pediatric clinic service lines directly to their inpatient hospital floors and created ties to the existing parking decks. “As part of our LEED strategy, there was no parking added for this building,” said Bienko. LED lighting around circular stations, ceilings and even elevator buttons adds a beautiful wash of color and serves as an intuitive wayfinding system, along with bold and colorful floor patterns. Beyond its visual appeal, the hospital’s rubber flooring offers durability and ease of transport. “We tested it in our old hospital for about three years,” said Collett. “We found rubber floors are easier to push wheelchairs and stretchers on.” With welded seams, the rubber floors are ideal for infection control, added Bienko. This child-friendly interior is filled with warm, vibrant spaces rich with color, including a large playroom sponsored by the U-M Athletics Department. The Radiology waiting area is a
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“Voice Of The Construction Industry”®
playful orange and even has a section dubbed The Tree House, a cozy play area with low-level windows at toddler eye-level. Overlooking the main lobby, the tree house’s exterior wall becomes a canvas for the shifting tones of iridescent LED lighting bathing the lobby’s upper reaches. “The color-changing kinetics can be programmed according to different seasons of the year,” said Bienko. Light adds its magic to other parts of the lobby with a field of pendant light fixtures twinkling with white lights. On the way to the new cafeteria, a small dome, painted a cobalt blue and dotted with fiber optic lights, resembles a star field. The lobby’s lighting and its natural themes, including a mezzanine glass wall etched in the same fossil pattern as the lobby floor below, are just what parents and families ordered for their new hospital. HKS presented disposable cameras to a parent focus group, sending them out into the community for two weekends to capture preferred images for the hospital interior. “Some images had a Disney feel with fireworks and strong colors and others were nature-based, including a young girl peering into a hole at the bottom of a tree,” said Bienko. HKS compiled a picture board of assembled images and translated them into the hospital’s interior spaces, creating a natural theme with a subtle touch of Disney magic. At the end of 2011, every pile had been drilled, every steel member welded and the entire convoy of scissor lifts in the interior had folded down their accordion-like shapes. The new hospital hosted 17 grand opening events, including a special day dedicated to the tradespeople and contractors on this immense project. The public opening on Nov. 6, 2011 attracted 20,000 to 25,000 people with lines snaking around the block. Dec. 4, 2011 marked the first day of operations at the new C.S. Mott Children’s and Women’s Von Voigtlander hospital. The hospital began operations at 7 a.m., and at 7:05 a.m. everyone knew the work of over half a decade had succeeded. “We walked through the NICU at 7:05 a.m. and a baby was in the isolet, mom was in the chair and dad was on the sofa watching television,” recalled Collett. “They were all comfortable, and we knew the hospital was working as wonderfully as we originally envisioned. “A family member found the comments page on our website through their flat panel Get Well Network,” continued Collet. “They said, ‘I can’t believe how beautiful this building is.” Thanks to Barton Malow, HKS, the University of Michigan Health System, and hundreds of design, construction and healthcare professionals, the children and families throughout Michigan and beyond can put their trust in this leading hospital’s ability to deliver quality, family-centered patient care in a wonderful setting. Available online at www.cammagazineonline.com
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Leaning Forward Into Battle — BAE Systems Sterling Heights Facility By Roy Jones, Contributing Editor Photos Courtesy of James Haefner Photography
Systems, the second largest defense contractor in the world, purchased a property from TRW Automotive in December 2008 with the primary purpose of being close to their main client, TACOM (Tank and Automotive Command) and TARDEC (Tank Automotive Research Development and Engineering Center). From the start of demolition in February 2009 to the ribbon cutting ceremony in March 2012, the facility is vastly different from the surrounding buildings in the industrial neighborhood, which encompass the northern end of Van Dyke Avenue in Sterling Heights. The facility sits on 80.6 acres which is comprised of a 164,000 GSF four-story Office Building, connected to a 55,000 GSF Prototype Facility. The remaining acreage supports a test track, secured entranceway and ample parking for visitors and employees - 800 spots in all.
BAE
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INNOVATIVE AND BOLD “The design of the building is innovative and bold, as if we are leaning forward into battle,” said Joe Hoffman, BAE Systems facilities manager. The curved clear glass edge leans forward with a simple elegant move - transforming a rectangle into a parallelogram, easing the southeast corner with a curve and then extruding the form while tilting it towards Van Dyke. “The exposed structural tubes, incrementally tilting forward and progressively rotating, remained perpendicular to the curve,” stated Luigi Coletta, project designer at SmithGroupJJR, Detroit. Transparency was a key factor in the design, as it is highly instrumental in the client’s own identity. The glass exterior allows for lucidity, while the frit pattern design on the glass provides the security of camouflage for the interworking of a highly private client. The metal panels on the building are black, as is the precast concrete, with no grey area – symbolizing BAE Systems’ mission to provide solid, determined protection for their clients. The fabric of the building was designed with clear insulated glass, low-E coating and a custom silk screen ceramic skin. Large portions of the exterior skin were created with curved and slanted glass. This was done in sections, beginning at the corner of the building to soften the ruggedness of the shape and create a pleasant face towards the street traffic. The north side of the building features black, high gloss metal system with black glass. The general shape of the building has an offset core, which allows BAE Systems to have large areas of space for their engineers for work activity, while also creating an enjoyable environment by maximizing daylight. According to Wayne Bills, AIA, LEED AP BD+C, vice president at SmithGroupJJR, “We wanted to create spatial layouts to support employee collaborating and encourage interaction. The glass design throughout offers as much daylight as possible.” SmithGroupJJR provided full architectural, structural, mechanical “Voice Of The Construction Industry”®
and electrical services on the facility for the programming and conceptual phase, as well as full architectural/engineering services for the second phase of a new facility. The design of the insulated exterior glass panels provided a challenge for SmithGroupJJR, as it was both curved and slanted. Each panel of the curved Insulated Glazing Unit (IGU) was progressively tilted forward. The purity of the form is evident in the smoothness of the curve. Manufacturing curved glass is a difficult process, with the production including many challenges. Coletta explained, “Producing tilted and curved glass for an IGU significantly increased the difficulty during the manufacturing process. The length of the curved glass also had restrictions, as it could not be manufactured at the same length as the rest of the IGUs. By embracing the truth of the material, we expressed this limitation with an additional horizontal break. Keeping the curved/tilted glass on the same surface and providing a continuous smooth line of the horizontal mullion was extremely important to our design. We achieved this by widening the mullion cap from their standard size, giving us enough bite to keep the IGUs on the same surface and by keeping the mullion cap plumb to the ground, while sweeping it along the curve in plan." SmithGroupJJR worked with glass and curtain wall manufacturers, as well as the SmithGroupJJR Building Technology Studio to create the design for the glass. Using Revit, the designers created the details for the panels. Collaborations between the glass manufacturers and installations were crucial. Trainor Glass, Allen Park, started the construction end of the glass project and worked well coordinating the design of the curved, fourstory curtain wall. As mentioned earlier, the design was difficult as it leaned out as it curved. “The teams from EFCO, Viracon and Old Castle Glass deserve recognition for their efforts to making it come together as well,” said Hoffman from BAE Systems. Ferndale-based Peterson Glass was among the few glazing contractors that Walbridge called to help complete this project. According to Hoffman, “They stepped up and helped sort out open issues, dealt with all the suppliers, and were able to complete the project prior to the ribbon cutting ceremony.” According to Scott Ashe, project manager at Walbridge, Detroit, “The management at Walbridge greatly appreciated Peterson’s willingness to jump into the project late and do whatever it took to make this section of the project a success.”
A TOTAL TEAM PROCESS BAE Systems was highly invested in an integrated team process, which included construction manager Walbridge; owner’s representative Plante Moran CRESA, Southfield; and architect/engineer SmithGroupJJR from the beginning of the design phase through construction. Bills stated, “Mike Bocek and BAE Systems understood the value of partnering and the strength of a collaborative effort from the very beginning of the project. The team met weekly to provide diverse views and objectives through all phases of design and construction, vetted out and distilled into a common vision.” In order to meet the client’s strict scheduling timeline, SmithGroupJJR utilized a multi-phased approach process (designbid-build) for accelerated progress of the facility site development, Prototyping Facility and Office Building. With an advanced multipronged knowledge, SmithGroupJJR had the capabilities to deal with all components of the project including the high security site, technologically advanced Prototyping Facility and high image Office Building. One of the major contractors that contributed to the success of the project was Detroit-based Motor City Electric (MCE). They were part of both phases which spanned over two-and-a-half years of construction. “Their field team worked under immense pressure and delivered on a tight schedule,” Ashe. “There are a lot of major players on this project that helped make it successful as well, but MCE was extremely consistent and reliable.” An additional unique design solution was the creation of a stateof-the-art conference center, named the Genesis Center, located on
WE PROTECT THOSE WHO PROTECT US BAE Systems’ motto is,“We Protect Those Who Protect Us.” Upon entering the lobby, visitors will notice a global company design with a Gulf War theme. A comfortable setting adds to the welcome. The lobby area also has a conference room named after the Gulf War battle “73 Easting.” This room is used also as an interna- The design of the bulding is innovative and bold as if leaning forward into battle. The curved tional meeting room for guests that can’t get clear glass edge leans forward — transforming a rectangle into a parallelogram. access to other areas of the facility for security reasons. the 2nd floor of the facility for increased client interaction, Conference rooms are named after famous battles from United showcasing BAE System’s products in a high technology States history such Gettysburg, Fredericksburg, Bunker Hill, Iwo Jima presentation and conference space. Another is the 2nd floor and Normandy among others. The first, second and third floors of the Telepresence Room, which enables the merger of meeting room four-floor main facility have their own themes: Civil War on the 1st; attendees with off-site attendees via large, life-like screen images. Revolutionary War on the 2nd; and World War II, Korea and Vietnam on According to Coletta, “There’s half a dozen people from all over the the 3rd. Available online at www.cammagazineonline.com
CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012 19
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world appearing as though they were in the same room. These unique design concepts were all made possible by the total collaboration of the team.” WORKPLACE OF THE FUTURE “Employee morale and overall mental and physical well-being is paramount to the success of BAE,” said Hoffman. The interior of the Office Building was conceptually
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designed as a “workplace of the future” with a column-free, open floor plan to support conference rooms and small collaborative spaces, as well as incorporate BAE System’s corporate standard workspace areas. Each floor in the Office Building contains a kitchenette with a shared space for employees. Additional amenities include a one-mile walking path for employees. Another employee perk is the 2,000 GSF “Voice Of The Construction Industry”®
corporate Fitness Center. The center is designed to help employees make positive changes to their health and lifestyles. Equipment includes treadmills, bicycles, nautilus and elliptical machines, as well as free weights. The Fitness Center has increased safety features including restricted keycard access for both the men’s and women’s locker rooms. In addition to the Fitness Center, there is a large employee Dining Room, capable of seating 200 people. The Dining Room features terracotta painted aluminum panels with an alternating concave/convex linear design, which includes lighting fixtures weaved within the aluminum panels. THE MAKING OF MODELS Attached to the four-story office complex is the Prototype Facility consisting of black stained precast concretes and dark grey insulated metal panels. The Prototype Facility supports 20 highbays for vehicle and subsystem modifications, integration and testing. In addition, the facility includes supporting labs and facilities that provide electrical assembly fabrication, software development and system integration of vehicle control and crew station electronics. The site also supports a full-service machine shop equipped with welding capabilities. Excess waste heat from prototype plant air compressors is harnessed to preheat the domestic hot water used in Prototype Facility processes and in Office Building kitchen and lavatory needs. The multipurpose room is an acoustical auditorium which will accommodate up to 150 people with fold-down tables. The carpeting is military camel-type designed to match the environment. GOING GREEN BAE Systems leadership was committed to going green and envisioned an environmentally sustainable project. The project is well positioned for LEED-Gold certification. Sustainable strategies and results included the following: Site • Redevelopment of a formerly used manufacturing and test site. • Site provides access to multiple public transportation routes and is planned for bicycle storage (with changing rooms) and preferred parking for alternative fuel and carpool/vanpool vehicles. • Site design conserves and restores the natural habitat and maximizes open spaces (54.17 acres of natural habitat, 67% Available online at www.cammagazineonline.com
CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012 21
environmentally friendly program, all recyclable waste such as returnable and non-returnable cans and glass, cardboard/wood, junk mail, newspaper, paper products and plastic bags/packing materials can be placed in one trash receptacle. The recycling program enables the Van Dyke site to be essentially “landfill free.”
WORKING ON A FAST TRACK In addition, the project’s fast-track schedule required Walbridge to construct the Office Building through winter’s harsh weather conditions. In order to keep View of the Multipurpose Room for military vehicle presentations. It is an acoustical auditorium which will construction moving in accomodate up to 150 people with fold-down tables. frigid conditions, the team wrapped the structure in reinforced ensure proper installation and of the site). plastic, essentially creating a massive cocoon, performance settings. • Use of EnergyStar compliant, high allowing workers to pour concrete and • Use of environmentally safe refrigerates reflectance and low emissivity roofing to complete tasks that couldn’t normally be Building management system to monitor reduce impact on microclimate and done during the winter temperatures. Interior and measure systems operations to human and wildlife habitat. finishes were able to be completed before maximize efficiency. the exterior skin of the building was fully • Participation with utility company for Water Efficiency installed. purchase of electricity generated from • Water efficient landscaping irrigation to In order to meet development for critical renewable sources (Green Power). reduce water consumption by 50% over contracts, the project was fast-tracked with conventional means. early design and construction of the Indoor Environmental Quality • Use of low-flow high efficiency plumbing Prototype Facility. The total project schedule • Permanently installed outdoor air fixtures to reduce water consumption by was accomplished between groundventilation monitoring systems. 44.3%. breaking in February 2009 and completion • Flush out of construction dust from in March 2012. Walbridge was the mechanical systems prior to move-in. Materials and Resources construction manager for all portions of the • Use of low-emitting indoor air • Over 47 tons of all non-hazardous project and many of the subcontractors containment (odorous/potentially construction waste/debris has been were used on both the Prototype Facility irritating to comfort) in carpeting, recycled back into manufacturing and Office Building. adhesives, sealants, paints and coatings. processes and diverted from landfills (43.7 The BAE Systems Sterling Heights Facility • Entryway systems to capture dirt and tons diverted of a total amount of 57.3 has the capacity to house approximately 600 particulates. tons, 83%). engineers, program managers, and support • Individual lighting controls. • Use of recycled building materials. staff; a workforce of experience and talent • Design and validation of thermally • Use of regionally processed and unique to this region, many individuals with comfortable environment that supports manufactured materials. skills born out of the world’s leading the productivity and well-being of the automotive manufacturers. The important building occupants. Energy work BAE Systems will do at this new facility • Systems design and selection to reduce means its high-quality Michigan workforce LANDFILL FREE energy consumption by 15% over the can accomplish the important job of helping In addition to the LEED requirements, the guidelines established by baseline energy make our troops safer and helping them Van Dyke site entered into a single stream models. carry out their vital missions, leaning recycling program with DeSantis Trucking • Enhanced commissioning of all major forward into battle. Inc., Warren. With this cost savings and mechanical and electrical systems to 22 CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012
“Voice Of The Construction Industry”®
PHOTO BY JUSTIN MACONOCHIE PHOTOGRAPHY
A redesigned gateway into the campus from Cass Avenue makes the renovated and expanded chemistry building accessible to all, and announces Wayne State’s commitment to science.
A WORLD-CLASS FACILITY: THE WAYNE STATE UNIVERSITY CHEMISTRY BUILDING
By Clare Desmond, Contributing Editor modern, efficient and strikingly handsome research facility is not the only thing achieved by a $71.2 million renovation and expansion of the Wayne State University Chemistry Building. The project, completed in September 2011, also achieved one of the university’s major goals as it embarked on the renovation planning more than 10 years ago: the new building has enhanced the chemistry department’s recognition both nationally and internationally and has increased recruitment - the life blood of any university department. According to WSU Chemistry Department Chair James H. Rigby, the department’s now state-of-the-art laboratories have been drawing interest globally from top-tier scientists, researchers and graduate students, and WSU is ranked among the top 100 chemistry departments in the country. The renovations and additions have turned the more-than-40year-old building into a research facility to compete with the best of them, and did it not only by its first-rate laboratories, but with modern eye-catching style, up-to-date mechanical and electrical systems, and an open, inviting space for users and visitors alike.
A
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Completed in two phases, the project involved a complete demolition of the interior to modernize and reconfigure the laboratories and office spaces on all four floors, replacing small private labs with large open ones, and adding distinct student workspaces - adjacent to the labs but separated by glass. The existing mechanical and electrical systems were replaced with highefficiency ones that included a new main air handling and lab exhaust system. The expansion included construction of a stunning 65-foot-high glass and steel atrium capped with a floating, curved metal roof, and fronting it, a new 150-seat lecture hall and a two-story office suite. New landscaping around a redesigned gateway entry from Cass Avenue welcomes students, faculty and visitors while it enhances handicap accessibility. The architect/engineer on the project was Harley Ellis Devereaux (HED), Southfield, and the construction manager (CM) was DeMaria Building Co., Detroit. DeMaria joined the project at the end of Phase 1 schematic design, and provided design assistance, design-to-budget validation, field inspections and “Voice Of The Construction Industry”®
selective demolition. The company also self-performed the concrete foundations for the Phase 2 addition and a new elevator installed in the original building. The new, approximately 200,000-square-foot chemistry building “has really given the department a ‘shot in the arm’,” Rigby enthused. “Last year, it was a strong selling point for us when recruits saw the new labs and fine new offices. We had one of the largest incoming graduate classes in many years, and many of them said this building was the deciding factor in their choosing to come here. We are getting chemists from around the world, coming to lecture in or attend lectures in the new lecture hall. So it’s paying dividends for us.” Rigby also offered that the building was “architecturally stimulating. It was designed so that when you’re on Cass Avenue you can look down the Mall and see it quite clearly. It plays a significant role in anchoring this quadrant of the campus.” The renovation and expansion are one result of a one-and-a-halfyear study started in 2000 to assess the university’s research portfolio and their needs, with a desire to align them with National Institute of Health design guidelines. The study was undertaken, in part, because of deferred maintenance deficiencies, operational performance issues, and the condition of the buildings. In particular, those issues interfered with the university’s ability to attract the best and brightest to its aging chemistry building, said James Sears, WSU associate vice president for Facilities Planning & Management.
accomplished in two phases, the first from 2004-2006 on the north half of the building, and the second from 2009-2011 on the south half of the building. All equipment and personnel had to be moved from the north half into the south half during the first phase, and then back into the north half for work to begin on the south half. Besides continuing the laboratory renovation in the south half of the building, Phase 2 of the project also saw construction of the atrium on the east façade containing a multi-purpose communicating space, the new 150-seat lecture hall, a two-story office “block” for administrative functions, and the installation of acoustic cherry wood panels over the original building’s east façade that are visible through the atrium’s glass curtain wall. Also completed was a new building entry and gateway from Cass Avenue on the east that added landscaping, reduced the amount of concrete, and eliminated some steps. ENERGY EFFICIENCY In addition to enhancing recruitment, another major goal of WSU was to increase the building’s efficiency in order to reduce the university’s operating costs. Critical to achieving that goal was adding to the number of fume hoods, snorkels, and exhaust connections for glove box work in the laboratory spaces. The new building increased the number of fume hoods to 235 from fewer than 100, as part of the mechanical and HVAC overhaul. They also were made more efficient at what they do, which is limit exposure to hazardous fumes, vapors and dust. “It used to be that the fume hood and exhaust system went all the way up to the roof, and then a little fan would puff the exhaust out
PHOTO BY JUSTIN MACONOCHIE PHOTOGRAPHY
A DONOR’S LEGACY That the project was aided by a $10 million donation from one of its own only adds to its appeal and functionality. A. Paul Schaap is a former WSU chemistry professor and scientist who, working in the chemistry building’s 40-year-old laboratories, developed a luminescent compound that would glow when laboratory tests determined evidence of some diseases in patients. The compound was so successful that he started a company, Lumigen Inc., Southfield, and eventually sold it to a major pharmaceutical company. Schaap and his wife, Carol, had maintained close ties to WSU, and their donation was made specifically to improve and strengthen its nationally recognized chemistry department. The new A. Paul Schaap Chemistry Building and Lecture Hall held its grand opening on September 16, 2011.When asked what he wanted chemistry students to feel as they use the new building, Schaap replied, “Inspired, in awe, stimulated, encouraged … all sorts of good things. Take the lecture hall, for instance. The chemistry department used to have to share a hall with other university departments. Now, they have a brand new, state-of-the-art facility all their own.” The renovation also included work in the two basements that contain the Lumigen Instrument Center, named after Schaap’s company and funded by an additional $3 million donation from Schaap, and the university’s Central Instrument Facility, both of which house highly sensitive research instruments. “It’s now a well equipped laboratory that’s attracting top faculty from around the world,” Schaap said. Schaap also donated an additional $6 million to endow research by students and faculty. His collaboration with the design and construction teams added invaluable information and advice in producing the world class facility, HED officials said. Because the four-story building had to remain fully The new lecture hall and two-story office suite, both with vegetated roofs, project operational during construction, the project was into the atrium. A curved metal roof hints at the joy of scientific discovery. Available online at www.cammagazineonline.com
CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012 25
on top of the roof, which would lay there and drift out over the edges,” noted HED’s CEO Gary L. Skog, FAIA, LEED®AP. “There was no dilution – whatever was in that chemical hood went up. Now, there are high dilution rates within the building itself, exhausting at a high velocity to get dispersions going, which eliminates fumes drifting out and into the intakes of other nearby buildings.” Reconfiguring the main supply air shaft allowed designers to recapture 6,400 square feet of existing utility shaft and corridor space that was then added to the laboratory space. Supply air is introduced into the labs through a raised ceiling that makes the entire ceiling the supply diffuser, to both minimize noise and turbulence at fume hood faces. Safety was also a major consideration for the chemistry department. “Contemporary Best Practices call for workers and researchers to do their work in a fume hood,” Schaap noted. “Now, each worker has their own dedicated hood, which is much safer. And now the lab space is segregated (by glass) from the office space, so office workers are protected.” Reducing the building’s energy use was the fastest way to get the biggest reduction in operating costs. The building’s laboratories need a constant flow of outside air that had been heated or cooled, used, and then exhausted immediately, with none of it re-circulated, Sears explained. “This new building was designed and constructed with amazingly efficient mechanical systems that allow us to minimize wasted energy,” he enthused. As well, the Phase 2 budget allowed for replacing three existing cooling towers to enhance efficiency of the new chiller plant. IT’S A STUNNER Aesthetically highlighting the expansion is the stunning new glass and steel atrium and the lecture hall that extends into the atrium space from the exterior. The two-story office suite, constructed with a Mankato stone façade over a steel frame, also projects through the glass curtain wall. At 30-feet-wide by 200-feet-long, the atrium is visible from Cass Avenue.With its modern, open and exposed super columns, inspired by DNA molecules, it proclaims that the chemistry building is a quality scientific facility and, by extension, that the WSU Chemistry Department is “serious about science,” said HED Managing Principal Michael F. Cooper PE, LEED®AP. The egg-shaped (chemistry departments are incubators of innovative scientific thought) lecture hall is an ellipse with sloping walls of architectural precast concrete and an ellipse-shaped vegetated roof tilted seven degrees, which makes it visible from the street. Inviting bench seating was installed all around the lecture hall, both inside and outside the atrium. The hall’s interior walls, installed by the Nelson Mill Co., Southfield, were constructed of American cherry wood acoustic panels that are curved and vertically angled 13 degrees.“Essentially, that means that every single kerf in the acoustic panels is in perfect elevation,” explained HED Project Architect Shaun Rihacek, LEED® AP. “In order to achieve perfect alignment, the panels had to be cut out on a CNC (computer numerical control) machine, and every single one of those radii, which define the arc of the kerf, is a different radii. There was a lot of engineering that went into detailing and fabricating that space.” The acoustic panels were designed and constructed by kerfing the front side and punching on the other side, to enable the sound to travel through the panel to be absorbed and diffuse some sound within the space, Rihacek added. The effect is elegant and sophisticated. The structural design for the lecture hall consists of four small steel columns holding two major girder sections that carry roof steel. Concrete block shear walls were embedded sight-unseen in the lecture hall’s interior. Nelson Mill also used American cherry wood acoustic panels to clad the exterior east façade of the original building 26 CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012
“Voice Of The Construction Industry”®
that is visible through the glass atrium. Ten, 17,000-lb., 65-foot-high super columns that support the glass and roof of the atrium were shop prefabricated by Casadei Steel Inc., Sterling Heights, and then trucked two at a time to the site in 60-foot-long sections that were erected the same day. Detroit Police cordoned off Cass Avenue to allow delivery of the structures in a continuous and tightly scheduled manner. Prior to final erection, the columns were placed flat in an on-site jig, and triangular outriggers, which would provide lateral support to the glass curtain wall against wind-driven load, were welded to the columns. Prefabrication helped achieve very tight tolerances and minimized the amount of steel pieces needing to be assembled on site. The super columns, constructed of 16inch-diameter tube steel with cross members of smaller tube steel, hold conduit inside for low-voltage electrical cabling, so the wiring is effectively routed but not visible. Truss-like steel sections that support the roof were also prefabricated and trucked to the site. Weighing about 4,500 lbs. each, the 50-footlong by five-foot-deep trusses cantilever over 12 feet.
Key structural issues for the addition, handled by structural engineer Desai/Nasr Consulting Engineers, West Bloomfield, were the foundation design and limiting movement in the tall and slender glass structure. Deep basements in the existing building, coupled with poor soil conditions, required the use of 28 caissons for the addition’s foundation, some of them as deep as 30 feet. Tolerance for the movement was especially small since the atrium’s curtain wall held pieces of glass four-feet-high by 10-feetlong, many of them placed more than 60 feet high. To contain movement while maintaining sight lines, the engineers designed a system using pre-tensioned HSS tube steel inside the curtain wall’s vertical members, which transferred load to the triangular outriggers that were welded to the super columns. Without the pre-tensioned tube steel to transfer load to the super columns, those columns would had to have been much larger. “That is very innovative,� HED’s Cooper said.“And it’s a great example of what an architect and engineer can do working together. You don’t want the space to be overwhelmed by the structure.�
Desai/Nasr also put its structural engineering skills to work designing the foundation for a new elevator constructed inside the existing building, from the subbasement through to the 4th floor. The new elevator is located adjacent to the facility’s rooms containing expensive and extremely sensitive research instruments that had to be protected. Therefore, the elevator’s foundation was constructed using helical piers to control vibration and noise. The building’s tight site and close proximity to three other buildings presented some challenges for the construction manager. “Overall, I would say the site logistics were the biggest challenge,� DeMaria’s Project Manager Mike Les said. “We didn’t have a lot of room for storage or laydown.� Adding to that challenge was working in an occupied building that had to continue operating, made more critical because of the nature of the building, the equipment housed in it, and the sensitive research that was done there. “We had to make sure we didn’t accidentally shut down systems that would affect their research,� Les said. He added that the company used
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CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012 27
PHOTO BY JUSTIN MACONOCHIE PHOTOGRAPHY PHOTO BY STEVE MAYLONE ARCHITECTURE PHOTOGRAPHY
The 150-seat A. Paul Schaap Lecture Hall’s elliptical shape symbolizes its role as an incubator for scientific discourse. A curving metal bench around its interior and exterior perimeter wall encourages interaction.
Renovated laboratories are large, open and inviting, providing abundant light and storage, while 235 new efficient fume hoods ensure the safety of researchers.
fire-rated partitions, logistics, and negative air machines to keep the dust out. They removed windows in a stairwell to bring in materials and equipment and remove debris. “It was a challenge working with all the trades in this tight space, and trying to maintain the schedule,” said DeMaria’s
Project Superintendent Frank Kamego. “But it worked out, and the coordination with all the trades went really well.” When asked if they had had to go “above and beyond” for the project, Les said: “Well, the steel contractor (Casedei Steel, Sterling Heights) definitely did. They worked very well with us and with
28 CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012
the other trades. They often had to stop their sequences to allow us to work with other trades.” The renovation and expansion was sparked in part following a series of workshops held in the early-2000s in which participants were asked to assess the university’s needs. All participants listed electrical reliability as the number one problem. “Across the entire university, the biggest complaint that they had was the frequent and intermittent voltage variation and loss of power,” WSU’s Sears said. “It’s hugely damaging to ongoing research activities.” He said, for example, the university has about 600 sub-80 freezers on campus that were highly susceptible to electric power losses. As a result of that study, the university invested $6 million in a full-building backup generating station for four campus buildings, including the chemistry building, and began planning for a complete renovation of the chemistry building. The university also invested in constructing its own steam plants, one of them for the chemistry building. As a consultant to the 2000 study, Harley Ellis Devereaux identified 16 WSU buildings with deficiencies, and the chemistry building was identified by participants in the study as being among the top contenders for renovation funding. SAFETY FIRST Because the area is pedestrian-heavy and the project site was tight, in the interests of safety DeMaria established a rule that all deliveries had to be scheduled and each delivery had to be escorted into the building by two workers. In addition, the CM teamed with the Michigan Occupational Safety & Health Administration in which a MIOSHA inspector visited the site to review any concerns the team had, and to make recommendations. Adding to the safety concerns is the close proximity of the chemistry building to two other buildings, close enough that on several occasions, work was required to be done during off-hours or on weekends when traffic presumably would be lower. DeMaria’s Les and Kamego required subcontractors to fill out an “Activity Hazard Analysis” (AHA) for hazard-prone activities, such as crane picks. The AHAs provided a plan on how to complete the task safely, and contingency plans if a problem should occur. It also included crane inspection forms, crane placement drawings, crane load charts, emergency phone numbers, and if the activity posed any life safety issues, or required egress of students or faculty. “Voice Of The Construction Industry”®
The effort that went into the design and engineering of the chemistry building renovation and expansion enabled it to achieve a Leadership in Energy and Environmental Design (LEED®) Silver rating. “And LEED Gold certification is our goal,” WSU’s Rigby noted. Adaptive reuse of an existing building that occupied a prime location on the WSU campus and the vegetated roofs on the lecture hall and office suite are obvious indicators of environmental concern. The office block’s green roof provides close-up views from inside the interaction space on the 3rd floor of the chemistry building, and the lecture hall’s tilted roof can be easily seen by pedestrians outside. Placed prominently as they are on a building devoted to science, both make a statement that Wayne State is, while dedicated to scientific research, also environmentally engaged. The re-design of the site also contributed to the environment by reducing the amount of concrete and replacing it with landscaping. These areas, and the vegetated roofs, help reduce stormwater runoff into the city’s sewer system, while adding beauty, interest and accessibility to the site. Landscaping included removing steps and replacing them with a sloping, elevated concrete walkway. Other environmental considerations are as significant but not as obvious, such as the high-performance glazing that provides natural daylight and the increased number of fume hoods and enhanced exhaust system that maintain safe environments in the labs while reducing energy consumption. For example, following extensive on-site testing of the variable air volume (VAV) and exhaust HVAC systems, it was determined that the fume hood face velocity – the velocity of the air passing through the work opening of the fume hood measured in the plane of the sash – could be reduced from 100 fpm (feet per minute) to 80 fpm, reducing fume hood exhaust that resulted in a significant reduction in the building’s energy use. In addition to adding modern research laboratories to the Wayne State campus, the renovation and expansion project has generated a sense of community among users of the space, the campus community, and passers-by. Its design helps draw people into the building, as evidenced by the almost immediate use of the public spaces, including the atrium and various lounge areas, following completion of the project. “It was great to have been part of a project that delivered such a wonderful facility to Wayne State University,” said Nick Salowich, HED project manager. Available online at www.cammagazineonline.com
CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012 29
Playing Against Type By David R. Miller, Associate Editor ctors who play one type of role particularly well, or maybe simply fit a set of physical characteristics, run the risk of being typecast. They could miss out on promising roles simply because casting directors lack the vision to see them doing anything different. Facilities can also be underutilized because people rely on basic assumptions instead of investigating all of the possibilities. The recently completed Berman Center for the Performing Arts (The Berman) in West Bloomfield provides a stellar example. One of many theaters located at Jewish Community Centers (JCC) across the country, The Berman is anything but ordinary. Built against the stereotype of a typical community theater, The Berman offers an unparalleled level of functionality and flexibility within a small space. Architect Neumann/Smith Architecture, Southfield, and Construction Manager Sachse Construction, Birmingham, led the talented project team that delivered this unique facility.
A
THEATER AMENITIES Theater amenities are among the many elements that elevate The Berman above expectations. Few features expand the capabilities of a theater more than a full fly loft. “You can lift every piece of scenery in its entirety,” explained Joel Smith, AIA, partner. “With many small theaters, you need to roll items 30 CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012
Photos by Justin Maconochie Photography on and off.” The fly loft opens the theater up for more sophisticated programs, but it also added considerable complexity. The project team designed a 50-foot loft to stay within the limits of code requirements that would take effect with a taller design, yet the 22 lines with expansion capabilities for six additional and counterweight pit allow for nearly any conceivable configuration. Intricate electrical systems for lighting and sound are another hallmark of world-class theaters and The Berman does not disappoint in this area. As Sachse Construction’s Project Superintendent, Marty Kozyn noted, a “boatload” of hidden electrical infrastructure was needed to provide the desired level of control. He praised Rich Osterman Electric Co., Inc., Clinton Township, for coordinating this intricate work with other trades to deliver it quickly and efficiently. Over 55,000 people have visited The Berman during its first year of operation. This number is a testament to the theater itself, as well as the quality of the programs made possible by its flexibility. In spite of the sophistication of the facility, its systems are remarkably easy to operate. “We didn’t want to be so high-tech that we couldn’t teach kids,” explained Mark Lit, executive director of the Jewish Community “Voice Of The Construction Industry”®
Center of Metropolitan Detroit. “We have 13 interns singed up from the high school next year. They have learned how to operate the lighting and sound systems, which are some of the most advanced as there are, but they’re just kids.” Though the fly loft is fully functional, it is operated with manual rigging instead of mechanized systems. Weights can be added, thereby allowing even the heaviest of stage elements to be safely and effortlessly whisked away. Catwalks were also designed with flexibility in mind. They provide easy access to two crows’ nests from which even novice technicians can control spotlights and follow spots. Hidden side doors at the calipers allow for an unparalleled level of interaction with theater patrons and scenery options. Of course there are times when performers do not want to seen, so The Berman includes backstage rooms from which performers can get ready. A common make-up room links two separate dressing rooms. The dressing rooms are configured to accommodate groups that have more male or female performers. A green room provides privacy for star performers, but it can easily be converted into overflow dressing room space if the need arises. Even with 100 children preparing for a performance, the audience will be blissfully unaware of the chaos backstage, as a solid concrete wall provides complete sound containment. Though they may not hear the sounds of eager performers as they make their way to their seats, audience members will have no doubt that they will be treated to a fine performance. The Berman was designed and built to make a statement at first sight and to maintain this expectation of quality throughout the entire experience. MAKING A STATEMENT At 17,950 square feet, The Berman is a relatively small addition to a much larger facility that includes a school and fitness center, but The Berman makes a strong impression on its own. “Because this [the JCC] is such a large complex, we wanted to make sure that the theater addition made a statement,” said Smith. “The building had a bold geometry, so it was a natural extension to apply that bold geometry to the new building. We distilled it down to its raw pieces and positioned it against the existing building to see how it fit. To our delight, it fit beautifully and we were able to embellish the form and we started playing around with it a little bit.” The Berman stays true to the sharp angles Available online at www.cammagazineonline.com
that define the JCC, but a “beltline” of materials was added to provide visual contrast. The main entry is marked with a bold canopy that fits in well with the geometry of the existing structure while calling attention to the addition. The finish floor level of the theater was dictated by the existing structure, so attractive and functional stairs were needed to provide access to the doors, but a gently elevated sidewalk provides easy access to a barrierfree entrance. Patrons entering through the main door are treated to a breathtaking foyer that is graced by a spectacular crystal chandelier that once hung in Detroit’s upscale Bonwit Teller department store. The lobby is also a high-energy space that is accented with fabric sails and dynamic lighting to create a kinetic feel. Light boxes add to this lively vibe while also publicizing upcoming events at The Berman. The entry is impressive, but it pales in comparison to the theater itself. The Berman has only 614 seats, but it boasts a large proscenium that is rarely found in similarly sized facilities. The 19-foot-tall, 66-foot-wide opening was made possible with the spanning capabilities of precast concrete. A 360-ton crane was needed to place the massive concrete beam that runs from pier to pier above the proscenium. The bearing capacity of precast concrete also provided enough strength to allow for a full masonry façade instead of lighter, thin masonry veneer. An added benefit of the precast concrete and load-bearing masonry
combination is a high degree of insulation from outside noise, but this would never have been realized without the dedication and professionalism of the precast contractor, Kerkstra Precast, Grandville, as the project was anything but typical. “Many people see precast buildings as pretty simple boxes, where they use cookiecutter production to make 30 panels that are 15”x28,” said Todd Sachse, LEED AP, CDP, president of Sachse Construction. “There aren’t too many panels on this building that are alike. Almost every panel is a unique size and shape with unique connection points. It really is a credit to the design and to Kerkstra that we were able to get all the benefits of precast, but it wasn’t easy for them to work with all of the pieces to the puzzle.” As Thomas Alva Edison said, genius was one percent inspiration and 99 percent perspiration in this case. Kirkstra solved many problems in the field, but none of these solutions came without real effort. “We had many coordination meetings to mesh the precast with the steel structure,” said Kozyn. “Joel’s [Smith] drawings are always great, but you will still run into interferences where you need to work something out. Kerkstra came to the table with solutions rather than saying, ‘Hey, I have a problem that you need to solve.’” Problem-solving was the order of the day on the project, but few solutions stand out as distinctly as the many methods employed to use the given space as efficiently as possible.
The lobby is a high-energy space that leads into the impressive 614-seat theater. CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012 31
ECONOMY OF SPACE The Berman rests atop a compact footprint, so space for many desired items was at a premium. The project team was able to overcome many difficulties by tapping into the existing Jewish Community Center. “From a design standpoint, we were challenged to find theater components where we could ‘double dip’ with the existing building,” explained Smith. “There is a lobby with the existing building and we needed a lobby for the theater. We might need a lobby that is twice this size for a freestanding theater under normal circumstances, but we were able to take advantage of the existing lobby. We were able to do the same thing with toilet rooms and the loading dock.”
The small size of this excavation allowed for stage accesses that are flush with the existing floor, thereby making the entire stage barrier free. Making a portion of this excavation deeper to accommodate an orchestra pit was considered, but the cost could not be justified. Instead, the first row of seats is removable to allow enough room for a small orchestra in front of the stage. The Berman and the existing JCC share many functions, but the addition is structurally separate. Precast concrete and masonry combined to make a structure that is far heavier than it would have been with other construction types. “Getting the foundations into the ground was very tough,” said Kozyn. “We had to get to elevations that were 40-50 feet below the finish grade to put in caissons, mini-piers
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Intricate electrical systems for lighting and sound are another hallmark of world-class theaters, and The Berman does not disappoint in this area.
The Berman is set off from the existing lobby with an attractive marquee sign that provides a separate access point to the theater. Lighted globes clearly identify the theater space with their classic design while embracing modern sensibilities with energy-efficient LEDs. Though the existing lobby dictated the theater’s floor height, the project team was able to scoop out a small portion to accommodate stadium-style seating.
32 CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012
and grade beams. We occasionally hit bad ground and we had to go even deeper.” The addition sits atop 22 caissons, which is quite rare for a structure as small as The Berman. Some of these caissons were drilled as close as seven feet from the existing building. Much of the foundation work was scheduled over the summer when fewer people visit the Jewish Community Center and Toledo Caisson Corp, Ottawa Lake, worked with the project team to develop a “Voice Of The Construction Industry”®
detailed plan that allowed enough time to prevent the extensive foundation work from disrupting the overall schedule. Mechanical work also required additional planning for a variety of reasons. Separate gas-fired rooftop units were installed for heating, but the existing electrical service and the chilled water system were tapped for the addition. The chilled water, in particular, was a good option to keep operational costs in check since the existing system had excess capacity and was only 10 years old. Mechanical work was further complicated by the need to offset the heat generated by theater lighting. Massive amounts of air move through large ducts that are designed to stifle noise. Places for these ducts were limited and careful planning was needed for all such installations. “When you are punching through concrete, you can’t change it later,” said Smith. “You have to make decisions up front.” Alliance Mechanical, Oak Park, received high praise from Kozyn for aiding this decision-making process by working ahead and identifying issues before they became problems. In fact, the entire project team looked at every element of the project from many angles. This systematic approach to value engineering yielded many benefits. Value Engineering The Berman hosts a variety of events, some with very broad appeal with others that cater to more select tastes. The facility has a unique ability to accommodate a large crowd while not looking empty for smaller events. The front of the theater features 338 seats. An additional 276 collapsible seats are arranged directly behind these in a multiuse area that can be closed off during a performance. As patrons enjoy the intimate surroundings that only a small venue can offer, they are often completely unaware that they are sitting in a venue that can be expanded to seat 614. “You can’t have 100 people in a 600-seat auditorium. It looks terrible,” said Lit. “We close the walls and 100 people look fine here.” Another advantage to this arrangement is that the back section of the theater can be utilized for a completely different function while a program is taking place in the front. The flexibility of multi-purpose room simplifies scheduling of events, but it complicated acoustical design considerably. Sound can either be reflected or absorbed when it strikes an object, so it reacts very differently to the closed wall of the multipurpose room than it would to additional Available online at www.cammagazineonline.com
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Patrons entering through the main door are treated to a breathtaking foyer that is graced by a spectacular crystal chandelier that once hung in Detroit’s upscale Bonwit Teller department store.
rows of seats. The Berman also hosts a variety of events ranging from lively dance productions to whisper-quiet book symposiums. No matter what the program or seating configuration was, high quality acoustic performance was desired. Extensive CAD modeling of early concepts resulted in significant design changes. “We originally had smaller openings separating the front seating from the collapsible seating area, but sound would get trapped in the back,” said Smith. “We needed to expand the opening and the operable partition to the full height of the room.” A drywall soffit would have been less
expensive than a full-sized operable partition, but the trade off in terms of sound quality was simply unacceptable. Through its careful design and quality construction, The Berman offers a very high quality theater experience. The project team needed to approach the project with flexibility in order to achieve the best results possible within the budget. Complex strategies were also employed to manage the bidding process. Two complete sets of working drawings were prepared, one set for a masonry bearing structure and another set for precast construction. Precast drawings were further separated into precast and steel roof sets.
34 CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012
After taking bids on all of the drawings, the project team was able to crunch the numbers to determine what type of structure would yield the best initial price. They could also cross-reference pricing against anticipated lifespan, projected maintenance costs, and other factors to determine the option that would offer the best value. “As we went through the process, we probably worked with a dozen different budgets that were done every step of the way,” said Sachse. “We also called in key subcontractors to get their opinions.” Like any major construction project, there was a “wish list” for The Berman. As savings were realized through value engineering, money was made available for many of these items. Of course, this would have been meaningless if the project had already progressed past the point where these desired items could be added into the project. The budget and schedule were constantly synced together to identify available funds before crucial decisions had to be made. The stage floor provides a good example. Many professional dancers will refuse to perform on a concrete stage because of the potential for joint damage. Theater designers can install a hardwood floor, which provides a little more flexibility, but it is also expensive and susceptible to damage. A floating floor sits atop sleepers with pads underneath, but this is also an expensive option. Money to install floating materials across the entire stage simply was not available, but the project team was able to incorporate a smaller floating surface that only covers the areas that would be used by dancers onstage with funds that were made available during the construction. In spite of the many steps that were taken to keep the project within budget, The Berman presents a luxurious environment that suggests lavish spending. Though the money was tight at times, the project team was rich with ideas on how to make the most of it. “I told them [the project team] what I was looking for up front,” said Lit. “I knew what I wanted, but they always found a better way of doing it and they made it look gorgeous.” Many Jewish Community Centers include theaters, but they often stress function over form and few would be called gorgeous. They also often lack the features and capabilities found at The Berman. The Berman will be playing against the typecast of a typical community theater for years to come, thanks to the vision of the owner and the talents of the project team. “Voice Of The Construction Industry”®
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The new crown jewel of Maize and Blue basketball glows at night, shining the spotlight on the blue iconic M within this grand 34-foot-tall lobby.
Home Court Advantage By Mary E. Kremposky, Associate Editor ractice makes perfect in NCAA Division I basketball. At The University of Michigan’s new William Davidson Player Development Center (WDPDC), the University and a talented project team joined forces to create the perfect place to practice men’s and women’s basketball. Two practice courts, an expanded sports medicine department and cutting-edge video technology once only available in the professional leagues will help the Wolverines apply the heat to the Buckeyes, Spartans or Hoosiers. At last, Maize and Blue basketball has a training facility to match its own competitive fire. The “game plan” for this 64,130-square-foot building of champions was developed by TMP Architecture, Inc., Bloomfield Hills, in association with Sink Combs Dethlefs, Denver. As a sports architecture firm, Sink Combs Dethlefs has designed sports facilities around the world and across the country, including a renovation and addition to the legendary University of New Mexico arena, simply called The Pit because of its depth below grade. As general contractor, Turner Construction Company’s Michigan office in
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Photography by Curt Clayton, Clayton Studio Detroit installed a complex underpinning system to stabilize the foundations of the WDPDC’s extremely close next-door neighbor: the massive Crisler Center, formerly known as Crisler Arena prior to its current renovation and expansion. The actual arena bowl will continue to be Michigan basketball’s field of glory, but the team now has incomparable practice courts and fantastic team facilities. Robert K. Rademacher, University of Michigan associate athletic director, facilities and operations, lists some of the “stats” on the teams’ former training spaces within Crisler: a cramped weight room not up to the standards of a Division I program, an equally small athletic training or sports medicine room, and the need to locate the offices of both coaches and athletic trainers off-site and in completely different buildings. Damon D. Grosz, facility manager, Crisler Center, adds to the list. Practice time for the men’s and women’s teams had to be staggered, because only the actual playing court was available for sessions. Practice time for both teams was sometimes curtailed by other events held in the arena. “At Crisler, we were 75 percent basketball,” “Voice Of The Construction Industry”®
said Grosz. “Now, the Davidson Center is 100 percent dedicated to basketball training and development.” Thanks to the new William Davidson Player Development Center, the Wolverines can now practice those three-point field goals any time. More than expanded services, the building embodies the pride and mystique of the Maize and Blue with its timeless materials, first-class finishes and the iconic letter ‘M’ dominating virtually every surface, ranging from the lobby wall and locker room floors to the very door handles on the lockers and the logo on the leather chairs. Sustainability is part of the game plan, as well. “The wood floor of the practice courts is sustainably harvested Maple from managed forests,” said David W. Larson, AIA, TMP senior vice president, chief design officer and project designer. “Crisler’s original wood floor is being replaced and reused as display walls in a 100-foot-long tunnel linking the WDPDC practice courts to the playing court in Crisler Center.” Clearly, this seasoned team of design and construction professionals has delivered a winning building in form, function and sustainability. “TMP and Sink Combs produced a well thought-out design, and the work of the entire team was great,” said Rademacher. The new Davidson Center is already a key player in the drive for a championship season. “It is a huge recruiting tool, and recruiting is what programs are built on,” said Rademacher. “We have seen an increased interest from highly rated recruits because of the upgrade in facilities. The Davidson Player Development Center is certainly part of that.”
with Crisler’s cast-in-place concrete exterior and its brick walls are in sync with Michigan Stadium. “This brick was the same brick that was used at the football stadium,” said Larson. “There was always an attempt to have a vocabulary of materials and an image that would relate the building to the other athletic facilities.” The WDPDC and Crisler Center will be united as one “team” of buildings in the near future. The Davidson Center is the first phase of TMP’s three-phase master plan for Michigan basketball’s building infrastructure. Completed last year, the second phase renovated Crisler Center’s building systems and undertook a minor to medium reconfiguration of the interior bowl, said William Frederick, AIA, TMP partner and project manager. Similar to the WDPDC, the new Crisler concourse expansion - currently under construction as the third phase - will be clad in a combination of brick, glass curtain wall and cast stone, added Frederick. Ultimately, the floor of the concourse expansion will flow directly onto a future Davidson Center rooftop plaza addition. As a visual link, “the concourse expansion will continue the curve of the WDPDC’s northern brick wall all the way to Crisler Center’s service entry,” said Ernest Joyner, AIA, LEED AP, principal, Sink Combs Dethlefs. Funding for the concourse expansion, however, was uncertain at the time of the WDPDC’s design, meaning the WDPDC had to be viable both as a stand-alone and as a type of linked structure. “We didn’t even know if the concourse expansion was going to be built,” said Larson. “The trick was to make the WDPDC an attractive, standalone building, because we didn’t want the building to look incomplete if funding did not become available.”
THE CROWN JEWEL OF MICHIGAN BASKETBALL MICHIGAN’S OWN VERSION OF THE PIT The William Davidson Player Development Center is the new The design team had to jump through many hoops to create a crown jewel of Michigan basketball. Ensconced in a circle of glass, state-of-the-art facility for shooting hoops. The first half of the an oval lobby forms the signature element of a practice facility construction “game” also proved to be challenging. The new already proving to be a real game-changer for the basketball building is wedged tightly against and placed deeply below Crisler program in both image and training capacity. “We use the metaphor Center, an arena originally built in 1967 and perched on a hilly of a ring with a gem stone set into the band,” said Larson. “With its mound. The WDPDC is set into the bottom of this mound with one oval geometry, the entry is a polished and faceted diamond, so to side flush with the actual arena and a second side adjacent to speak.” Crisler’s concrete monumental stair at the time of construction, said Glass fins project fritted glass panels - blanketing the entire upper half of the oval - three feet beyond the actual glass wall to heighten the lobby’s faceted appearance. At night, the illuminated lobby beams like a lantern and shines the spotlight on a large, blue iconic M emblazoned on the main interior wall of this grand 34-foot-tall lobby and hall of fame. This new kid on the block maintains a strong presence and holds its own in a neighborhood of fabled arenas, while still blending with the rest of the athletic campus. “The real challenge was adding onto such a pure oval shape as the Crisler Center,” said Larson. The challenge was clearly well met. The oval lobby and its widebrimmed soffit resonate with the neighboring Crisler Center and the even larger oval of Michigan Stadium, aka the Big House. The rest of the Davidson Center arcs away from the oval lobby, stretching its brick and cast stone walls toward Crisler Center. The building itself maintains a perfect flow with exterior brick visually slicing into the lobby’s The new locker rooms cultivate a winning attitude, fueling the team’s competitive fire with interior brick wall in a smooth, continuous arc. inspirational phrases and a room arranged in a team-building circle. Likewise, the WDPDC’s cast stone is in harmony Available online at www.cammagazineonline.com
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The team meeting rooms are filled with sports graphics for motivation and cutting-edge film technology for instruction.
Robert Bowen, LEED AP, project executive, Turner Construction Company. One of the reasons for tightly nestling the two buildings was to preserve as much surface parking as possible in an athletic campus with a high level of daily activity and regular waves of die-hard Wolverine fans. “Parking is at a real premium in the area,” said Larson. Adding further complexity, the new building’s “roots” and practice courts are placed at a level lower than Crisler’s foundations. “We were below the existing foundations by about 10 feet,” said Bowen. Two needs drove the building downward: the need to set the WDPDC’s roof height at a level matching the concourse floor and the need to maintain a regulation height of at least 25 feet for the practice courts. “All of this led to sinking the practice courts about six feet down into the ground,” said Joyner. This tight and deep placement called for “a structural retainage system of auger castin-place piles with ground anchors,” said Frederick. “The ground anchors or tiebacks are drilled underneath Crisler Center at an angle, and they use the force inherent in the soil to resist the overturning motion.” Turner “installed the auger cast piles all the way across the outside face of Crisler’s existing foundations to a depth of about 20 to 30 feet,” said Bowen. “We then excavated down in lifts and installed the tieback system.” Turner conducted an initial survey and then periodic surveys throughout the course of this sensitive task. “We had to periodically survey the existing arena to double check the position of the existing 38 CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012
foundations to make sure it didn’t move at all as a result of our excavation and foundation work,” said Bowen. This complex undertaking was only one of three intricate surgeries below grade. Turner also had to shore the area adjacent to Crisler Center’s massive concrete stair. Turner excavated in successive lifts, drilling three levels of tiebacks at roughly 5-foot intervals and working all the way down the side of the staircase. “Our excavation ended right up against the side of those stairs, which remained in place throughout construction,” said Bowen. The stairs were removed at a later date to make way for the concourse expansion. Work below grade also included excavation and shoring of the 100-foot-long tunnel that links the practice and playing courts and extends beneath the seats of Crisler Center. Turner used a narrow, lowclearance drill rig to install smaller piles and a single-level tieback system to aid in the tunnel’s construction. “We cut a hole through the side of the wall and actually drove into Crisler Arena,” said Bowen. “We set the rig on the slab and drilled the piles, working off the existing arena floor.” AN ADVANCED GEOMETRY LESSON Above grade, the building’s irregular geometry added another level of complexity. Between the oval lobby and the building’s arced lines, nothing is simple or square about this structure. “We learned our geometry very well,” said Bowen. “Nothing was a square wall.” In a repeat performance of the work “Voice Of The Construction Industry”®
below grade, Turner engaged a professional surveying firm to establish all the control points and to double check the work throughout construction. “Typically, surveying is performed only once,” said Bowen. “The surveyor sets the horizontal and vertical control points and walks away. On this project, we had to keep double checking the work to make sure everybody was working off of the same points.” Every facet of this jewel of a lobby was carefully crafted and coordinated, beginning with the assembly of the glass wall, fins, and the “veil” of fritted panels. Universal Glass & Metals, Inc., Detroit, poured its energy into crafting the glass fins’ connection to the wide soffit at the top of the oval. “There wasn’t enough room to make the connections, so our glazing contractor tested several different approaches on paper and even with a mockup to figure out the best sequence,” said Bowen. “They had to determine what element should go in first to make sure they didn’t install a piece that would ultimately cut them off from being able to advance to the next piece. Universal Glass did a lot of homework with our staff to figure out how to make that whole system work.”
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THE MICHIGAN DIFFERENCE Within the lobby, the very architecture invokes a sense of grandeur with its high ceiling and wide sweep of space. A big, blue M dominates the lobby and rests in the center of a large photo montage called the “Day in the Life” wall. The graphic depicts Michigan basketball players in class, on the court and in the community. “One of the things that the University of Michigan prides itself on is that student athletes get an experience outside of the court,” said Rademacher. “Coach Beilein always talks about the fact that we want our players to be students first and then athletes. The pictures on the wall show student athletes practicing on the court, going to the library and visiting hospitals.” At night, maizecolored LED lighting blazes around the edges of this photo wall, highlighting the M and making its presence visible to the community beyond. Within the lobby and mezzanine, the art of design joins forces with the craft of construction in spaces cloaked in a beautiful assembly of materials. Courtesy of Artisan Tile, Brighton, a stunning terrazzo floor with bright flecks of cobalt blue blankets the lobby. This gorgeous floor saves both embodied and actual energy, being longlasting and incorporating a radiant heat system. “Terrazzo is a forever floor,” said Available online at www.cammagazineonline.com
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reception desk and showcases Michigan basketball teams of the past. Another signature blue M is mounted in the middle of it all, basking in the glow of maize-colored LED lighting. On the other mezzanine wall, photos of the current men’s and women’s basketball teams are mounted on a wall of sustainably harvested wood. “We wanted to showcase the rich history of Michigan basketball,” said Joyner.
An oval lobby forms the signature element of a practice facility already proving to be a real game-changer for the basketball program in both image and training capacity.
Larson, “and with radiant heat, the lobby needs less heat to warm the space. It is a much better and a more sustainable way to heat the lobby rather than trying to pull all of the heat from above.” Turner created a polished flow of materials in both lobby and mezzanine, beginning with the perfect alignment of glass wall mullions, stainless steel mezzanine balusters and the grout lines of limestone wall tiles from Portugal. “All of these materials had to be laid out and sized appropriately, particularly the limestone tiles because the tiles could only be ordered in certain size pieces,” said Bowen. “As a long-lead item from Portugal, the tiles were air freighted in to make sure we had them in on time.” The wall hosts stainless steel letters, spelling out the words the “Leaders and Best,” a phrase taken directly from the Wolverines’ famous fight song. The gleam of stainless steel column covers, beam wraps and railings give a contemporary edge to the lobby’s traditional stone and brick elements. This blend of contemporary and traditional materials in a timeless design without the glitz and hoopla of other athletic venues is exactly what the University wanted. The project team delivered a building with a timeless image honoring a men’s program
dating back to 1908 and a women’s program originally began in 1973. “We didn’t want it to be a circus,” said Joyner. “You can over theme an athletic facility. We were trying to strike a balance between athletic theming and tradition.” The University is clearly pleased with the results. “We wanted it to be first-class and cutting-edge but still bound to tradition,” said Rademacher. “I think we have met that contradiction very well.” THE INTERIOR GAME PLAN The lobby leads to the heart of the facility. A ramp swirls across the full circumference of the lobby, offering easy access on one side of this grand entry to the practice courts, the locker rooms and the tunnel on the lower level. On the other end, a wellcrafted, angled stairway, with perforated stainless steel risers and stainless steel rails, leads to the mezzanine, the gateway to the coaches’ offices, team meeting rooms, the strength and conditioning room, and the Victors Suite for recruiting and special gatherings. The mezzanine reception area, with the men’s facilities peeling off to the left and the women’s facilities to the right, continues the love of the game with the very carpeting patterned after an actual basketball. Another photo montage rises behind the
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A BUILDING OF CHAMPIONS The design team “huddled” with the coaches and athletic staff to design a championship facility. “We are very involved in interfacing directly with the coaches and the athletic staff, because our area of expertise is providing the team what they need to win championships,” said Joyner. The new building has a greatly expanded strength and conditioning facility that merges directly with its newly renovated counterpart in the Crisler Center for double the amount of workout space, plus added room for a nutrition station and a cardio area directly overlooking the practice courts. “In the old facility, we had to move sideways to get between the machines,” said Grosz. The sports medicine department is more than double the size of the former one and even contains hot and cold hydrotherapy. “An aquatic treadmill aids in injury recovery, rehabilitation and training, which are all critical to continual success during a long physical season of NCAA basketball,” said Joyner. Video technology is truly what places this facility in a whole new league. As the team is returning to the locker room after the first half of the game, the video system can transmit plays executed only five minutes ago directly to the locker room for immediate review. A video coordinator acts as the mastermind who controls filming from a central video technology room in the Davidson Center. Video monitors and film technology are available in the playing court, the practice courts, the team meeting rooms, locker rooms and coaches’ offices. “The ability to send video anywhere in the facility for coaches to review is pretty cutting-edge,” said Rademacher. A full record of every game and of every practice is also readily available for review at any time. Once only available to the pros, heightened video playback capability is infiltrating the NCAA, along with the use of telestrators, basically “a television you can write on with your hand to teach a play,” said Joyner. “Multi-media and technology is changing very fast, and we find with every project the bar is raised. I would say this “Voice Of The Construction Industry”®
project is the highest bar we have yet reached in terms of technology.” The building is also paperless. “Every locker has its own iPad to transmit training schedules and meetings to each student athlete,” added Rademacher. Both the WDPDC and Crisler Center now have another important piece of infrastructure: air conditioning. Densely packed MEP systems snake through the building to provide building services. With the roof reserved for a future plaza addition, the mechanical infrastructure is located within the building rather than on the roof. Turner threaded these systems from the mechanical areas on the far side of the practice courts and through a large, dry-wall wrapped truss over the practice courts before branching out into the rest of the building. “Everything had to fit like a puzzle through this one large truss,” said Bowen. “With such a limited amount of space, we used BIM modeling to make sure everything fit.”
and when the players hear the crowd going wild, it gets their adrenaline going. We feel that this promenade was one of the big successes of the project.” The teams moved into their new home in November 2011. After the first season in the new facility, “we had our best year in a while,” said Rademacher. “I think the building did make a difference. I think the opening of the facility created an
excitement around the basketball program with the fans and with the student athletes. Both said, “Wow, they finally built a home for Michigan basketball.” Turner Construction Company, TMP Architecture and Sink Combs Dethlefs have created a cutting-edge building with a polished level of pure class, making the new center a great teammate for the pure oval of Crisler Center and for the success of Maize and Blue basketball.
WINNING IS A STATE OF MIND Beyond conditioning and strategy, the building itself cultivates a winning attitude with sports graphics, inspirational phrases, and a high level of finishes, giving dignity to the game, the University and the student athlete. The locker rooms are arranged in a team-building circle with a large maize M in the middle and the words, “Work Hard” and “Play Smart” printed along the cornice. The team meeting room has leather chairs with the iconic M, and a wall-size sports graphic of players in the heat of competition emblazoned with such sayings as “Every Day is a Try-Out.” The tunnel is geared toward psyching players and fans up for the big game. On game day, the players travel through the tunnel illuminated with the glow of blue cove lighting. The team jogs past the walls filled with inspirational quotes and photos of the glories of Michigan victories, past the Maize Rage banner, and into a circle of terrazzo flooring with the University of Michigan seal. Thanks to the new video technology system, an overhead camera broadcasts the team’s final huddle on the scoreboard screen, revving up the fans and the players before the team even bursts onto the playing court. “Suddenly the lights will go down and then the image of the players doing their pre-game ritual will be broadcast on the board,” said Joyner. “We are trying to create excitement around the program. All of this pageantry and the design of the promenade - how the players get from the locker room to the court - enhance the fan experience, Available online at www.cammagazineonline.com
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The 184-foot Grand Mariner from Cleveland was the first cruise ship to arrive at the new Detroit/Wayne County Port Authority Public Dock and Terminal.
PORT OF CALL ON THE RIVERFRONT The Detroit/Wayne County Port Authority Public Dock and Terminal By Roy Jones, Contributing Editor he Grand Mariner, a 184-foot cruise ship from Cleveland, and its 40 passengers arrived at the new Detroit/Wayne County Port Authority Public Dock and Terminal (DWCPA) in mid-July 2011, making it the first large cruise ship to use the long-awaited dock and facility. While the passengers spent the day visiting Detroit area attractions, a ribbon-cutting ceremony took place in front of the cruise ship and the new $22 million facility. Among the dignitaries who took part in the ceremony were Detroit Mayor Dave Bing, U.S. Senator Carl Levin, U.S. Rep. Hansen Clark, and Wayne County Executive Robert Ficano. Senator Levin was a driving force behind this project, which received federal funds and grants and was years in the making. The port, a 1.2 acre site, is located between Hart Plaza and the Renaissance Center along Detroit’s revitalized riverfront area. The 21,000-square-foot Port Authority Terminal Building overlooks the 250-foot offshore Port Authority Wharf and the three-mile riverwalk between Cobo Hall and Rivard Street. The project is the
T
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key to hopes of luring Great Lakes cruise ships, dinner cruisers, tour boats, tall ships and other vessels which will, in turn, have a direct economic and positive impact on the city of Detroit. “We have been working hard to restore Detroit as a destination for the Great Lakes cruising industry,” said John Jamian, president and CEO of the DWCPA, “This port becomes an essential piece of a continuation of the rebuilding of this city.” Detroit was one of the only cities with a major port to not have a modern public dock and passenger terminal. Without a dock, the Great Lakes cruising industry has been dormant in Detroit since 1967. This industry has reemerged as a growing market and is having a strong economic impact on cities throughout the Great Lakes region, including Chicago, Cleveland, Toledo, and Windsor. Says Jamian, “The new public dock and terminal will provide residents and visitors direct access to the river. It is a vital part of the overall vision for a transformed Detroit Riverfront and a contender in the Great Lakes tourism market.” In 2012, there will be an estimated 14 visits by Great Lakes cruise ships. “Voice Of The Construction Industry”®
below-grade elements on the site, understand the basis of design OFFSHORE WHARF CHALLENGES for the existing wharf, understand the complex interaction of The construction of the new offshore wharf was faced with many utilities built within and shoreside of the wharf, understand the obstacles. In simple terms, the water needs to be deep enough to impact of the Detroit-Windsor Tunnel (1930s) and the Raw Water accommodate cruise ships. A 200 x 30-foot steel pile-supported Intake and Pump Station construction on the existing wharf, structure would be needed to reach 40 feet into the river. perform the analysis of the wharf in its present deteriorated state, The site’s shoreline was comprised of the 40-foot-wide Bates and select repair and stabilization methods. Street combined sewer overflow (CSO) structure, a 112-foot length of unimproved shoreline, and a 368-foot-long wharf thought to be 32 feet wide. The proposed terminal building area was located north of the wharf and west of an existing onestory brick pump house. Known impediments to development were a CSO outfall and the Detroit-Windsor Passenger Car Tunnel (DWT) within and below the eastern portion of the existing wharf, and a 36-inch raw water force main traversing the proposed building site. The initial site investigation revealed the presence of an abandoned water intake and significant structural deterioration of the eastern portion of the existing wharf, rendering it unusable for a deep water port. The western portion of the wharf was found to extend up to 57 feet inland and significantly reduced the proposed terminal building area. In addition to the force main known to bisect the proposed terminal site, buried concrete vaults located east of the Bates Outfall and wharf counterfort elements extending into the building footprint impacted building space Construction obstacles with the new off-shore wharf were met head-on by the entire project planning and impeded building foundation team, opening a new front door to the international maritime community. construction. To further complicate The existing wharf was constructed in 1921 and consists of a development at this site, local water, gas, and electric thought to timber pile-supported concrete deck with a concrete bulkhead on exist under the adjacent street had been either abandoned or the out-shore side to retain approximately four feet of removed as part of other development projects in the vicinity. miscellaneous fill soils. Integral to the structure of the eastern Faced with the discovery of the deteriorated condition of the portion of the wharf are the Randolph Street Outfall, and the Raw existing wharf, an unanticipated reduction in the land available to Water Intake and Pumping Station that service the Renaissance site the building, and the complex interaction of existing below Center and the City-County Building. In addition, the timber piling at grade structures and site utilities, the DWCPA had to decide whether the eastern end of the wharf is believed to have been cut and cast to abandon the project or move forward. The project team assisted into the crown of the Detroit-Windsor Tunnel when it was mined the DWCPA with development of a new conceptual plan consistent beneath the wharf in 1930. Integral to the structure of the western with the original vision. Working together, the Owner’s portion of the wharf is a concrete bulkhead supported on timber Representative John Kerr, director of economic development of piling constructed pre-1910. This former dock structure is restrained DWCPA; construction manager White/Braun LLC; program managers laterally by concrete beams extending up to 22 feet landward of the SDG Associates; architects Hamilton Anderson Associates; and wharf structure into the terminal building footprint area. engineers HH Engineering, NTH Consultants, LTD, Peter Basso & Condition assessments of the existing structures indicated that Associates, Shymanski Associates, and Tucker Young Jackson and the wharf concrete deck and timber piles were generally in good Tull, revised the project plan to include a new offshore wharf, repair condition; however several piles over the Detroit-Windsor Tunnel and re-commission the existing wharf to a new use, and overcame had section loss at the underside of the wharf deck. In addition, the the impediments to building construction. out-shore face of the concrete bulkhead had suffered significant The project team worked closely with the Owner’s Representative freeze-thaw damage, and the horizontal steel tie rods that provide John Kerr and the DWCPA to address the concerns of the owners of lateral restraint for the eastern half of the wharf were either missing utilities that cross the site and other stakeholders for this project or corroded. including: the Detroit Water and Sewerage Department; the DetroitThe age and condition of the existing wharf, combined with Wayne Joint Building Authority, the Detroit-Windsor Tunnel, the GM recent development north of the wharf that restricted access for Renaissance Center, and the Riverfront Conservancy. repair of horizontal restraint elements precluded use of the existing Detroit’s Engineering, Public Lighting, and Water and Sewerage wharf as a deep-water port. Replacement with a newer structure was Departments allowed the project team to research their historical not an option due to the presence of the DWT beneath the existing archives. The documents obtained from those archives and the DWT wharf. As a result, repair options were limited to repair of piles in enabled the creation of a decade-by-decade site development contact with the tunnel, riprap placement to stabilize the east wharf chronology starting in the early 1900s, that was used to target onslope, and selective demolition/repair of the shoreline bulkhead. site investigations, confirm the locations and condition of Available online at www.cammagazineonline.com
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Built from the ground up, construction of the 21,000-square-foot terminal building was accomplished within an extremely tight working space.
SUCCESSFUL SOLUTIONS TO THE CHALLENGES The many challenges that existed at the Port Authority site were addressed with a rational approach by White/Braun, LLC and the total project team. As an example, directly underneath the Port Building exists a 36” Raw Water line that draws water from the Detroit River and serves the county buildings for their cooling needs. It was critical that this water line not be impacted during construction. White/Braun implemented several safety measures in place to ensure the water line was protected and not damaged. Ground penetrating radar was used to accurately locate the line and settlement monitoring points were installed to gauge whether any construction activities were impacting the line. Vibration monitors were set up during pile driving operations to monitor the ground vibrations. Within close proximity exists the DetroitWindsor Tunnel, the Port building and Wharf, which are pile-supported. So there was concern that the pile driving operations may create excessive vibrations and potentially damage the tunnel. While no damage occurred, White-Braun installed vibration monitors in the tunnel to monitor the vibration throughout the piling operations. The Port Project was funded by both state and federal funds. Each phase of the project required separate funding, and separate contracts. In total, there were nine separate contracts compiling the overall scope. This presented several scheduling challenges and
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paperwork challenges. The Port site was extremely small and tight. Timing for work and deliveries was critical due to the site constraints. White/Braun had to accurately manage all equipment and material staging to effectively keep work on track. Working within the waterways of the Detroit River for the seawall work and the offshore wharf presented some untypical construction elements. Several permitting requirements were needed from the MDEQ and Corp. of Engineers, and these permits had timing restrictions of when the work could be done. Furthermore, the weather had its own challenges, especially with the work in the river. “E.C. Korneffel (Trenton), the marine contractor, fought the elements, in particular ice conditions, and was still able to complete the work and remain on schedule,” explains Kevin Donnelly, project manager for White/Braun. “ Korneffel performed all of the seawall restoration, the work for the off-shore wharf, and installed all of the piling systems for the building and wharf.” Donnelly continues, “Their expertise was critical to the project’s success, and they executed the work seamlessly.” Since the Riverwalk was in use prior to construction, the project team had to closely “Voice Of The Construction Industry”®
coordinate Riverwalk closures to allow access around the site during construction, while at the same time protecting the public during work. “Albanelli Cement (Livonia) worked well under these conditions,” said Donnelly. They performed all of the concrete work including the decorative colored concrete along the Riverwalk.” ENGINEERING AND TECHNOLOGY AT ITS BEST The project team deployed a comprehensive approach to adaptive re-use and repair of the existing wharf and construction of a new offshore wharf and terminal building. A flexible design process allowed the project team to address unforeseen issues as they arose. An extensive instrumentation program efficiently monitored the effect of construction on existing infrastructure. Value engineering throughout construction allowed implementation of less costly means and methods suggested by the contractors. Frequent communication encouraged continued cooperation of stakeholders and ensured that concerns and risks were addressed. Recommissioning the existing wharf, for use only as the Riverwalk, reduced horizontal design loads to a level where placement of rip rap on the underlying slopes and river bottom delivered adequate support, acting as a buttress against movement and providing erosion protection. Construction of an offshore wharf in naturally occurring deeper water eliminated the need for significant dredging during the original construction and planned maintenance, environmentally benefiting the Detroit River. Also, smalldiameter coffer cells used to support the offshore wharf and resist mooring loads addressed boater safety concerns raised by regulatory agencies. A value engineering approach, integrating suggestions by E.C. Korneffel, was used to restore the deteriorated timber piling located above the DWT. Lightweight foam used to fill abandoned vaults under the building mitigated potential settlement. The development of an in-pipe relining plan, using no-dig technology, was a catalyst for the Detroit-Wayne Joint Building Authority to allow construction of the Terminal building over their transmission main.
N ITROGEN PIPE PIPE FREEZING FREEZING NITROGEN Used to to perform perform maintenance maintenance and and repairs repairs • Used without building building sh ut d owns a without shut downs and/or nd/or lloss oss o off large volumes volumes o ater o large off w water orr treatment treatment chemicals chemicals Allows restoration restoration o rculation on off ci circulation on system system • Allows adjacent to to freeze freeze adjacent PIPE DISINFECTION & LEGIONELLA CONTROL A ccost-effective ost-effective ““one one sstop top sshopping” hopping” approach to your pipe disinfection needs. Our disinfection service provides flushing, chlorination and testing using A WWA A AWWA e also provide emergency standards. W We response programs. • Detection, prevention & outbreak response using a team of experts • Rapid response of disinfection disinfection Turnkey implementation implementation of • Turnkey • No disruption in building operation • Corrosion control • Long term infection control CLOSED LOOP LOOP CLEANING CLEANING CLOSED loop systems systems require require mo Closed loop Closed more attention re a ttention filtering will will a ccomplish. Pro than filtering than accomplish. Program gram includes: includes: Filtering: multiple multiple levels levels of of treatment treatment • Filtering: Syst e m cl e a n i n g t o re mo o ve d ebris System cleaning to remove debris, • buildup and bacteria • Water sampling and analysis • System improvement recommendations
THE TERMINAL – 21,000 SQUARE FEET OF SERVICE The contemporary, glass façade Terminal building was designed as a large flexible space spread over two floors that included Available online at www.cammagazineonline.com
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Despite the icy winter conditions, the seawall restoration was completed within the required time frame.
46 CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012
the Port Authority Offices on the second floor; future customs and border patrol spaces on both the first and second floors; a baggage area on the first floor; the embarkment lounge on the second floor; and public restrooms on the first and second floors. The upper and lower levels not only have board rooms and meeting rooms for port authority business, but also have space available for rental to local businesses for special events, educational exhibits, and non-profit organizations. The upper level meeting room will seat approximately 260 and the lower level meeting room will seat 168. The lower level Homeland Security station is still waiting for funding to complete. This space will serve as an all-important cruise ship security area for passengers. The Terminal building was built from the ground up and was met with the same challenges as the off-shore wharf in terms of the extremely tight working space. The foundation configuration of the new Terminal building was strongly influenced by deep soil deposits placed to reclaim the waterfront in the late 1800s and early 1900s,
“Voice Of The Construction Industry”®
and the foundations left in place from previous use of portions of the site as a lumber yard, freight warehouse, steamship dock, Public Lighting Department power plant, and a Detroit Fire Department pumping station. In addition, site development was coordinated with active underground facilities including two Detroit Water and Sewerage Department outfalls, a raw water pump station and distribution mains, the Detroit-Windsor Tunnel, and the USACE Bates shoreline restoration completed in 2006. With the building footprint fixed somewhat by underground features, space planning for the building interior was a challenging opportunity. One of the unique structural engineering features was the 95 H-piles which support the Terminal building. Each pile is rated at a nominal 100 tons bearing on the glacial till overlying the bedrock at a depth of 95 feet below the ground surface. The exterior of the building has metal composite panels, curtain wall, glazing, sunshades and burnished block. The MEP Systems for the building were all design/build. Dynalectric of Michigan, Madison Heights, not only performed all of the electrical work for the project, but also all of the security required for the Riverwalk and the facility. FUTURE VALUES ATTAINED Availability and access to historical documents for structures demolished in the 1960s was critical for the success of this project, underscoring the importance to the engineering community of safeguarding these historic records. The service life of aging infrastructure in crowded urban environments can often be extended through adaptive re-use in combination with new construction. This project showcases innovative use of technologies and processes for delivering sustainable, economic and communityfocused solutions in rehabilitating the Country’s abandoned and historic infrastructure. The use of less invasive processes, materials and designs, such as inpipe relining, lightweight foam fill of abandoned vaults, and rip rap for stability, erosion and environmental impact, introduce and demonstrate viable solutions for complex engineering challenges. Public and private partners collaborated to navigate a myriad of challenges presented by one of the shortest, yet arguably most complex, stretches of urban waterfront. Eliminating an eyesore and creating a public use where none existed, this linking of the East and West Riverwalks Available online at www.cammagazineonline.com
opens Detroit’s front door to the international maritime community. Assessment, repair, and integration of a 90-year-old wharf eliminated the high cost and environmental impact of replacement, as well as risks to adjacent infrastructure associated with construction of a new wharf. Rip rap placed to stabilize the existing wharf and protect the embankment from erosion
was supplemented by additional rip rap underneath the wharf to enhance fish habitat. Countless below-grade obstructions and associated restrictions on foundation locations required innovation by the architect in space planning, and by the structural engineer in design of foundation systems.
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Contact: Tom Doyle, Real Estate Construction Partner 248.223.3575 thomas.doyle@plantemoran.com plantemoran.com CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012 47
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A DIFFICULT TASK AND SUCCESSFUL ENDING This project demonstrates what can be accomplished with the cooperation of multiple stakeholders and innovative professionals committed to delivering a social, economic, and sustainable solution for development. Assessing risk and addressing complex and differing concerns, this team strived to thoroughly understand site conditions, and incorporate effective and innovative engineering to development, while safeguarding existing public and private infrastructure. Tasked by the DWCPA to achieve the original vision of a deep-water port that would serve as Detroit’s front door to the international maritime community, the project team tackled the increasingly complex below-grade remnants of a previous urban waterfront. The project team deployed a comprehensive approach to adaptive re-use and repair of the existing wharf and construction of a new offshore wharf and Terminal building. A flexible design process allowed the project team to address unforeseen issues as they arose. An extensive instrumentation program efficiently monitored the effect of construction on existing infrastructure. Value engineering throughout construction allowed implementation of less costly means and methods suggested by the contractors. Frequent communication encouraged continued cooperation of stakeholders and ensured that concerns and risks were addressed. The total duration for construction was 26 months. Residents of Detroit and Wayne County can now proudly boast about their new front door to the international maritime community. Reminiscent of a more prosperous time, this transformation of a dilapidated remnant of Detroit’s industrial past stands as a testament to the fortitude of its people, the community, and the professionals dedicated to its rebirth.
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48 CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012
“Voice Of The Construction Industry”®
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PHOTO BY CURT CLAYTON, CLAYTON STUDIO
Glazed with a structural sealant, this sleek precision cube of glass houses the lobby of LG Chem Michigan’s advanced battery plant.
JUMPSTARTING A NEW INDUSTRY RONCELLI BUILDS THE FIRST U.S. ADVANCED BATTERY PLANT FOR LG CHEM MICHIGAN By Mary E. Kremposky, Associate Editor sleek precision cube of solar blue-tinted glass announces the presence of LG Chem Michigan Inc.’s new advanced battery plant in Holland. Clean, crisp, high-tech and contemporary, the grand lobby within this seamless cube of glass embodies the technical expertise needed to produce lithium-ion cells for the advanced battery packs in electric vehicles. Visitors must slip off their shoes and don plastic foam shoes – and sometimes even pass through an air shower for particulate removal – before entering over 177,000-square-feet of clean and dry rooms within this facility. These specialty spaces are pivotal in producing advanced batteries for the Chevy Volt, General Motors’ extended-range electric car with an on-board gasoline generator. This nascent industry holds out the promise of launching a new era in the automotive industry, and ultimately in creating a more sustainable world. Roncelli, Inc., Sterling Heights, as the design/builder along with architect of record Rossetti Associates, Southfield, and engineer Ghafari Associates, LLC, Dearborn, used their expertise to create these clean rooms for a cleaner environment and to lead an entire team of industry professionals in the creation of Phase I of this 615,000square-foot H-Project Battery Manufacturing Plant. Working closely with the Rossetti and Ghafari team, Roncelli collaboratively integrated the efforts of all project stakeholders in managing the
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52 CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012
design, construction, installation, start-up, testing and turn-over of all building and select manufacturing systems, including systems that support one of the industry’s most advanced clean/dry rooms with an incredibly low relative humidity level. The same level of precision produced the perfectly flat metal panels cladding much of the building exterior and doubling as an interior wall in the warehouse areas of this efficient building. Beyond the craft of construction, the art of communication was vital in the creation of this $303 million dollar plant rising amid a former farm field in West Michigan. With over $110 million in construction costs alone, Roncelli had to not only construct a building, but also “build a bridge” strong enough to span the cultural, language, corporate and construction differences inherent in working with a large global corporation headquartered in Seoul, Republic of Korea. With $100 billion in revenue, the holding company, LG Corp., is engaged in the chemical, telecommunications & services, and electronics industries through its affiliates LG Chem, LG Electronics and a host of sister companies. LG Chem Michigan is the company responsible for LG’s first advanced battery manufacturing facility in the United States. LG Chem Power Inc. maintains a Southeast Michigan presence with an office in Troy devoted to the research, development, engineering, and design of lithium-ion battery solutions. “Voice Of The Construction Industry”®
RENDERING BY ROSSETTI ASSOCIATES
Way. With its manufacturing facility now poised for future growth, “LG Chem’s critical objectives for the Holland plant are to supply Chang Ki Kim expressed a heartfelt, “thank you” to the entire project batteries for the GM Volt and to support the Michigan workforce, said team for the plant’s successful and timely delivery. LG Chem’s Construction Manager Chang Ki Kim. As part of working in the global economy, Roncelli engaged the TULIP CITY BLOOMS WITH BATTERIES services of Elizabeth Yoon as interpreter, Asian business and cultural Beginning in May 2009, Kim began reviewing over 100 prospective consultant, and customer liaison. Yoon was brought on board shortly sites in Michigan, winnowing the submissions down to 13 semiafter Roncelli submitted its initial proposal. Part interpreter/part finalists. After touring all 13 sites and recommending three, Kim ambassador, “she has been a significant part of our overall team invited LG Chem Vice Chairman & CEO Peter Bahnsuk Kim to visit the success,” said Roncelli Director John A. Raimondo, PE. “Reading the three finalists, ultimately selecting Holland as the new home for its mood in the room and understanding the way words are interpreted manufacturing facility. were critically important as part of our overall win strategy. She While the other two finalists had city officials alone conduct an helped us understand our client’s body language and tone of voice, official presentation, some of Holland’s largest companies personally so that thoughts could be clearly understood and expressed, and met with LG Chem, “talking shop” from one corporation to another. mutual understanding could be achieved. In order for Roncelli to The City of Holland coordinated the event, bringing the top deliver the best solution to our customer’s needs, it was important for management of Haworth, Herman Miller, and Gentex on board. “They us to understand exactly what our customer wanted.” talked to us about actual operating costs,” said Chang Ki Kim. “They Securing the contract required earning the trust of the LG Chem talked about labor availability and the strong work ethic in the area.” team. With its own company culture and its prior experience LG Chem toured the facilities of the three corporations, gaining building GM’s Global Battery Systems Laboratory in Warren, Roncelli first-hand knowledge of Holland’s business climate. Ultimately, LG was able to cultivate this intangible quality and seal the deal with this Chem chose Holland because of its lower labor rate and less costly leading global supplier and recognized leader in the development utilities. According to Chang Ki Kim, utilities are about 15 percent less and production of lithium-ion batteries. “Because we don’t know the in the Holland area as compared to the other two finalists in Macomb system here, we were looking for a partner we could trust,” said Kim. and Wayne Counties. “Electric battery manufacturing is a very “We wanted a partner in whom we could see the dedication in their electrically intense process,” added Steve Skaglin, Roncelli senior eyes and in their actions. We saw that from Chairman & CEO Gary project manager. “The fact that Holland is a good place for families Roncelli and from Roncelli President & COO Thomas Wickersham, as was another factor in its selection. Employees are very important to LG well as from the whole Roncelli team.” Chem as shown by the plant’s fitness area and cafeteria,” offering a Creating a cultural rapport between professionals from Southeast pastoral view of a pond. Asia and Southeast Michigan was pivotal to the project’s success. “We recognized from the onset that the most important factor in the HYBRID DELIVERY success of the overall project was cultural alignment,” said Raimondo. After site selection, the search was on for the ideal project delivery “We saw that it was going to be critically important to achieve this method. On board prior to Roncelli, Rossetti and Ghafari alignment even if it meant reshaping our entire organization to see recommended a hybrid design/build approach capable of integrating the work through our new client’s eyes and perspective, including the building and its sophisticated manufacturing equipment and the way they interpreted our industry.” processes in a seamlessly efficient line of delivery. “This was a twoThe project team had to navigate differences in Korean and phase program,” said Kim. “In the first phase, the architect/engineer American technical terminology and even construction methods, did 40 to 60 percent of the design, and then the project was plus contend with new, often proprietary, technical advances in the transferred to a design/build manager for finalizing the design and electric battery industry, itself. Not to mention “translating” LG delivering the construction.” Chem’s four-story plants and manufacturing processes in landEven as a bidder, Roncelli “constructed” a collaborative relationship limited Korea into a mainly single-level facility in the wide, open with the Korean manufacturer. “LG Chem asked that the bidders be fields on the outskirts of Holland. Add the logistics of a site visit from very collaborative, open and the President of the United transparent with their States to round out this information,” said Raimondo. challenging mix. “From the beginning, we Ultimately, Team Roncelli began sharing our ideas and delivered the design/build thoughts to enhance the equivalent of Olympic Gold, project, as well as to reduce successfully completing this the cost and strengthen our complex project on a world relationship with this stage a full three months potential new client.” earlier than originally In selecting Roncelli, LG scheduled. Chem balanced price with Initially, LG Chem qualifications and the ability Michigan believed to generate innovative constructing such a solutions. Rossetti/Ghafari’s precision plant in 13 months final recommendation of was extremely challenging. Roncelli as designers of the Thanks to Team Roncelli, the bridging documents used challenges were overcome This 615,000-square-foot plant will produce advanced batteries for the Chevy during the bid process made and the plant now stands Volt, General Motors’ extended-range electric car with an on-board gasoline it all official, and the gears of along a roadway called 1 LG generator. Available online at www.cammagazineonline.com
CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012 53
the project began to move rapidly with LG Chem and the project team meeting several times a day for an entire week-and-a-half. “The meetings lasted morning through evening in the post-bid proposal review phase,” said Raimondo. “We began to not only build the relationship and understand the group’s chemistry, but we also began to work collaboratively to vet out or validate the systems identified by Rossetti and Ghafari in the bidding documents and the ideas from the Roncelli team on improving the project.”
PHOTO BY RONCELLI, INC.
NERVES OF STEEL In the preconstruction phase, LG Chem Michigan and the project team co-located in Ghafari’s office from mid-April to mid-July 2010 to improve communication and streamline design review. Roncelli identified two systems critical to the project’s success: structural steel and the clean/dry rooms. Co-locating in the preconstruction phase was pivotal in placing an early mill order to meet the critical schedule milestones of this fast-track project. The project team had to order steel for the structural frame immediately after contract award to avoid
With its white surfaces, glass and stainless steel, the lobby mirrors the high-tech efficiency of the electric car. Natural light and greenery are ideal elements in a facility devoted to this emerging clean technology.
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missing the mill’s production window. “We only had one week to do the mill order after the contract was awarded,” said Sunghoon Jung, LEED AP, Rossetti project manager. “The steel process was that rapid.” Roncelli chose Bristol Steel & Conveyor Corp., Davison, as a structural steel partner. “We wanted someone who shared our vision for success through collaboration and who understood the critical challenges of the project,” said Raimondo. “Bristol did a very good job responding to our needs.” Ghafari’s engineering and software expertise quickened the formulation of the mill order and steel fabrication. “We used special software in which we actually checked drawings, reviewed drawings, and checked approvals in a completely paperless process,” said Ghafari Executive Vice President Michael A. Neville, AIA. Ghafari’s portfolio includes GM’s Volt engine, Volt assembly and a Romulus battery plant. In the preconstruction phase, several other subcontractors were brought into this group “mind meld” at relevant points, including Hodess Construction Corporation, an Attleboro Falls, MA-based clean/dry room
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Detroit Cornice & Slate Co. M.W. Morss Roofing, Inc. Romulus MI Ferndale MI 734.942.0840 248.398.7690
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design consultant and construction coordinator hired by Roncelli. MEP contractors joined the co-located meetings as well, including Shambaugh & Son, Southfield, Circuit Electric, Kalamazoo, and John E. Green, Ann Arbor. “At one meeting, we offered a suggestion that tailored the environmental conditions of the clean/dry room more appropriately to LG’s manufacturing process,” said Raimondo of this proprietary process. “Because these types of innovative solutions were provided during the preconstruction phase, nothing was built that required change during construction. As importantly, our team was able to procure the systems cost competitively, while leveraging enhanced value delivered by our subcontractors and suppliers to further reduce project cost and improve schedule performance.” In suggesting this technical revision, Roncelli leveraged its expertise and demonstrated its unwavering commitment to LG’s complete success by offering solutions to improve the project that may not have necessarily been viewed favorably by the client. The entire team, including primary system technical disciplines, worked together during these pre-award collaborative design meetings to identify “best for project” solutions. YOU SAY H BEAM, I SAY W SECTION Yoon, along with Rossetti’s Project Manager Sunghoon Jung, helped the project team successfully bridge differences in language, culture and professional terminology. “Koreans use a great deal of English terminology in their design and construction vocabulary, but the actual meaning behind the terminology is often different than ours,” said Jung. “For example, we say W section and they say H beam. But even so, when they say H beam sometimes it’s different from our W section.” Achieving a clear understanding of ideas, suggestions and even basic meanings had to be patiently cultivated. “Review of drawings took place over a period of three to four months, but between the whole team, we probably added over an entire man-year to the review process,” said Neville. The differences between Korean and U.S. construction methods added further complexity to the project. “For example, there are not a lot of gas lines within a Korean plant,” said Neville. “Also, they do not run drain lines underneath the plant.” GM even attended occasional meetings to ease the process. Beyond co-locating in Ghafari’s offices during the preconstruction phase, the project team and select subcontractors went to Korea several times to tour LG Chem’s advanced battery plants. These crucial visits helped the project team “translate” the building from a vertical Korean plant to a horizontal plant in a Michigan cornfield. “In translating the building, items such as the conveyor openings had to change, but then while we were designing and constructing the building, the technology was also changing slightly,” said Skaglin. “Some of the components are made in Japan, some in Korea, and some in the United States. Basically, we were dealing with changing information and proprietary information from several sources, and we were translating it all into a different building type.” PLANTING A NEW CROP Co-locating in Ghafari’s office and the series of Korean tours gave the project team a crystal clear understanding of LG Chem’s vision, resulting in high-speed construction further accelerated by the overlapping of design, construction, equipment installation and virtually all phases of the project. In the very beginning, Roncelli secured an agreement with the City of Holland to approve the design in phases to permit the early launch of critical construction activities. “We phased the design to match construction, rather than wait for the “Voice Of The Construction Industry”®
total design to be completed before beginning work in the field,” said Skaglin. In June 2010, Roncelli began site work on this former farm field whose sandy clay soil once sprouted corn but now produces the latest “crop” of lithium-ion batteries. With the land sloping west to east, Roncelli balanced the site by cutting 12 feet from the west and placing about 12 feet of engineered fill on the east, said Skaglin. Roncelli also managed unsuitable wetland soils in the middle of the site, installing a wetland mitigation project with trails and other amenities adjacent to a nearby city park. THE PRESIDENTIAL SEAL OF APPROVAL The official groundbreaking ceremony was held on July 15, 2010. One of the dignitaries present was none other than the President of the United States, along with then-Governor Jennifer Granholm. “This is more than just building a new factory,” said President Barack Obama as quoted on the Roncelli website and in the Holland Sentinel. “It’s about building a better future for this city, for this state, and for this country.” The plant received federal funding through a U.S. Department of Energy stimulus grant under the American Recovery and Reinvestment Act, according to Roncelli-supplied information. LG Corp. Chairman & CEO Bon Moo Koo and LG Chem Vice Chairman & CEO Peter Bahnsuk Kim welcomed President Obama and introduced this exciting new development to the world. “LG Chem was committed to making the presidential visit a top-notch event,” said Nick Contesti, Roncelli project manager, facility manager and events coordinator. “They succeeded in making it a wonderful experience.” As a type of “concierge construction,” Roncelli has its own in-house group specializing in the coordination of highprofile events. Contesti and his team worked with LG Chem, the White House, the Secret Service, and Hillside Productions on the presidential visit and groundbreaking ceremony. “The President’s visit required significant logistical, security and crowd control measures, all coordinated to minimize the impact on construction activities,” said Contesti. Once the convoy of presidential helicopters left the site, Roncelli continued construction, installing spread footings - with trench footings in between – followed by foundations and structural steel. Roncelli sliced the facility into five zones, sequencing construction in a smooth wave of activity. “We were putting in finished equipment in Zone 1, while we were installing flooring in Zone 2, placing concrete in Zone 3, finishing Available online at www.cammagazineonline.com
the shell in Zone 4, and working on the shell in Zone 5,” said Skaglin. Construction and equipment installation was carefully sequenced. “All of the plant’s construction was sequenced to meet LG Chem’s phased process equipment installations, including critical testing of manufacturing processes prior to product launch,” according to Roncelli-supplied
information. “BIM was used to eliminate clashes between construction and process equipment, avoiding costly schedule delays and field-driven, on-the-fly changes.” Adding to this list of best practices, lean construction principles were used to avoid waste and unwanted cost, and metrics were established and tracked to achieve the owner’s objectives.
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An elegant fountain is part of the world-class ambiance, image and presence of LG Chem Michigan’s new Holland facility.
A PRECISION BUILDING The enclosed building has a precision skin of glass curtain wall and light gray and slightly darker gray metal panels. “They are two-inch-thick insulated panels almost 40 feet high,� said Gregory T. Sweeney, AIA, LEED AP, Rossetti associate, director of technical design. “The canopies have slightly different metal panels with concealed fasteners.� The exterior expresses the precision manufacturing practices taking place within the plant. LG Chem Michigan wanted perfectly flat metal panels. “Those are two words that make any metal panel manufacturer cringe – perfect and flat,� said Sweeney. Rossetti visited the metal panel manufacturing facility near Toronto to make sure the plant could deliver a product capable of meeting this high standard. “We then assured LG Chem that the product was coming only from that specific manufacturing plant,� said Jung. Equally precise, a blue-tinted glass curtain wall wraps the lobby, select areas of the plant, and the cafeteria. “The curtain wall is glazed with a structural sealant,� said Sweeney, “meaning that there are no exterior mullions. It basically looks like butt-jointed
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glass from the exterior.” Interior construction of the clean/dry rooms demanded a mind-boggling level of technical precision. “These rooms are constructed within the overall shell of the plant’s structure and create an architectural partition and ceiling “seal” between the interior of the rooms and the plant’s internal environment,” according to Roncelli-supplied information. Stainless steel flooring and special walls and ceilings block rust formation and the generation of dust flakes, said Skaglin. The aluminum panels offer a clean, impervious surface with insulated, high-density foam cores, all sealed and joined for dust control and to maintain an extremely low relative humidity level. The density of the panels creates a ceiling with a walkable surface. “The panels have to be of such a density to span structural supports,” said Skaglin. “Suspended from the structure, the walkable ceilings allow maintenance staff to access the fan filter units above the ceilings or conduct checks on the sprinkler pipes and other infrastructure pieces.” Due to LG Chem’s proprietary and confidential manufacturing process, many of the intricate systems incorporated into the Design-Build approach cannot be described. What can be shared is that the systems were seamlessly integrated by the Roncelli team through collaboration, 3D BIM, and continuous communication to eliminate costly rework during field installation; unwanted costly change was less than one percent over the life of the contract. Systems included: dual insulated ceilings, moisture control, low shrinkage concrete, positive pressure environmental systems, antistatic surfaces, dehumidification, particulate control, and noise suppression. “One of the assembly area rooms maintained a humidity level that is extremely rare in our industry,” said Neville. “Desiccant dryers or dehumidifiers burn off the humidity, so you are basically extracting all the water and moisture out of the room.” An extensive commissioning process ensures the proper operation of systems vital for production. Altogether, the facility houses nearly 90,000 square feet of Class 1,000 clean rooms with an additional 90,000 square feet of Class 10,000 clean rooms, designating a more stringent level of particulate control. Even in office areas, Rossetti selected a very low profile carpet to keep dust down, said Jung. Building occupants must don protective clothing before entering certain areas of the plant. “No one walks around the Available online at www.cammagazineonline.com
building in their street shoes,” said Skaglin. “Depending on the area designated for entry, there are further degrees of cleanliness required, such as clean suits.” Each clean/dry room is “guarded by” air lock vestibules with some areas requiring actual air showers prior to entry. “The air shower hits the clean suit with a certain amount of pressure to remove particulate,” said Neville.
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steel staircase with glass railing. “The metal staircase, connecting the lobby to the offices above, also functions as a type of balcony increasing circulation throughout the building,” said Jung. Crisp and contemporary, the second-level offices and conference rooms are wrapped in glass enclosures, as well. The lobby and its companion spaces “were intended to mirror the sleek efficiency and clean technology of the electric car,” said Jung. “The selection of glass and metal, complemented by white space, extends the hightech look of the exterior into the interior, unifying the space.” Natural light fills the lobby, “creating an inspired environment for both staff and visitors,” continued Jung. “Conversely, the interior glows from the inside out at night, turning the building into a shining beacon for the community.” The office areas have high-end carpeting and lighting, as well as selections of quality office furniture from the major furniture manufacturers of West Michigan. “The interior really represents the LG Chem brand,” said Raimondo. “The building exterior and interior represent the quality, innovativeness and the value that their product represents to the marketplace and to GM.” WORKING IN THE GLOBAL ECONOMY Roncelli has clearly excelled in its performance on the world stage, working in the global economy with expert planning and delivery, sheer nerve and diplomatic aplomb. The building received its certificate of occupancy well ahead of schedule on July 15, 2011. “It was Chang Ki Kim’s leadership, wisdom and vision that allowed our team to succeed,” said Raimondo. “Our senior project manager, Steve Skaglin and Chang Ki Kim
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became like this,” continued Raimondo crossing his fingers, “so that together they accomplished the impossible. And of course, none of this would have happened if it weren’t for the Rossetti/Ghafari team’s talent and commitment, along with the entire Roncelli organization.” ARE YOU PEV READY? The automotive industry is on the brink of a new era, and some of the infrastructure to make it all happen is taking shape in the State of Michigan, the original home of the internal combustion engine. If Chevy Volt sales expand, LG Chem Michigan envisions the creation of a large technology park in Holland, said Kim. LG Chem has massive technology parks for advanced battery manufacture in Korea and China. Sales of plug-in electric vehicles (PEV) are expected to expand as the 21st Century progresses. Today, some communities are already planning for the Change. Oakland County Economic Development & Community Affairs even held a September 2012 conference called “Are You PEV Ready? Planning for Plug-In Electric Vehicles in Your Community.” GM and LG Chem, along with Roncelli, Rossetti, Ghafari and a host of skilled subcontractors, have joined forces in Holland to begin building this new industry and hopefully a more sustainable world, both environmentally and economically. Team Roncelli not only translated the words of the Korean language but perfectly translated LG Chem’s vision into a world-class building with pioneering advanced battery manufacturing capabilities. At the end of the day, everyone on the team spoke the universal language of quality, respect and mutual success.
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Now called The M@dison, the newly renovated office building is a hub for technology entrepreneurs in downtown Detroit. Above, concrete plinths at the base of stairs serve as bench seating, while modern furniture, fixtures and graphics contrast with exposed vintage steel, concrete and reclaimed wood. PHOTO BY JUSTIN MACONOCHIE PHOTOGRAPHY
By Clare Desmond, Contributing Editor here are many things about a renovation project that can make a Design/Build team proud. Some projects stand out for beauty, others for detail, complexity, delivery, or any number of characteristics. In the case of the $12-millionplus renovation of the approximately 50,000-square-foot (not including an 8,500-square-foot rooftop terrace) Madison Theater in downtown Detroit, it’s all of the above, and more. Bought and renovated specifically to be a hub and business incubator for technology start-up businesses, the newly wrought building dazzles with its youthful, energetic and tech-centric urban design that was accomplished under a startlingly rapid construction timetable and on a maximally tight construction site. But representatives of the project’s owner, architect and contractor all say they are most proud of the impact the project has had on the City of Detroit. “It’s becoming a ‘go-to’ place,” said Joel Smith AIA, principal, Neumann/Smith Architecture, Southfield, the architect of record on the project. “People are asking, ‘Have you been to the M@dison?’ I
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didn’t realize what an impact this has had on the city. It has been a game-changer, with everybody wanting to experience it.” Neumann/Smith’s project manager for the M@dison renovation was J. Michael Kirk, AIA, LEED® AP BD+C, principal; the project architect was David Masco AIA (retired); and Jaimelyn Neher LEED® AP®BD+C, handled design. “There is a new energy in and around the M@dison Building that has transformed the area into a hub for high-tech professionals to live, work and play,” said Jim Ketai, managing partner with Bedrock Real Estate Services. “The building is 100 percent occupied, and the neighborhood is buzzing with activity. Being part of the M@dison Building’s reinvention has been among the most rewarding experiences of my real estate career.” Bedrock is a property management firm based in downtown Detroit that specializes in purchasing, leasing, financing, developing and managing commercial space. It is part of Rock Ventures LLC, the umbrella entity formed to provide operational coordination, guidance and integration of Rock Ventures’ and Quicken Loans’ Founder and “Voice Of The Construction Industry”®
Available online at www.cammagazineonline.com
CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012 63
PHOTO BY JUSTIN MACONOCHIE PHOTOGRAPHY
technology entrepreneurs could collaborate and benefit from their Chairman Dan Gilbert’s portfolio of companies, investments and real proximity to one another. That some of their team members might estate. choose to live and play, as well as work, in downtown Detroit was “Anchor tenants focused on entrepreneurship and creativity, like also part of the goal. Detroit Venture Partners, Bizdom and Skidmore Studio, perfectly The M@dison has put that goal well on its way. Once the center of demonstrate our long-term vision for downtown Detroit,” Ketai the burgeoning entertainment industry in 1920s Detroit, the added. “The amazing work of the architects, designers and M@dison is now becoming one of the pioneering centers for contractors involved helped create a distinct space and successful technology company development in the Detroit of 2012. redevelopment of a historic building that is a remarkable feat in our city’s ongoing revitalization. And we’re just getting started.” It’s a “destination,’ noted John Olszewski, vice president for construction with Bedrock, which oversaw the purchase and subsequent renovation that transformed the 95-year-old building into a modern, edgy and open space. It was re-named the M@dison, with the “@” used purposefully to demonstrate the building’s emphasis on young technology entrepreneurs. In January 2011, more than a decade after the last attempts by others to resuscitate the property, Gilbert acquired it, with the idea of creating a hub for high-tech entrepreneurial activity and special events. The refurbished M@dison, at 1555 Broadway, is currently home to more than 20 technology or creativity-based companies, many of them start-ups. Besides the youthful, hip, techcentric design, it has also attracted tenants with the camaraderie and collaboration that the design fosters. Featuring several large open spaces, the building invites Newly crafted artistic signs recall the M@dison’s former life as a 1920s-era movie palace. The signs feature key words in Dan Gilbert’s vision for Detroit as a place to Live, Work, Play. communication among its tenant companies. “It all started with a vision,” Olszewski said of theM@dison. “Each of Rock Ventures’ buildings According to his Quicken Loans website, Gilbert made a is different. This one was set up to lure venture companies that are commitment in 2009 “ … to play a role in developing a creative, not necessarily part of the Rock Ventures family,”although its Detroit tech-focused urban core where people want to live, work and play,” Venture Partners, Bizdom and Doodle Home are anchor tenants. imagining a tech hub he labeled “WEBward Avenue.” The vision was Gilbert also created Bizdom, a non-profit that provides the support, that the work environment should reflect the lifestyles of the resources and mentoring to help aspiring entrepreneurs get their workers who use the space, explained Todd Sachse, president of businesses off the ground. Gilbert is also one of four partners of Sachse Construction, Birmingham, the construction manager on the Detroit Venture Partners, a venture capital firm that invests in earlyproject. And it was to lure young workers especially back into the stage technology companies. The other partners are Josh city, Neumann/Smith’s Neher added. “The genius of this project was LinknerCEO, Brian Hermelin and Earvin “Magic” Johnson. Linkner is a the vision articulated by the owner,” Sachse said. tech entrepreneur and the founder of ePrize; Hermelin is the The Madison Theater was built in 1917 by owner John Kusky and founder of the private equity investment firm Rockbridge Growth renowned theater architect C. Howard Crane, who specialized in Equity; and Johnson is, well, Johnson, the hall of fame basketball star, designing elaborate early 20th Century “movie palaces.” According entrepreneur and philanthropist. to historicdetroit.org, the 1,806-seat theater opened on March 7, After the Madison Theater shuttered for the final time in 1984, its 1917, and was the first of the grand theaters that Crane would marquee advertising the last film to be played there, “The Dead design. As were many theaters of that era, the Madison was built Zone,” ironically remained for more than 20 years. The City of Detroit, with an office building attached to provide additional commercial once called the “Paris of the Midwest” in part due to its architecture, space for the growing office clientele. The office building’s classical was on a downward slope. The theater portion of the structure was design was removed by a modern facelift in 1961 and the theater torn down in 2000 to make way for a surface parking lot, and the succumbed in 1984 to the declining movie trade downtown. It remaining five-story attached office building remained unoccupied eventually was purchased by the Michigan Opera Theater, which and deteriorating. had plans to restore it for live, small stage productions. That project was abandoned and the building was sold in early 2000. The new A REALLY FAST RENOVATION owner’s plan to develop the office portion of the building into loft Following a six-month renovation started in May 2011 and condominiums also faltered, and some initial repair work ended. completed in November of the same year, the building is “dead” no The new M@dison’s design, executed by Neumann/Smith and more. The hope was that the success of the building in attracting its Rock Ventures’ Doodle Home, features open interiors and generous target tenants would spur similar development elsewhere meeting and seating areas that foster communication among the downtown. Gilbert’s dream was to provide a space where
PHOTO BY JUSTIN MACONOCHIE PHOTOGRAPHY
A variety of seating adds communicating or relaxing space around a core of work stations for tenants.
building’s various tenants. Edgy and sometimes humorous graphics, partial walls covered with IdeaPaint so they can be scribbled on and dry-erased, and seating areas circling a core of workspaces encourage tenants to congregate or collaborate informally. The building features spaces on the 2nd through 4th floors for anchor businesses and a “desk-for-a-day” environment for enterprising “techies” who might come into the building. A combination of conventional and unusual seating in the spaces that rim the open work stations includes a hanging swing. A variety of wall art is youthful and innovative, but it remains in keeping with the Design/Build team’s desire to incorporate as much of the old building with the new while maintaining a spirit of freedom. Existing graffiti, for instance, was left in place on several of the old masonry walls, and fabricator markings on new steel were left exposed. “It was artwork,” Smith said. The design also tips its hat to the old theater, with decorative signage created from steel beams and Hollywood lights reminiscent of the theater’s marquee, featuring single words that are key elements
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of Rock Ventures’ philosophy about the “new” Detroit: Live, Work and Play. A JEWEL WITH GREAT VIEWS One of the jewels of the renovation is the stunning, approximately 8,500-square-foot rooftop terrace that provides unobstructed views of Grand Circus Park, Comerica Park and northward up Woodward Avenue to the Fox Theater. The space contains two bars, a commercial kitchen with three barbecues, and multiple flat screen televisions. In the raised center portion of the terrace, modern furniture tops flooring constructed of recycled concrete pavers set on one-foot high pedestals over a membrane to provide drainage. A wood slat floor around the perimeter is also set on a series of wood sleeper pedestals. “All of the water perks through the pavers and into the roof drains,” Smith said. Three elevators, one of them a freight elevator, service the building. Mechanicals for the structure are placed out of view on top of the service elevator. A 42-inch-high railing constructed with capped masonry posts and stainless steel cables rims the terrace to enhance the mostly unobstructed city views. The look is modern, with lighting and touches of wood and foliage to soften the space. At nearly 10,000 square feet, the building’s 5th floor offers open gathering spaces, a two-story auditorium, two private conference rooms, lounge seating and tables, plus a full catering kitchen and bar facilities. A skylight brings in enough natural light during the day that the space is usable without having to turn on the lights. Multiple tall windows provide views on the east and north sides. Italian tile and light fixtures in the modern bathroom compliment polished concrete floors and countertops. The wall tile is a taupe-grey color around the countertop, while white tiles, some with a three dimensional design on the face to add artistic detail, are used at the other end of the space. The 135-seat auditorium on the 5th floor is “all new,” Neher said. “It didn’t exist before the renovation.” Colorful acoustical tiles line the walls, and each seat in the auditorium is fitted with a collapsible laptop platform with power available for re-charging equipment. The auditorium is equipped with full light rigging, and the room is acoustically suitable as a small performance venue. The south end of the first floor features independent coffee shop Chez Zara, a reception area for upper floor tenants, and an Italian restaurant anchors the northeast corner. The remaining floors of the building Available online at www.cammagazineonline.com
each feature a core of work stations surrounded by a rim of open meeting spaces. Skidmore Studio, a creative company, moved to Detroit from Royal Oak last year and occupies the entire 4th floor. Each floor is distinguished from the others with graphics, furniture and modern LED lighting that contrast with the existing vintage structure. Exposed original clay tiles were left in place on the ceilings and re-
patched where structural bracing was needed, or covered where required. Floor steel decks were sprayed with K-13 acoustic spray for noise reduction and insulation. Steel was left exposed on the existing stairs between the second and third floors and is incorporated into the stairwell design. Stair treads were constructed of reclaimed barn wood to add to the vintage look, while adding warmth to the space. Reclaimed barn
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PHOTO BY CURT CLAYTON, CLAYTON STUDIO, DETROIT & TORONTO
The stunning 8,500-square-foot rooftop terrace features a commercial kitchen, two bars, three barbeques, multiple flat screens, and gorgeous views of the city and its sports venues.
wood was also used in private offices and in reception areas. Two types of large colorful graphics are used throughout the space. Some are manufactured papers with bold abstract designs and others are large murals, with some custom designed and created or executed either by Neumann/Smith’s Neher or by Doodle Home, a Rock Ventures’ Webbased interior design firm that worked with the architect on interior design for the project. One of the purchased wallpapers graphically depicts aspects of city living, including fire hydrants, streetlights and foliage. The first floor lobby graphic is a large aerial map of early-1920s Detroit that has been enhanced with neon lights highlighting major streets and noting the location of the M@dison with a “You Are Here!” sign. Fathead, best known for its lifesized wall graphics of sports and entertainment personalities, and another of Rock Ventures 50 companies, created many of the stunning graphics that cover entire wall expanses. Crisp black and white early 20th century photos of downtown Detroit and the M@dison are especially dramatic. LOTS OF CHALLENGES The M@dison renovation presented various challenges and obstacles, notably the owner’s need to be able to have the building occupied only six months after its purchase in January 2011. To meet that
demanding schedule, the owner, architect and contractor agreed to a Design/Build strategy. Some construction actually began before the design was completed, Bedrock’s Oleszewski said, praising both the contractor and design team for their “flexibility” in dealing with “lots of changes, lots of unforeseen issues.” For example, stair assemblies weren’t supported, and they discovered that one exterior wall was not reinforced. In addition, construction on the project was actually started before there was a design, he said, further complicating the project execution. “I commend both groups, architects and contractors, for trying to implement the design and construction simultaneously,” Olszewski said. Smith agreed, noting “the joke was that this was a Build/Design project,” he said, attributing the quip to Todd Sachse. “We built something, and then figured out how to design it.” When the design team first entered the building, not much remained of the interior. “It showed a lot of water damage,” architect Smith recounted, “and not a whole lot else. There were stairs and elevator shafts but no elevators, and that’s about it.” There were few interior walls. Perhaps the biggest challenge from a design perspective, Smith said, was organizing the mechanical and electrical systems. “You want it to look good,” he said, “but you also want it to work well.” Dealing
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with the inadequacies of the building within the timeframe allowed was another big challenge, he said, and designing and realizing the rooftop terrace rounds out his top three challenges. Team collaboration from start to finish was required, Sachse said, to “get it done on the fly … to take the owner’s vision and deliver it in an unconscionable amount of time.” Details, such as the urban-inspired wallpaper and graffiti left in place, “started to hone in during construction,” Neher noted. She said visits by the client during construction usually “brought with them another ‘Aha’ moment,” among them, using some of Gilbert’s favorite “isms” (words of wisdom) to decorate the frosted glass stair railings. For Sachse, it was the very fine installation and craftsmanship required on new materials brought into a very old and neglected building, and accomplishing their installation very, very quickly. “The schedule and the construction techniques and materials were challenging,” Sachse said, explaining that they were bringing new materials into a “very raw” building and those materials were going to be exposed and become part of the design, upping the ante for their installation. He noted, for example, that the joints and finishing on the reclaimed barn wood were “like casework” and done with “tremendous precision” and with very high quality. Also challenging the project was the tight, urban site at the corner of Witherell and Broadway Streets, across from Grand Circus Park on the north, with the Detroit People Mover track running on Broadway St. along the building’s east façade. The building itself occupies the entire site, with the exception of the small surface parking lot, which was used for a construction office and small staging area. All deliveries, Sachse said, were scheduled in a “just-in-time” manner and, because there was no elevator, they all had to be lifted to their appropriate floor using boom trucks of various sizes, or carried by hand to their destination inside the structure.“Not a single piece of equipment could be fed into the building from that side because of the People Mover track,” Sachse explained. No lost-time incidents marred the renovation of the M@dison. Sachse’s safety director, Doug Henderson, conducted safety training and orientation classes for all workers before they were allowed on site. Regular safety inspections were performed throughout construction to ensure that all trades and vendors adhered to Sachse’s policies. “Voice Of The Construction Industry”®
1 *#1 Y 1#04'!# Y . 021 Y 0#,2 * MODERN ENGINEERING SOLUTIONS & ENVIRONMENTAL CONSCIOUSNESS The M@dison was fitted with a two-pipe water loop heat pump system, using individually zoned water-to-air heat pumps. The system has three high-efficiency condensing boilers to add supplemental heat to the loop piping, and a cooling tower to reject excess heat. This type of water loop heat pump system efficiently transfers and recycles the building load. Heat that is removed from the first floor restaurant, for instance, can be conditioned and added to the loop to heat offices on the fourth floor. Outside air is directed through a Heat Recovery Ventilator (HRV) that removes the energy from exhausted air either heated or cooled, and transfers it to the incoming outside air. The HRV recovers about 80% of the energy from the exhaust air, which otherwise would simply be lost. Individual heat pumps were hidden above the enclosed offices, which lowered the ceilings in those office spaces, but which allowed one heat pump per run to feed between the structures.
Access to the plenum for these runs, which also contain the sprinkler mains, is superinsulated and isolated to control noise in the offices below. As might be expected, the entire building, including the rooftop terrace, is wireless and has a direct point-to-point wireless bridge from the mainframe three blocks to the south. Three-bulb direct/indirect florescent lights were suspended parallel to the ductwork and sprinklers. The M@dison was foam air-sealed throughout, and superinsulated underneath the rooftop terrace’s floor. SMART Building energy credits have been approved for the new mechanical system upgrades and lighting systems. Renovation of the M@dison shows a commitment to conserving land and resources by its rehabilitation of a historic gem that had been abandoned for more than 20 years in the heart of downtown Detroit. “It demonstrates what you can accomplish with an old building when you re-purpose it,” Sachse enthused. The rooftop already has been used for many private events.
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COLLABORATION COL LLABO ORATION Ryan W. Jezdimir counsels owners, contractors, and suppliers in all stages of WKH FRQVWUXFWLRQ SURMHFW b+H ZDV LQFOXGHG LQ WKH FRQVWUXFWLRQ SURMHFW b+H ZDV LQFOXGHG LQ the 2011 and 2012 lists of Michigan Super Lawyers Rising Stars, and recognized as a top construction litigator by DBusiness PDJD]LQH b5\DQ LV D FXP ODXGH JUDGXDWH PDJD]LQH b5\DQ LV D FXP ODXGH JUDGXDWH of Wayne State University Law School.
Don W. Blevins is a litigation attorney with extensive experience handling complex commercial disputes. Practicing law in Washington, D.C. for over a decade, he represented clients in major disputes throughout the country. Don is a cum laude graduate of the University of Michigan Law School.
RESULTS RES ULTS McAlpine has a track record of success, helping its clients recover more than PLOOLRQ LQ VHWWOHPHQWV DUELWUDWLRQ DZDUGV DQG MXU\ YHUGLFWV b,Q WKH SDVW PLOOLRQ LQ VHWWOHPHQWV DUELWUDWLRQ DZDUGV DQG MXU\ YHUGLFWV b,Q WKH SDVW 18 months, McAlpine has obtained the following results: PLOOLRQ PLOOLRQ settlement for a micro-tunneling contractor PLOOLRQ PLOOLRQ settlement for a site contractor PLOOLRQ PLOOLRQ jury verdict for a residential builder PLOOLRQ PLOOLRQ net favorable jury verdict for a multi-skilled contractor PLOOLRQbDUELWUDWLRQbDZDUG IRU D PHFKDQLFDO FRQWUDFWRU PLOOLRQbDUELWUDWLRQbDZDUG IRU D PHFKDQLFDO FRQWUDFWRU
Marcus R. Sanborn practices extensively in the areas of complex construction litigation and is experienced in all phases of contract formation, mediation, trial and appeal. A graduate with high honors from Washington University School of Law, Marcus was included in the 2012 list of Michigan Super Lawyers Rising Stars.
Construction law is challenging, complex‌and our specialty. 'RQČ W VHWWOH IRU D ˉUP WKDW GRHVQČ W ' RQČ W VHWWOH IRU D ˉUP WKDW GRHVQČ W XQGHUVWDQG \RXU EXVLQHVV bZH XQGHUVWDQG \RXU EXVLQHVV bZH speak your language. Our clients turn to us for advice throughout the construction process so that they can concentrate on what they do best. For a no-obligation consultation, contact us and put the experience of the McAlpine team to work for you.
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The Rotunda features UAW people who have embraced World Class Manufacturing methodology, complete with LED perimeter lighting, graphics, and an interactive wall.
BUILT FOR SUCCESS The UAW/Chrysler World Class Manufacturing Academy By Roy Jones Contributing Editor
Photos Courtesy of Commercial Contracting Corporation
hrysler Group LLC recently opened their state-of-the-art training center in Warren, designed to teach its work force the principles of “World Class Manufacturing.” The 117,500-square-foot renovation of Chrysler’s World Class Manufacturing Academy (WCMA), previously known as the UAW Technical Training Center (TTC), was completed in time for a January 2012 grand opening. Chrysler introduced all plants to World Class Manufacturing (WCM) as part of the alliance with Fiat in the 2nd quarter of 2009. The foundation of this system is to continuously improve performance, with all activities oriented towards achieving zero accidents, zero wastes, zero breakdowns, zero inventories and zero defects, with a focus on the “Top Problems 1st” in every area. The system is centered around technical pillars, each with seven steps of implementation, and managerial pillars, each with incremental levels of results. This approach translates into both the creation of value for the business and customer satisfaction, ensuring product quality, and maximum flexibility in responding to customer needs and empowering all employees. The success of World Class Manufacturing is based on the participation of employees, who are continually encouraged to
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contribute suggestions, all of which are considered for implementation and ultimately lead to the development of a continuous improvement culture. UP TO THE TASK / RENOVATION CHALLENGES Commercial Contracting Corporation (CCC), Auburn Hills, was tasked with providing general contracting services to renovate the UAW TTC and construct the new WCMA. The project, designed by Barton Malow Design, consisted of renovating the existing space within the facility which totals 117,500 square feet. The UAW TTC renovation now contained within the Academy, consisted of 92,500 square feet, and the WCMA Lab construction was 25,000 square feet. CCC had originally planned on splitting the 117,500-square-foot project into five phases; however, despite delays with contractual agreements that pushed the start date out by two months, the target completion date remained the same, which presented a myriad of difficulties from the very onset of the project. The first of these many challenges was coordinating the building operations with CCC’s renovation schedule and meeting the phased dates that both Chrysler and the UAW requested. The intent was to “Voice Of The Construction Industry”®
determined the best way to complete this portion of the job in order to stay on schedule and not impede other work was as follows:
work with the UAW TTC trainers and their class schedule to make sure the work was done around them, allowing the UAW TTC to remain open and functional and conduct their business as usual. Due to the overwhelming size of each of the phases, and the fact that each renovation phase encompassed several main corridors, scheduling became exceedingly difficult. However, working with a strong local subcontractor base, CCC was able to provide detailed phasing plans to both Chrysler and the UAW that specified on a day-by-day basis exactly what would be under construction, which areas would be available for use, and which areas were off limits. The World Class Manufacturing Academy lab was the first phase of the project. From a scheduling perspective, it was the simplest portion for CCC to complete, as it did not interfere with the daily operations and classes that were held in the building. The area had a separate entrance and separate loading areas keeping it isolated from the rest of the building. However, while the general construction was made easier because of the ease of accessibility, the interior finishes that the WCMA lab required were extremely difficult. The space was to include a ¼” epoxy system beginning with a layer of epoxy aggregate mix placed and leveled, followed by application of a top coat of epoxy. While this floor was being applied it could not be traveled on during the application or for 24 hours afterwards, which presented a challenge due to the size of the floor. CCC Available online at www.cammagazineonline.com
• Begin the major renovation by installing the miscellaneous steel which holds up the drywall partition that is above the eightfoot glass walls that divide the training rooms from the actual Academy lab. • Once the steel was installed, CCC moved on to the 17,000 square feet above-ceiling work. Above-ceiling work included: • Installation of sound reduction panels • Upgraded fire protection • HVAC replacement • Campasso grid clouds that are color coded to identify different lab areas • Cord reel access throughout the lab for both electrical and air • New acoustical lay-in ceiling tiles with stainless steel mesh air returns • After completion of the ceiling work, the floor was divided into two sections and the ¼” epoxy system was placed. CCC held-off on placing the top coat of epoxy so that the trades could begin their finishes. Chrysler, CCC and Hoover & Wells, Inc., Toledo, OH, worked together on the three main flooring systems installed at the facility. Says Hoover & Wells Vice President John Corsini, “We pre-planned the flooring applications to meet the owner’s budget as well as reduce down time without sacrificing quality or vision.” Work within the WCMA Lab area was centered around four crucial pieces of large
equipment, including a 29,000 pound CNC machine and three 6,500 pound robots that needed to be placed by CCC prior to the final coat of epoxy. The equipment’s positioning and layout had to be exact because all other items in the lab were to be placed around it. As construction moved forward, CCC was given changes that required them to aggressively adjust their schedule without affecting the completion date. One such change was the decision to use whiteboard dry-erase paint which presented a challenge due to its application procedure. Once the paint is installed, it can’t be written on for two weeks and due to its properties, if the wall is damaged or scratched you can’t simply repaint the damaged area – the whole wall must be repainted. This forced CCC to install the product at the last moment. The end result allows the teachers and trainers to write anywhere on the wall while conducting a class, a feature they have thoroughly enjoyed. The original schedule called for the UAW TTC renovation to begin after the completion of the WCMA lab but CCC was requested to begin the renovation during the WCMA Lab construction. This meant that previously scheduled classes and training had to be rescheduled which presented another challenge. Working with the UAW trainers and their trainees, signs and directional maps were created and posted throughout the building. Because of our project manager’s close collaboration with the TTC’s staff, both their training and our construction was able to continue without interruption or delay.
View of the engine assembly line simulator inside the WCM Academy. CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012 71
Panoramic view of the WCM Academy Lab area. The equipment was designed to complement the workspace and match the function required for the curriculum being taught.
The UAW TTC space consisted of four large labs and 28 classrooms. CCC “gutted” these classrooms down to the existing drywall. The new classrooms that emerged were totally up-to-date with new carpet, ceilings, freshly painted walls, efficient lighting, and high-tech interactive projectors. The interactive projectors work with a wireless pen that gives trainers the ability to be anywhere in the room and annotate, highlight, and change their presentation materials on the fly. The renovation also included updated lab spaces
that now have energy efficient high bay lighting, newly painted walls and ceilings, and epoxy floors. These enhancements serve to brighten the atmosphere and create an appealing environment for teaching and learning. One area, the Welding Lab, could not receive the now-standard white epoxy flooring for safety and aesthetic reasons, so a polished concrete was chosen which will hold-up longer and better maintain its newlyfinished look. The last phase of the project was the
renovation of the front lobby (947 square feet), the rotunda (1,205 square feet), and the WCMA Lab lobby which is better known as the “Labby” (1,757 square feet). In lieu of starting with the front lobby and moving inward, CCC decided it was most efficient to work from the inside out, starting with the renovation of the Labby, and then moving on to the rotunda, and finally the front lobby. The most challenging aspect of this phase of renovations was the terrazzo floor that was to be a continuous system, extending from
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KEVIN J. GLEESON Construction Law Practice Group Leader E-mail: kgleeson@swappc.com • www.swappc.com SOUTHFIELD MICHIGAN
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the front lobby all the way into the WCMA lab. The installation of terrazzo flooring is labor intensive and extremely specialized work. During the 72-hour installation period, walking in the area was curtailed until the final grinding and polishing had been completed. Due to scheduling of other trades in critical areas, and in order to maintain schedule, the terrazzo installation had to be phased and installed in segments. However, due to the contractor’s craftsmanship, this installation appears to have been done as a continuous system. The terrazzo flooring wasn’t the only high-end finish that was used during this renovation. The materials used to build out the walls of the lobby, rotunda and Labby are a mixture of Birdseye Maple veneer wood panels stained black, and pure white Trespa, a specialty product ordered and delivered to Detroit in time to meet the aggressive timelines of this project. The most noticeable addition to the lobby, rotunda and Labby is a custom-designed system of interactive monitors and touch screens found in two of the three areas. These interactive walls allow a person to use their hand positions to choose a video that is
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loaded onto custom software, uniquely created for this application. Moving from the rotunda and into the Labby, a state-of-the-art 11’x 4’ touch screen allows visitors to review the World Class Manufacturing doctrine prior to entering the WCMA Lab. The lobby, rotunda and Labby work together to tell the storyline of “This Is Who We Are,”“This Is What We Do,” and “This Is Why We Do It,” which gives everyone a full understanding of their purpose and their mission in their work for Chrysler. THE FINISHED PRODUCT - A SENSE OF PRIDE IN “THIS IS WHO WE ARE,” “THIS IS WHAT WE DO,” AND “THIS IS WHY WE DO IT.” Leveraging the huge sense of pride UAW members have in both their Union and in the products they craft, the lobby, rotunda, and Labby are tied together with the storyline of “This Is Who We Are”, “This Is What We Do” and “This is Why We Do It”. THE LOBBY The main lobby is where first impressions are made. The area is open and airy and very professional in look and feel. According to
CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012 73
Chrysler Facilities Manager Ed Lash, “Guests are immediately made to feel like they are respected and appreciated.” Recessed monitors play a looped video that reinforces “This Is Who We Are,” emphasizing that UAW members are more than just workers, but family men and women who participate in a variety of activities outside the workplace. THE ROTUNDA Inside the rotunda, the storyline continues with “This Is What We Do,” and features UAW people who have embraced the World Class Manufacturing methodology. The area is alive with ever-changing LED perimeter lighting, graphics, and an interactive wall that peeks into various manufacturing plants and showcases people who have made a difference. The interactive wall has three levels of engagement. Level one is designed to showcase the plants and people. When activated, guests are taken to level two where they can choose from four
Class Manufacturing and how they play a key role in ensuring the WCM culture is alive and active in all working environments. The ‘Labby,’ while a transition space from the public Rotunda to the WCM Academy, provides the student with a view into the Academy architecture. Lash explains, “It continues the theme of an inviting entryway offering a high tech, hard to forget first impression within a comprehensive learning environment where people quickly understand ‘who we are,’ ‘what we do,’ and ‘why we do it.’”
THE WCMA LAB AND QEC Chrysler and Commercial Contracting Corporation detailed out the need for equipment that complemented the workspace and matched the function required for the curriculum being taught. They further defined the stringent schedule and that they would need a creative partner with a history of project success to achieve this. Chrysler and CCC turned to Quality Engineering Company (QEC) to help in this regard. With very few design limitations imposed by Chrysler, QEC was given the ability to innovate traditional equipment into the sophisticated yet highly functional equipment displayed at the WCM Academy. QEC’s equipment offers a blend of style and purpose. The basic color palette that includes bright anodized aluminum, soft gray and white quickly catches the eye, but a closer examination of the equipment sheds the real beauty. The equipment was designed using modular assembly allowing for the reconfiguration of the equipment as the needs for it change. This added function of the equipment allows the instructors to utilize the equipment design as part of their curriculum, as opposed to just a means for completing an activity. According to Bill Iordanao, VP product engineering at QEC, “It’s this function and harmony that we are most proud of. QEC recognizes not only the importance of design function in the work space but also the design harmony within the workspace and its surroundings. QEC excels in design innovation and keeps this spirit as a pillar of the company.” The southwest side view of the Labby which is the final stop before entering the QEC was founded in 1981 as a design services WCM Lab and classrooms. partner to the automotive and construction industries. QEC’s specialty is process equipment installation engineering and personal stories about UAW members who raised their hand with a their efforts can be seen in many automotive powertrain facilities. In better idea. Level three features a personal story from the member’s the early 2000s, QEC’s product offering expanded to include the point of view about that idea and how it had a positive impact on design and manufacture of material handling equipment, as well as improving quality and reducing waste on the manufacturing floor. automotive OEM accessory products. “The pride they show in knowing that their thoughts and opinions matter is obvious,” explained Lash. A WCMA MISSION STATEMENT Chrysler’s mission statement for the World Class Manufacturing THE LABBY Academy is to create a culture of continuous improvement using the The World Class Manufacturing lobby, or Labby, is the final stop latest WCM standards and best practices to spread know-how in a way before the WCM Lab and classrooms. It is a fully immersive learning that is easy to understand and apply immediately. It is delivering the environment that allows guests to understand the importance of right training at the right place and at the right time which creates what they are about to learn. Organized around “This Is Why We Do It,” new possibilities. guests can control the pace and depth of their learning experiences. According to Scott Tolmie, WCMA lab manager, “Unlike any other A six-panel interactive touch screen wall with iPhone®-like controls production process or program I’ve been involved in before at and software allows them to pick a specific topic within World Class Chrysler, WCM is a structured and fully integrated manufacturing Manufacturing dogma and proceed to various levels of information system that ensures proper logic is used to apply the most and understanding. A three-screen movie wall allows viewers to pick appropriate tools and methodologies with a focus on checking for and choose from an ever-changing menu of video clips that includes results of every action. The Academy is a great opportunity for everything from commercials featuring Eminem, Clint Eastwood and Chrysler to develop WCM Certified Trainers, and standard “ChryslerJennifer Lopez, to press conferences from UAW and Chrysler ized” material to deliver the most pertinent WCM concepts and executives, to mini-movies on key successes on the plant floor. iPads® techniques to only those individuals who need to use it now.” are also available to help fully understand the importance of World
74 CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012
“Voice Of The Construction Industry”®
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CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012 75
Working in the soybean fields, Aristeo hoists one of five sections composing the 328-foot tower.
A BUMPER CROP OF WIND TURBINES Aristeo Builds Largest Wind Development in Michigan By Mary E. Kremposky, Associate Editor you stand on the edge of any country road near Breckenridge, you can hear the corn rattle in the constant breeze. Flat, wide open and with few trees, the farm country of central Michigan is clearly a choice location for the largest wind energy generation facility in the state. Invenergy, LLC, a large-scale renewable and clean energy firm based in the Windy City of Chicago, tested the area’s wind resource and gained the support of hundreds of landowners to assemble the Gratiot County Wind Project, a development spread across 33,000 acres of corn tassels and soybean fields, rippling in the wind like gentle swells on a lake. Today, a drive in the country north or south of this small village offers a glimpse of this sea of widely spaced wind turbines, rising from the soil and spinning their blades in a pastoral landscape of white farmhouses and red barns. “The project is the largest single-phase wind development in Michigan and one ranking in the top 10 percent of wind farms in the Midwest,” said Project Director Jim Scheloske, Aristeo Construction Co., the Livonia-based general contractor responsible for building the 212.8-megawatt project.
If
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Photography by Jeff Garland Aristeo mounted a logistical and tactical campaign to install 133 turbines spread over four different townships and encompassing 80 square miles of land. The company crafted two action plans in the preconstruction phase: the first plan created a route for the transport of turbine components over the narrow farm roads and bridges due east of Alma; the second devised a strategy to move 660-ton capacity cranes from one turbine site to another without potentially harming the schedule by frequently disassembling these leviathans. “We would have lost an entire week of production for each complete disassembly,” said Scheloske. Metro Consulting Associates (MCA), Belleville, brought their surveying expertise to the project in both the planning and construction phases. Working with Invenergy, MCA undertook the meticulous task of conducting an American Land Title Association (ALTA) review of this mind-boggling number of private landowners. The actual survey of the site contours and structures on this 80square-mile jobsite was conducted by plane with MCA hiring Aerocon, an aerial photography and mapping company based in “Voice Of The Construction Industry”®
Willoughby, Ohio with offices in Lake Odessa, Michigan. Working with Aristeo, MCA won the bid for the Balance of Plant civil design and construction layout. “During construction we pinpointed the location for each turbine and for each access road,” said MCA Manager of Engineering Services Damon Garrett, PE. The Gratiot County Wind Project was MCA’s first, but the company has since gone on to secure work at the Lake Winds Energy Park near Ludington and the Beebe Community Wind Energy Park just south of the Gratiot project. Beyond logistics and aerial surveys, keeping the lines of communication open was a pivotal part of the project. “Wind projects are people projects,” said Garrett. “Communication is one of the things that Aristeo does very well with both landowners and county officials. It made the project go very smoothly.” Aristeo was a good neighbor throughout the project, knocking on farm house doors to inform landowners about upcoming work and carefully preserving the topsoil - the black gold and life blood of every farmer. Invenergy commends Aristeo for its rapport with the entire project team and with this community of family farmers. “Aristeo worked well with our other contractors, and maintained a positive relationship with the local community,” said Invenergy Vice President of Procurement & Construction Dan Ewan. “Aristeo did a good job for us. They completed the project on schedule with good quality and an excellent safety record throughout construction.” GETTING WIND OF NEW WORK As a full-service general contractor and construction manager, Aristeo self-performed tower foundation, tower erection and managed the road construction services for the Gratiot County Wind Project. The firm can add installation of these 1.6 megawatt GE turbines to the extensive list of wind developments it has erected in Ohio, Maryland, Indiana and New York, as well as in Saskatchewan. “It was great to land a project in our home state of Michigan,” said Scheloske. Overall, Aristeo has produced turbine installations with a total capacity in excess of 1,200 megawatts. The wind developments have diversified a company whose bread and butter had always been the automotive industry. “In 2004, we felt some strong headwinds in the automotive business, and we started looking into alternative energy and power generation in general,” said Scheloske. Aristeo’s big break in the wind business arrived in 2007. With the wind industry booming in Iowa, New York and Texas, a power generation company that once eyed a project in Michigan’s Thumb invited Aristeo to work in New York State. “We had the resources to do the project, and because everyone was so busy at the time, they were in need of contractors in New York,” recalled Scheloske. “We made substantial capital investments, bought a lot of cranes and equipment, and that made us a player in the game.” The company’s ability to self-perform civil, concrete and turbine erection added to its capabilities. Aristeo brought these formidable capabilities to its first wind project: the installation of a 633-megawatt, multi-phase project for Noble Environmental Power in New York. In one phase, Aristeo poured 700 yards of concrete daily to complete 121 foundations on a fast-track schedule; its rigging crew erected the 1.5 megawatt GE turbines. With such able execution and solid experience, it’s no wonder that Invenergy – the largest independent wind power generation company in North America – invited Aristeo to join a prequalified bidder’s list for the competitive bidding of the Gratiot County project. Ultimately, Invenergy selected Aristeo and MCA “due to their previous experience, competitive pricing and positive attitude,” said Ewan. “We Available online at www.cammagazineonline.com
also like that they are Michigan companies, with Michigan employees, building a Michigan project.” Invenergy develops, owns and operates power generation facilities in North America and in Europe. The company has developed and placed in service 33 wind projects, totaling over 3,000 MW. Invenergy wind turbines spin in the wind from Judith Gap, Montana to the farm country of Brownsville, Wisconsin, and on both sides of the Atlantic from Le Plateau wind park in Quebec to Tymien, Poland. At Gratiot County, Invenergy developed the entire wind project and transferred ownership of nearly half the project to DTE upon turbine completion. “Invenergy developed and built 64 turbines in the project, and sold them to DTE at the completion of construction,” said Ewan. “The Gratiot County Wind Project has a 20-year power purchase agreement to sell the power output from the other 69 Invenergy-owned wind turbines to DTE.” GROWING A NEW INDUSTRY Michigan’s Renewable Portfolio Standard (RPS) – a mandate requiring 10 percent of the state’s energy to come from renewable sources by 2015 – created a good climate for the state’s growing crop of wind turbines. (A Michigan Energy Michigan Jobs ballot proposal in November calls for an RPS of 25 percent by 2025.)
A 660-ton capacity crane hoists the rotor assembly skyward to ultimately link with the nacelle at the top of the tower. CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012 77
placement of a maximum of three wind turbines in approximately 28 of the 36 sections composing each of the four townships (Wheeler, Bethany, Lafayette and Emerson). MAPPING A STRATEGY MCA’s first mission was to turn lush farmlands into lease memorandums via an ALTA survey of participating landowners. “We assembled all the title commitments for each parcel,” said Garrett. “Then we pieced together all of these individual parcels and made one big map.” Aerocon flew a Cessna at an altitude of 5,000 to 6,000 feet over this wide area, taking 3D, digital infrared photos of the land below the plane’s wings, said Garrett. “Conventional surveying couldn’t cover that amount of land in the given time frame, so we hired Each concrete foundation is composed of 30 tons of rebar and 350 yards of 5,000 PSI concrete, a heavier mix Aerocon to take aerial photos,” than the standard 3,000 to 4,000 PSI. said Garrett. “As part of the ALTA survey, we had already marked all the section corners in the field Invenergy elected to “plant” the state’s largest wind project near to provide targets and coordinates to show Aerocon where to shoot Breckenridge for three core reasons: wind, transmission lines and and to accurately position the project boundaries.” community support. After measuring the wind resource in the area Using 3D technology, Aerocon extrapolated the existing contours for several years, Invenergy found it to be “strong and consistent, due of the land from the photos. “The photos also marked the location of to the flat and open topography,” said Ewan. “Second, there are also houses and other structures, which was important for the developer, high-voltage transmission lines in the area that have the capacity and because every wind turbine has to have a setback of 1,000 feet from accessibility for delivering the power produced by the turbines to the habitable structures,” said Garrett. electrical grid. Third, the local community embraced the idea of Aristeo mapped out its own strategy for transporting the unwieldy hosting a wind project, and welcomed the economic investment. In blades and other turbine components on the country roads addition, an approved county zoning ordinance enabled the siting of surrounding Breckenridge.“We had to turn trucks loaded with 120-footthe project.” long blades on narrow, country roads traveled by combines, tractors Invenergy set the tone for positive community relations. “Over and other farm vehicles,” said Scheloske. Aristeo widened several several years, Invenergy was proud to build a relationship with the intersections, softening the curve and allowing the big rigs to make the community through open discussion and a transparent, consistent turn. “If we put in a turning radius at every intersection, we’d still be out dialogue about project development and construction,” said Ewan. there,” said Scheloske. “We had to figure out an optimal plan.” “The Gratiot community was proactive in attracting wind The logistical plan was at least three months in the making. Aristeo development to the area, and we valued the informative discussions consulted with county officials to identify recently paved roads and we had with landowners, public officials, and civic leaders about the weight limitations on bridges. “We had to determine if we should construction and long-term operation of the facility.” upgrade the bridge or go to a different intersection,” said Scheloske. Pinpointing the actual site for each turbine is based on a host of “We also reviewed MCA’s map of landowners. In one instance, all four factors, ranging from “zoning ordinance requirements, landowner of the landowners were not in the project, so we had to go to the next participation, wetland and wildlife conditions, and the need for proper intersection and backtrack. All of these elements became part of the placement to allow for optimal performance,” added Ewan. preconstruction plan. We could not afford to have the crew and the Using meteorological towers, anemometers, windcube LIDAR (Light cranes waiting at a site to unload the components just because the Detection and Ranging) and other tools to test which way and how truck couldn’t make the turn.” strong the wind blows, Invenergy conducted studies to select optimal Aristeo coordinated transportation logistics with General Electric, wind areas within this vast acreage. “The studies pinpoint the best for the drivers had to know the designated route through this road areas,” said Ewan. “The wind may be blowing well on one farm, but if version of a “corn maze.” “They would tell us what was coming, and you go a quarter-mile down the road, the wind is significantly less, we would tell them where and what site we needed them to be,” because there may be trees or a slight depression in the land.” said Scheloske. “We might need blades at Site 33 and tower sections Clearly, the entire development was as carefully cultivated as the at Site 28.” crops growing in the sandy clay soil. Ultimately, the end result is the 78 CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012
“Voice Of The Construction Industry”®
Communication was vital in keeping track of components being shipped from different parts of the country. “We had components on the job coming from Texas, Iowa, Illinois and Florida,” said Scheloske. “Some parts were transported by rail to Detroit and others to Indiana. The components were then trucked to the site from both rail yards.” CRANE WALKING Arrival of the turbine components stirred Aristeo’s fleet of two to three Liebherr LR1600 crawler cranes into action. In traveling from site to site, Aristeo minimized the crane’s almost 40-foot-square footprint by following the collection easements – the temporary pathways created by installation of a network of underground cables linking all the turbines to a substation. “The underground cables are designed to follow the most efficient route from turbine to turbine,” said Garrett. “The cable routes also avoid the header pipes of the drain tile field.” Walking the lumbering cranes in the easements was also protective of the topsoil. “Because that land is a farmer’s livelihood, we stayed in the collection easements that go to every turbine,” said Scheloske. The way was not without obstacles, including crossing deep ditches, bypassing a non-participating landowner or traveling under a transmission line with the crane and its equally massive boom. “All of this meant that we had to break the crane down at some point and to some degree,” said Scheloske. In disassembling a 660-ton crane and in all things, a good rule of thumb is to have a partial rather than a complete breakdown. Complete disassembly of this beast of a machine would take two days, at least 12 semi-trucks for transport to the next site, and two days for reassembly. In one example of a less time-consuming partial breakdown, only the boom is removed to slip under an overhead obstruction. “If the transmission line is high enough and the ground is good enough, we take off the boom, removing a few sections to prevent it from sagging and breaking,” said Scheloske. “We lay the boom down flat on the back of a semi, and then move the truck and crane forward in tandem.” The project had a total of 24 partial and complete crane breakdowns, all carefully planned to meet the demands of the schedule. “We had to plan where and to what degree we were going to break down the cranes,” said Scheloske. “We had to know that in preconstruction to avoid impacting Available online at www.cammagazineonline.com
our overall schedule.” The best of plans is flexible. “We adjusted the plan throughout the course of the project,” continued Scheloske. “Heavy rains might have made the route too soft or road work might require a shift in our plan. This made communication with the county important for the project’s success.” Aristeo also coordinated its work with gas
and pipeline companies to create a crossing plan for the network of gas lines crisscrossing the area. “We built dirt berms with oaken crane mats, which are 12-by-12inch timbers bundled together, to disperse the weight of the cranes,” said Scheloske. These flat, windswept farmlands also have an unseen blanket of drain tiles embedded within the rich loam of the soil. The crane’s
Art Hug Jr. Gene Auger Patrick Landry Jack Russell, Secretary Chuck Raeder Brett G. Jordan
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giant footprint disperses the weight of the machine, avoiding damage to this vital infrastructure. The direction of the crane relative to the placement of the tile still had to be monitored. “Walking the crane across the drain field disperses the weight, but you have to be careful if the crane is walking parallel to the drain field,” said Garrett, “because if the weight is at a certain angle it might damage the tile.” Under Aristeo’s watchful eye, tile breakage was rare and easily remedied.
the excavation) in the morning and then move on to the next roughly eight- to-tenfoot-deep excavation.” One crew poured foundations and another set anchor bolts. “In automotive plants, a worker does the same job every day,” said Scheloske. “On a large wind farm, a person does the same job every day, but instead of the work moving past him, he moves to the work.” This assembly line moved like a well-run train over this vast jobsite, with Aristeo
The above wind turbines are among the 133 wind turbines spread over four different townships and encompassing roughly 80 square miles in Gratiot County.
A HIGH-SPEED TRAIN With all plans in place, Aristeo constructed four roads in December 2010, before launching the project in full force in April 2011. “We started in the south part of the site, and we basically built the project in a counterclockwise path,” said Scheloske. “We chose that path because the eastern side of the project was going to be turned over to DTE upon completion, and we had to complete their turbines first.” Aristeo staggered the construction of each project phase, setting this amazing project in motion with the control and precision of an assembly line. Aristeo began building the access roads a full month ahead of the next phase, ultimately creating 35 miles of permanent access roads leading from the main road to the base of each 328-foot tower. Each phase was broken down into smaller tasks and assigned to specific crews that traveled from one turbine site to another executing the same work. “Each 60-foot diameter foundation took five to six days, but we used specialized crews for every task,” said Scheloske. “For instance, one crew will pour mud mat (the concrete in the bottom of
pouring two to three foundations per day, followed by backfilling. “We didn’t want the ‘train’ to get either too stretched out or too close together,” said Scheloske. “If we hit an unknown, the train would back up, so we left a small gap between each task.” Even the concrete batch plants joined this massive exercise in efficiency. Rather than establishing a portable batch plant, Aristeo used two existing batch plants, one located on the east side of the project and the other in Alma to the west. “Those two existing plants joint ventured to feed the entire project,” said Scheloske. Each concrete foundation is composed of 30 tons of rebar and 350 yards of 5,000 PSI concrete, a heavier mix than the standard 3,000 to 4,000 PSI. Placing foundations required replacing the surrounding drain tiles underpinning these flat farm fields that have been sprouting corn, soybeans and wheat for generations. “We cut the drain tile, installed a new header on either side, and then rerouted the tile around the foundation,” said Scheloske. For excavation and foundation work, communication was pivotal in ensuring
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accurate placement of each turbine site in this immense weave of farmland divided into hundreds of different parcels. Aristeo kept the lines of communication open with Plan of the Day (POD) meetings. “Aristeo’s superintendent, Dwight Carter, was in constant contact with our surveying crews,” said Garrett. “For the entire project, maintaining communication between the landowner, the contractor, and our company, as well as county officials, the road commission and the drain commission – this entire stream of communication – was the biggest challenge.” BUILDING POWER Aristeo began erecting the wind turbines in September 2011, again working in a staggered sequence across the entire area. “When we were beginning to erect the fivesection towers, our foundation crews were still finishing their work on other turbine sites,” said Scheloske. “We also had crews working on both sides of the project. We had to make sure we had the right people and equipment at the right place and time.” Rooting these great wind machines in the ground took a 75-ton and a 500-ton crane for the placement of each tower base and midsection. “We do not just set the base and midsection on the concrete,” said Scheloske. “A team shims the base section and places a grout ring of high-strength, quick set epoxy grout.” With the aid of an assist tipping crane, the 660-ton crane did the heavy lifting of the main tower sections and the nacelle, the hub housing the generator, gearbox, drive train and virtually all the components responsible for making these giant “pinwheels” rotate in the wind. A crew actually enters the nacelle and checks the wiring, the torque on the bolts and all the mechanical systems. Hoisting and attaching the rotor assembly (three blades connected to the central hub) to the nacelle completes the wind turbine assembly. The crane operator and the crew, working hundreds of feet in the air, must guide the rotor assembly to the pilot stud, a stud only half-inch longer than the other 120 arranged on a large ring. “The person tied off on top of the nacelle is in radio contact with the crane operator,” said Scheloske. “That person has to find the pilot stud and guide the rotor assembly to it. Then everything else rotates into place, and others inside the nacelle will bolt the rotor assembly to the nacelle.” As one of the final steps, the electrician installed the tower wiring, climbing an interior steel utility ladder like Jack and the Beanstalk - but tied off and with a head lamp “Voice Of The Construction Industry”®
- to bring light to the tower interior. GE and Invenergy conducted a final inspection, giving each wind turbine their seal of approval. Aristeo completed wind turbine erection in February 2012. The company’s final task was site restoration and road repair. “The intersections were returned to their original state,” said Scheloske. “Because walking the big crane across a public road leaves indentations in the road surface, we regraded the gravel roads and repaved the asphalt ones.” Stripped top soil for the turbine sites had been stockpiled and was now returned to the land. “Top soil is like gold to the farmers,” said Scheloske. “All the top soil stripped for the turbine sites and access roads was also rolled back into the fields.” HARVESTING THE WIND The Gratiot County Wind Project became operational in June 2012, their great blades rotating and supplying power for the equivalent of 50,000 homes. Wind energy is growing in the United States and in Michigan. The U.S. wind industry reached a
historic milestone in early August 2012: “the industry has now installed 50,000 megawatts or 50 gigawatts of generating capacity. Fifty GW is enough to power 13 million homes, or as much electricity as produced by 11 typical nuclear power plants or 44 coal-fired power plants,” according to an American Wind Energy Association (AWEA) press release. “There are over 10,300 MW currently under construction spanning 30 states plus Puerto Rico.” Another AWEA press release also states that Michigan “as of July 1, 2012 had 487 megawatts of wind-powered electrical generating capacity online, with enough wind farms currently under construction to double that by the end of the year.” Invenergy may develop future projects in Michigan. “This is Invenergy’s first wind project in Michigan, and we have plans for additional projects in the state,” said Ewan. “Market conditions will dictate where, and when, our next project would be built.” Both Aristeo and MCA have positioned their firms well in the wind marketplace. “It’s good to be in the alternative energy industry, because it’s a growing business,” said
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Scheloske. “To build all 212 megawatts in one phase in one season was an accomplishment. We are excited to have been part of this project. It was a good partnership with Invenergy, and everyone that worked on the project, including MCA and Fisher Contracting, a Midland company that built the roads for us.” The members of the following trades also greatly contributed to the project’s success: Carpenters Local 706, Laborers Local 1098, Operating Engineers Local 324 and Ironworkers Local 25. In Garrett’s view, “wind is adding diversity to the U.S. energy portfolio. I think entering new areas is good for the economy.” Today, an entire industry is taking that most intangible of elements – the wind – and turning it into power. Traveling down M-46 near Breckenridge, the change in the skyline is clearly visible. Add the spinning blades of wind turbines to the silos, water towers and church steeples of this rural area. Thanks to the expertise of Aristeo Construction and Metro Consulting Associates, farmers in the area have a new “crop” to take to market and the entire State of Michigan has a wonderful source of renewable energy.
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Building Design Focuses on Student Safety THE NEW MACKENZIE PK-8 SCHOOL By Roy Jones, Contributing Editor hen you imagine a pre-kindergarten through 8th grade school (PK-8), one of the first questions that may come to mind is, “How will they be able to separate the children and control age behavior differences?” One community in Detroit is going to experience a unique and safe learning experience with the completion of the new 110,000-square-foot Mackenzie PK-8 School, scheduled to open for the fall 2012 school year. The new $22 million PK-8 school was built adjacent to the nowclosed Mackenzie High School, at the corner of Wyoming and West Chicago Streets on the city’s west side. The surrounding neighborhood is a community with an aging infrastructure of schools and amenities in need of replacement. It is the intent that the new Mackenzie PK-8 will provide the state-of–the-art environment and resources desperately needed by young people in this area. The school is located on the site of the former Hammerburg playfield. When Mackenzie High School was in operation, this field received considerable use from the school’s students and athletics department. Now that the high school is closed, the field and its amenities are not used by the Detroit Public Schools (DPS), and have no longer been maintained. As of late there had been very little activity on Hammerburg field. The new school is situated on the site in a manner where it addresses both adjacent thoroughfares and emphasizes the intersection. It is the intent of this placement to breathe some life into this corner and the adjacent neighborhood. DPS, along with the support of the local community, have worked closely together to help transform Detroit’s educational environment. According to Emergency Manager Roy Roberts,“We have engaged the community throughout the bond construction program from day one, beginning with the design and consistently with community meetings and updates, and through our Oversight Committee.”
W
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Photos Courtesy of SHW Group Detroit voters approved Proposal S in November 2009, which enabled the district to access $500.5 million for school capital improvement projects. DPS received the sixth largest allocation in the nation. This was one of the largest construction projects in Detroit which enabled the school system to build and renovate 18 public school facilities, logging more than 500,000 hours for workers of Detroit-headquartered companies. SAFETY FIRST The building design is focused on student safety and is environmentally-responsible through the adherence to national standards set by CPTED (Crime Prevention through Environmental Design) and LEED (Leadership in Energy and Environmental Design). The minimum goal was to set a level of Silver LEED Certification. The building consists of two academic educational wings. One wing is for the middle school students and the other wing is for the pre-kindergarten and elementary school students. The academic wings are separated by a commons area that contains administrative offices, modern media center, kitchen and cafeteria, a full size gymnasium, band/music room, and a multi-purpose room. “The center commons area is shared by all the students, but it has been designed to allow the school district to carefully schedule these areas to be used by the middle school and elementary students at different times,” explained Michael Tobis, project manager from the George W. Auch Company, Pontiac. “In fact, the way the two wings are situated, while in their core teaching areas, the two different age groups of children cannot even see each other. The flexibility within the building design not only allows the school to avoid interaction between the elementary and middle school students, but saves the district in both construction and future operational funds by combining the core assets of what was traditionally within two separate schools all into one combined school.” “Voice Of The Construction Industry”®
A panoramic view of the new state-of-the-art 112,000-square-foot Mackenzie PK-8 school located on Detroit’s west side.
The new construction also includes exterior play areas with age appropriate equipment attached to each wing, along with the associated parking lots and bus loops required for the school. The playground equipment itself has been safety approved for all ages. The overall building is designed with bold colors in common spaces to excite and stimulate the minds of the children. The color schemes are designed to match certain age groups. For example, the color for the prekindergarten through 2nd grade is blue with matching blues for the accent walls, floor and millwork. The children will identify with this color and know that they are in the right area. Likewise, the 2nd floor color scheme is yellow for the 3rd, 4th, and 5th grade students. The 1st floor of the middle school wing is made up of specialty labs, which consist of art rooms, computer rooms and state-of-the-art science laboratories. The color scheme for the specialty labs area is orange. The middle school 2nd floor is all instructional classrooms and the color scheme is purple. “These color scheme designs and floor plans assist the students to find their own way around the building, giving them a level of comfort knowing that they are where they are supposed to be” says Tobis. “Everyone knows where they need to be at all times.” DESIGN-BUILD PARTNERING The construction project utilized the design-build project delivery method, where the architect, SHW Group, Berkley, is the project partner with the design-builder, MIG/Auch, LLC, joint venture. SHW Group is one of the nation’s leading educational architectural and engineering firms. The firm has extensive experience both in Michigan Available online at www.cammagazineonline.com
and nationwide in designing environments that inspire, support and promote the discovery and exchange of knowledge through a commitment to learning, stewardship and craft. SHW Group designed Mackenzie PK-8 School to provide optimal learning environments for both the younger grades as well as the older students, all housed under one roof. Utilizing a designbuild partnership with MIG/Auch has allowed the entire team to collaborate from early design through project completion, to fasttrack the project. MIG/Auch is a Detroit-headquartered partnership built upon the strengths of each team member’s experience and skills, which includes considerable experience working in the City of Detroit and constructing schools throughout Southeast Michigan, in many cases with SHW Group as the architect. The
firm has engaged the local community, Detroit’s Barton McFarlane Neighborhood Association, by presenting the project at local community meetings and conducting question and answer sessions with residents. The firm has ensured that the surrounding community is aware of what is planned and supports the project. “From the very beginning of the project, the residents have been encouraged and excited about the new school coming to their neighborhood,” says Tobis. “From my observations at these meetings, the Barton McFarlane neighborhood is a proud and family oriented area of Detroit. Our team was proud to work with them to help build their children a new school, and moreover, a new cornerstone for their community.” The DPS is the largest school district in the State of Michigan. In recent years, declining
The MacKenzie PK-8 structure consists of two academic educational wings. One wing is for the middle school students and the other for pre-kindergarten and elementary. CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012 83
enrollment and a shrinking tax base have forced the district to close and consolidate many facilities. Money from the bond program is being used to upgrade existing facilities and provide new facilities that will be fed from existing schools slated to close. Mackenzie will be fed students from two
nearby schools slated for closure. Because of the limited time in which to implement the construction, all bond program projects are being constructed using the design-build method. Contract documents were prepared by the Walbridge Joint Venture, a conglomeration of
The building is designed with bold colors to provide a lively and inspiring environment for the children.
An exterior view of the blue glazed brick at the entrances echo the MacKenzie school colors while being graffiti resistant. 84 CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012
construction, design and program management companies hired by the Detroit Public Schools to outline the scope of each project and oversee construction. The joint venture prepared bridging documents for each building; these are preliminary design drawings that outlined the scope and district mandated requirements for each facility. These documents were used to obtain bids from local design-build firms who would then complete the design and construct the new building in accordance to the requirements outlined in the bridging documents. THE LEED PROCESS Since the initial design of the building was outlined in bridging documents the design builder had no input in the earlier decisions with regards to sustainability and LEED certification. Because of this, achieving certification has focused primarily on material selection, lighting, and thermal performance of the building envelope and HVAC system. This is not to say that the bridging documents were prepared with no regard to Green design; indeed the intent of the design has always been to seek certification and the preliminary design reflects this. But in this case, it should be noted that the design-builder’s involvement is primarily in the later half of the design process. For materials, special attention was paid to LEED requirements and provided products with recycled content and low VOC emissions. Masonry and concrete materials are quarried from locations within 500 miles of the site, and a minimum of 50 percent of all lumber is certified. The interior environment has also been addressed by providing ceiling tile that optimizes acoustical performance and adequate lighting. Classroom lighting has been adjusted from its original bridging document layout to allow for more efficient use of electricity while optimizing the lighting for educational spaces. Outdoor light fixtures have been shielded above and aimed downward to minimize light pollution. The HVAC system was engineered and modeled with an emphasis on energy efficiency. It will perform well above the minimum requirements of ASHRAE 90.1. Additional insulation has been specified in exterior wall cavities to enhance the performance of the building envelope. SHW Group also augmented the design with site and building amenities that facilitate the overall goal of sustainability. These items include spaces for sorting recycling, bicycle lanes and parking spaces, walk-off mats, and other items that assist in creating a more efficient and environmentally-friendly facility. “Voice Of The Construction Industry”®
OVERCOMING OBSTACLES Of course, any project of this size would have its share of challenges. MIG/Auch’s first hurdle was to accommodate the district’s desire to revise the building’s layout on the site from the one originally shown; working with the school district to finalize the location and orientation of the building, and then the district needed to obtain the property from the City of Detroit for the school to be built upon. Once those obstacles were overcome, they were authorized to begin construction on April 4, 2011. Then, record-setting rains in April and May 2011 occurred, and they were staring at an unknown schedule impact that needed to be made up right off the bat. “We were praying for dry weather, but began to plan out a recovery schedule to get us back on track while staying within budget,” said Tobis. Once the rain stopped, the team was able to pour their first concrete foundations on June 13, 2011, eight weeks behind the original schedule. The diligent planning allowed the team to make up the lost time, and by November 2011, the project was completely caught up and on track to finish early. The next curve ball encountered was the
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minor contamination found within the native soil. This contamination was less than the typical contamination found in urban Detroit area construction sites. The team had to work closely with the owner’s consultant, NTH Consultants, Detroit, to implement a remediation plan in accordance with federal, state, and local requirements for schools. “Because this site was being used as a school, the remediation requirements were much more robust than your typical construction project,” said Tobis. “All of the site remediation efforts needed to be completed in conjunction with the construction of the building, and coordinated so it did not impact the finish schedule of the project. With total involvement and cooperation of all team members, this was achieved.” Despite all obstacles encountered, the design-builder, MIG/AUCH and SHW Group, have provided a state-of-the-art, clean, efficient and healthy environment for the children of the City of Detroit. Mackenzie PK8 will provide one of many learning centers that will further stabilize and empower children and residents in a neighborhood that has been looking forward to this important resource for their community.
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Extensive windows draw natural light into successive layers of office and laboratory space and into a two-story atrium.
A New Breed of Building for MSU By Mary E. Kremposky, Associate Editor hose leafy green wonders called plants are perfectly designed to turn sunlight into a three-course dinner. This fusion of the practical and the beautiful is present in most of nature and in the best of buildings. SmithGroupJJR, Detroit, has designed the perfect facility for advanced plant research, creating a building clad in an organic weave of variegated green and brown brick. Switchgrass was the image chosen for a custom ceramic frit. The slender blades of this fast-growing prairie grass and potential bio-fuel are spread across a three-story curtain wall of Michigan State University’s new Molecular Plant Sciences Building. Built by The Christman Company, Lansing, the new 90,000square-foot facility is now the hub of this land grant college’s nationally acclaimed plant research programs. Extensive windows draw natural light into successive layers of office and laboratory space and into a grand two-story atrium blanketed in the beauty of wood. What better place to talk plants or host a post-conference gathering than under the high canopy of the atrium’s wood-clad ceiling. The subtly grained panels flow down the entire east wall in this signature space designed as the new front door to MSU’s entire plant research complex. On the west wall, international artist, Albert Paley, has turned science into art with a wall-mounted sculpture of metallic leaves, cellular structures, and
T
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Photography by James Haefner Photography thylakoids – the structures in a leaf hosting the light reactions of photosynthesis. This four-story building and its atrium extension connect the existing Plant Biology Laboratories and the Plant and Soil Sciences Building. The new $43 million facility bridges a 40-foot gap to create a continuous indoor pathway connecting MSU’s extensive network of plant research buildings, classrooms, and greenhouses in an indoor route vital for the transport of plants in Michigan’s often brutal winter weather. “Below the atrium is the new corridor that links everybody to the greenhouses in an enclosed environment,” said SmithGroupJJR Design Director and Vice President Paul R. Urbanek, FAIA. “The people get the benefit of the atrium; the plants get the benefit of the corridor.” Linking the buildings fosters collaboration between different disciplines, with the atrium being the hub of a great wheel of scientific inquiry joining basic biological research with horticulture, agriculture and other applied sciences. This gathering space and the facility’s open, collaborative and flexible laboratories generate a fruitful “cross pollination” of ideas. “The building integrates the different departments and creates what we call translational research, in which basic science is translated from the lab bench to the field,” said David L. DeWitt, MSU professor, Department of Biochemistry & Molecular “Voice Of The Construction Industry”®
Biology; Associate Dean for Research and Budgets - College of Natural Science; and Director, Research Technologies Support Facility – Office of the Vice President for Research and Graduate Studies. THE SWAT TEAM MSU selected SmithGroupJJR based on their extensive national, and increasingly international, experience in laboratory design. “We were looking for a team that could bring us the cutting-edge in lab design in the United States,” said Amr Abdel-Azim, architect III, MSU Physical Plant Engineering and Architectural Services, “and we were looking for firms that would bring their ‘SWAT team’ to the project.” Christman was also part of the “SWAT team” from the project’s inception. “Working together from the very beginning of the project represents the collaborative nature of the actual building,” said Christman Project Executive Daniel P. Rooney, LEED AP, AVS. Christman brought its estimating and budgetary expertise to the project, helping the design team to deliver 50 percent more research space for about half of the expected cost. Christman’s estimating savvy was pivotal in leading the University to opt for a fourth floor in an originally three-story building. “Christman was able to produce the estimates to give the University the knowledge base to make intelligent decisions,” said Urbanek. Initially built as shell space, the added floor immediately became occupied space. “It gave real value to the University,” added Rooney. THE SEEDS OF A GREAT BUILDING This great building was started from the smallest of seeds with the project team given only a budget and the directive to maximize lab space. SmithGroupJJR even designed the facility without an end user being established. “Faculty and staff in the plant sciences were consulted extensively in the planning stages,” said Urbanek, “but in many ways, the labs had to be designed generically to accommodate different scientists, and the spaces had to have the ability to be customized when necessary.” The project team analyzed multiple sites to determine the selected site, beginning discussions in the proposal stage. “Originally, we thought of locating the site on a parking lot near Plant and Soil Sciences, but as we started to explore possibilities,” recalled Urbanek, “we began hearing more and more about what they refer to as the 40foot divide between Plant Biology and Plant and Soil Sciences.” The selected site bridged this gap, and in ecological terms, became the equivalent of a habitat corridor, a strip of land that aids in the movement of species between disconnected areas of their natural habitat. In this case, “the gap separated the whole plant research and teaching effort,” said Urbanek. “We concentrated our efforts on assembling a building to bridge the two existing buildings and to link the entire complex together.” CROSSING THE GREAT DIVIDE The connections between the buildings celebrate the plant life being studied within the laboratories. The main connector between the new building and Plant and Soil Sciences is a four-story diagonal curtain wall imprinted with the switch grass frit. Sunlight casts reedlike shadows on the interior, while looking outward offers a grand view of the horticultural gardens. A bridge connector – floor and sidewalls lined with alternating light and dark stripes of sustainable bamboo - spans the edge of the atrium, linking the second-level labs and Plant Biology annex in a functional and remarkably beautiful design expression. “The bridge connector is sloped as a solution to some of the elevation and level changes between the two buildings,” said Rooney. Linking the different levels of three buildings involved creating a combination of Available online at www.cammagazineonline.com
ramps, steps and sloped connections. The building is also sited on a prominent corner along Wilson Road, drawing attention to this showcase structure and to MSU’s entire plant research effort. “It took a lot of thought to come up with this beautiful solution,” said DeWitt. “There was quite a bit of discussion and it took a great deal of problem solving to discern where to site the building, how to fit the new building in with the other buildings, how to get the most efficient footprint, and how to blend in the atrium. SmithGroupJJR came up with some very elegant solutions to solve these problems.” The solution was elegant and cost-effective. “It was the best selection for the dollars, because we maximized connectivity and research space,” said Rooney. “Dollars had to be factored into every decision that was made.” WORKING IN CLOSE QUARTERS Working on a building tightly tucked between its neighbors influenced virtually every phase of the project. Christman arrived on site in May 2010, installing auger cast piles to a depth ranging from 30 to 60 feet. “Because we were placing the building in between two other buildings, we used auger cast piles to avoid impacting the adjacent structures,” said Rooney. Portions of Wilson Road were closed for site utility installation in the summer, but reopened during the entire school year, squeezing the material laydown area into a narrow zone. “The excavation was almost to the edge of the sidewalk, so we didn’t have much laydown area
This glass connector links the new building, clad in a variegated weave of green and brown brick, with the existing Plant and Soil Sciences Building. CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012 87
This stunning bridge connector is wrapped in the glory of wood. The bridge is lined with alternating dark and light stripes of sustainable bamboo; the ceiling overhead is formed of durable and beautifully grained Prodema panels.
while we were doing the concrete,” said Rooney. The building’s steel skeleton rose swiftly even as Christman navigated a host of site constraints, including working next door to MSU’s popular and publically accessible horticultural gardens, directly across the street from another construction project (MSU’s Facility for Rare Isotope Beams, also designed by SmithGroupJJR) with major utility work, and in extremely close, floor-to-ceiling proximity to adjacent buildings. “The air intake for the Plant and Soil Sciences Building was on the north face of that structure, and as our building is due north, air for the building occupants flowed right past all of our construction,” said Rooney. Christman worked with the building manager to continually monitor work and to obtain feedback from building occupants. They had to maintain the same vigilance during the conversion of this three-story void into the building’s utility chase. Christman even had to temporarily shore the underside of the atrium floor in order to drive front end loaders across the floor slab and into the courtyard-like area for work on the building’s west face. “The atrium was the only entrance into that area,” said Rooney. “The other side is surrounded by the gardens and other buildings.” SPARTAN GREEN Much of the new building is draped in a unique, organic, virtually hand-crafted brick. SmithGroupJJR initially proposed a living wall of 88 CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012
plants as the first-floor cladding, but the durability of plants on a north-facing wall and the potential maintenance investment steered the team toward a new approach. “Because it’s a plant science building and green is MSU’s school color, we went with the suggestion to go with a green brick,” said Abdel-Azim. The brick selection was rigorously scrutinized by MSU’s brick committee with the University president ultimately granting the final seal of approval. The green brick ranks as the most distinctive and beautiful on campus. All the brick is pre-tumbled, meaning virtually every brick has a unique “topography” of marks and indentations. “While the clay is soft it is rolled inside of drums, resulting in little nicks that give architectural character to the brick before the glaze is applied,” said Rooney. “The level of tumbling was a factor that we had to control during that whole process.” Like an artist mixing a palette of oil paints to obtain different hues, about eight different shades of green, brown and subtle blue were brought to life by using two different colors of glaze on each brick. “Because the double-glazed bricks are double-fired, you can read iridescent colors in the brick,” said Urbanek. Brick Tech with Pacific Clay provided the glazed bricks. At times, the process was challenging to control. “Some bricks would come out too brown,” said Urbanek. “It’s not an exact science as much as it is an art based on the knowledge of glazing and how to fire the bricks in the kiln.” Christman even conducted research on this unique brick “to understand the characteristics of a brick that was not only new to the MSU campus, but also to us,” said Rooney. The mason contractor, Schiffer Mason Contractors, Holt, prepared several brick mockups during the process. “They were helpful in assembling large enough samples so that we could get a feel for the brick,” said Rooney. “The brick itself is not consistent. It is organic and ever-changing as you go around the building. Because it is almost a handcrafted art, it was a challenge to duplicate it multiple times.” The goal was to achieve fairly consistent masonry walls, but still retain the lovely variations that give the building envelope its singular character. The brick almost resembles moss and is probably the closest brick can come to being a living wall of plants. AN ENERGY-EFFICIENT GREENHOUSE High-performance glass offsets the handcrafted brick, infusing the interior with natural light and creating a type of “greenhouse” for working scientists. The low E coating even lends a slight green tint to the glass, minus the clear, low iron glass of the stair tower serving as vertical circulation between the lab floors. This transparent glass chrysalis draws daylight into the building and attracts attention from the street. On the east end, the building’s bright orange, structural cross bracing is clearly visible to pedestrians. This zone houses kitchen and pantry areas on every floor. “One of the principal investigators (PIs) said he loves it, because with a place to eat, the students spend more time in the lab,” said DeWitt. The new building also banishes the traditional, dimly lit laboratory wrapped in cinder block walls. With predominately north-facing windows, SmithGroupJJR layered the open interior by function and divided the different functions by interior glass partitions to boost natural light levels. Conference spaces, offices and informal living rooms form the first tier along the glass curtain wall, followed by a corridor and work stations for lab technicians. Every other work station has a glass door leading into the open labs separated only by an open corridor from the last tier: the lab support spaces stocked with tissue culture hoods, autoclaves, incubators and other equipment. “The design is completely different – and nicer – than anything we’ve ever had on campus,” said DeWitt. “Voice Of The Construction Industry”®
CELEBRATING PLANTS This brick and glass building is capped by an inverted roofing membrane, an MSU roofing standard for every campus building. With insulation placed on top of the roofing membrane rather than under, “this system prevents the thermal shocking of the membrane, because it is protected by insulation and a ballast layer,” said AbdelAzim. A small green roof is visible from one of many informal meeting spaces, turning this rooftop area into a living carpet of sedum and perennials. The interior continues the new building’s celebration of all things botanical. Three different colors of cork flooring line the main laboratory corridors, while linoleum - floor covering made from solidified linseed oil, pine rosin, ground cork dust, wood flour and other natural materials – is the flooring of choice in other areas. The glass ceramic tile in the restrooms and near the drinking fountains is embedded with minute materials resembling small, green pieces of reeds, leaves and stems. “We used a plant-driven material wherever we could in an effort to relate to what the building is about,” said
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Urbanek. “The carpet patterns are chosen in many ways to look as though you are flying over the farm fields of Iowa. The patterns are meant to resemble the patchwork quilt of wheat and corn fields we have in the Midwest.” A host of sustainable materials fill the interior, including Richlite countertops made of recycled paper and resin, doors made out of fast-growing, sustainable eucalyptus, and cabinetry made out of Plyboo® (laminated bamboo plywood). CELEBRATING SCIENCE As a research facility, the building is designed to honor scientific inquiry in subtle ways. The terrazzo floor pattern in the atrium is a series of Voronoi tessellations, basically polygons resembling a slightly irregular honeycomb. Urbanek explains: “Begin with an abstract field of points. Draw a line halfway between the two immediately adjacent points and continue to connect the dots, ultimately forming an unending series of irregular polygons. Voronoi tessellations play a role in making your cell phone work and even helped to track down the location
of the greatest concentration of cholerainfested wells to help stop an epidemic in 18th Century London.” In the atrium, the whole point of these connected points was to stimulate students’ scientific curiosity. Science, art and craftsmanship all converge in this new gathering space with tessellations on the floor and a carefully crafted fastening pattern on the ceiling. Christman took great care in installing the fasteners to complement the beauty of the Prodema wood panels. Prodema, a durable, natural wood veneer impregnated with resin, fills the atrium and even extends to the outdoor entry canopies. Christman Constructors, Inc., Christman’s self-perform group, installed the grand wall sculpture of metallic macroscopic and microscopic plant components. “Christman Constructors worked directly with the artist to align and orient all the pieces,” said Rooney. The sculpture is mounted on the brick wall and filled-in windows of the annex’s originally exterior east wall. A portion of this abstract metallic plant actually “escapes” the atrium and graces the adjacent outdoor wall.
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The building’s two-story atrium is draped in wood and filled with natural light, offering the ideal meeting place for plant scientists and students.
TEACHING TOOLS The collective expertise of SmithGroupJJR and Christman converged on the atrium to create a showpiece for the entire plant research complex. Prior to this building, there was no place to gather for either a casual lunch or a conference in this vast labyrinth of research facilities, classrooms and laboratories. Great care was taken to preserve the atrium’s aesthetic appeal, including “disguising the heating elements as part of the architecture,” said Rooney. “The benches in the atrium house the air ducts that pump air in from below. We also have radiant panels in the underside of the bamboo bridge connector.” The nearby auditorium is the perfect companion to the atrium. “I am amazed at the auditorium, because no matter where you sit, you can clearly hear the speaker, even when they don’t use the microphone,” said DeWitt. “Every corner of that auditorium is acoustically perfect.” What is even more amazing is that the auditorium is constructed directly above the mechanical and electrical rooms. The auditorium is a room within a room isolated from the main structure. For the walls, attractive walnut acoustical panels nest inside of the auditorium’s burnished concrete block walls and structural steel frame. For the floors, “there are basically two slabs: the building’s structural slab, an insulation layer and then the auditorium’s
floor slab,” said Rooney. For the ceiling, the sidewalls of the structural beams are tilted or angled to confer even greater acoustical control. “We used the actual structure to boost the lateral acoustics from one side of the room to the other,” said Urbanek. Talaski Group, Chicago, was the acoustical consultant on the 120-person auditorium. Christman provided budgetary control for the auditorium. Originally, the idea was to build over the top of an existing auditorium on the north side of Plant and Soil Sciences. Christman provided the cost information for this approach vs. the road actually taken of demolishing the existing auditorium and building a new facility of more benefit to the University. The new double-tiered auditorium can be used for either lectures or collaborative learning. Students can break out into small discussion groups with the next tier of students with a simple turn of the chair. “We have created this doubletiered layout in auditoriums at several other universities around the country,” said Urbanek, “and it has worked very well for both didactic and collaborative-type teaching.” As another teaching tool, every floor has two or three small, informal meeting spaces equipped with whiteboards often filled with the wild scrawls of impromptu ideas quickly written. “All of these interactive spaces are used to sketch ideas and talk about science,” said DeWitt.
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LAB EVOLUTION The heart of the building is three floors of laboratories for students and for some of MSU’s most productive plant researchers. As the only open lab on the MSU campus, these collaborative labs without walls are a radical shift for MSU researchers and students. The labs service a rich mixture of disciplines, an approach in sync with the collaborative spirit of the entire building. The spaces are also a shift from traditional labs with furniture cemented to the floor and serviced by underground piping. In the new labs, overhead infrastructure services each lab bench via Quik Connects for water, electricity and the Ethernet. The lab furniture is equally flexible and adaptable. “The lab furniture has moveable cabinets, the shelving heights are easily adjusted, and the benches have different heights, because the actual legs can be raised or lowered,” said Rooney. Christman brought in mockup lab systems for user review. “The mockups gave the researchers the opportunity to see and touch the systems early in the process, and were a big part of this collaborative effort,” Rooney added. This level of flexibility will serve the University’s evolving needs. “We can’t predict what kind of research will be underway in the next 10 to 15 years, so this arrangement allows us infinite flexibility as to how we organize and arrange the different labs,” said Abdel-Azim. DeWitt adds, “Currently, we have three floors of wet labs and at some point we might want to make one entire floor for computational spaces.” What makes the new laboratory spaces particularly vital is the creation of more computational spaces and high-speed connectivity to the Ethernet. A computational space is simply a desk and a cubicle, but the building makes space for large servers managing immense data streams and consuming almost 20 tons of refrigeration for cooling. “One of the basic premises of this building is the acknowledgement that computation will play an increasingly important role in all areas of biological research,” said DeWitt. As an aid in designing this lab, SmithGroupJJR used its own proprietary program called Lab-Sim™, a computer modeling tool for the rapid, targeted assessment of a laboratory building program using a continually evolving database of current information. “It is basically a first draft that speeds the process,” said Urbanek. “We still need the end user to tell us if we are moving in the “Voice Of The Construction Industry”®
right direction, because every single lab owner and laboratory has idiosyncratic needs.” These labs have a wide range of idiosyncratic needs. For people, every MSU lab must have a personal health room for medical needs or private phone calls, said Urbanek. For plants, “every floor has a couple of cold rooms for experiments that need to be done at 4 degrees C,” said DeWitt. Specialty equipment includes tissue culture hoods that emit a flow of laminar air for the creation of a sterile zone around the plant material under study. Chemical hoods are used for handling stained gels involved in the microscopic viewing of DNA. A HIGH-TECH GARDEN In this high-tech garden, trays of Arabidopsis (rock cress) – the first plant to have its entire genome sequenced – dominate several lab benches with their slender spindles of green. With the aid of Arabidopsis, MSU’s nationally respected scientists peer into the very blueprint of life. Christman unraveled the actual building blueprint to manage the installation of all
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the lab furniture and the majority of this vast array of specialty equipment. Christman also equipped all the labs with emergency power to protect decades of valuable research. “Half of the plugs in the equipment corridors are on emergency backup,” said DeWitt. “Biologists work with perishable materials and live cells. If you lose power to a freezer or incubator, you could lose years of research, cell lines or possibly even a new plant variety. Thus the backup system, marked by the red plugs, is an essential design element in the research building.” Christman used the BIM model developed by SmithGroupJJR for the laboratories and for the building’s own MEP infrastructure. “BIM was the key to success,” said Rooney. “We were able to use the model not only for the entire structure but for every system within it. BIM also allowed us to prefabricate a great deal of the piping systems and speed the installation.” The project team also created a basement with high floor-to-ceiling heights to accommodate three, immense plant growth chambers. “They are essentially big
refrigerators that maintain the proper temperature, control how many hours the lights are on, and sometimes even control the exact level of carbon dioxide,” said DeWitt. “With all the lights, the chambers need to have refrigeration just to maintain room temperature.” The lower level also houses 10 plant growth rooms for experiments demanding less rigorously controlled conditions or for preparation of plants before placement in the growth chambers. Vernalization rooms are used to examine how plants respond to cold, and to cultivate plants that require a period of cold to reproduce, added DeWitt. In the past, MSU plant researchers have given the world such new potato varieties as the Jacqueline Lee and the Michigan Purple. MSU is now researching switchgrass and other plants, as well as algae as sources of biofuel. Thanks to SmithGroupJJR, The Christman Company and MSU, one can only imagine what great developments will find their way into our collective dinner plates or gas tanks as a result of the January 2012 opening of this amazing new Molecular Plant Sciences Building.
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SPECIAL ISSUE SUBCONTRACTOR LISTS
C.S. MOTT CHILDREN’S HOSPITAL AND VON VOIGTLANDER WOMEN’S HOSPITAL Owner: University of Michigan Health System, Ann Arbor Architect: HKS, Inc., Dallas, TX Contractor: Barton Malow Company, Southfield Subcontractors • Casework and Millwork - Nelson Mill Company, Southfield • Casework and Millwork – ISEC, Columbia, MD • Caulking and Fire-Stopping – RAM Construction Services, Livonia • Concrete – Devon Industrial Group, Detroit • Curtain Wall – Contract Glaziers, Detroit • Doors and Hardware – FBH, Flint • Dry-Side Mechanical – Dee Cramer, Holly • Drywall – Brinker Team, Detroit • Elevators – Otis Elevator Company, Farmington Hills • Exterior Rough Carpentry – Pontiac Ceiling & Partition, Pontiac • Fire Alarm – Dynalectric, Madison Heights • Flooring – Continental Interiors, Troy • Foundation – Hardman Construction, Ludington • Glass – Curtis Glass, Troy • IMRIS Shielding – ETS-Lindgren, Glendale Heights, IL • Kitchen Equipment – Great Lakes Hotel Supply, Detroit • Lighting – Center Line Electric, Center Line • Main Entrance Canopy – LinEl Signature, Mooresville, IN • Masonry – Baker Construction, Whitmore Lake • Metal Panels – C.L. Rieckhoff Co., Taylor • Misc. Metals - Ideal Shield, Detroit • Painting – Madias Brothers, Inc., Detroit • Plaster – Acoustical Ceiling & Partition, Ann Arbor • Pre-Cast Panels – High Concrete Group, Kalamazoo • Roof-Top Helipad – FEC Heliports, Cincinnati, OH • Structural Steel and Miscellaneous – Midwest Steel, Detroit • Telecommunication – Motor City Electric Technologies, Detroit • Terrazzo Flooring – Michielutti Brothers, Inc., Eastpointe • Tile – Empire Tile & Marble Company, Eastpointe • Underground Utilities – John Darr Mechanical, Ann Arbor • Wet-side Mechanical – John E. Green Company, Ann Arbor
BAE SYSTEMS STERLING HEIGHTS FACILITY Owner: BAE Systems, Sterling Heights, MI Contractor: Walbridge, Detroit Architect: SmithGroupJJR, Detroit LEED Consultant: SmithGroupJJR, Detroit MEP Engineer: SmithGroupJJR, Detroit Security Consultant: Vantage Technologies, Concord, MA
Owner Representative: Plante Moran CRESA, Southfield Civil Engineer: Nowak & Fraus Engineering, Pontiac Landscape Architect: Nowak & Fraus Engineering, Pontiac Lighting Designer: SmithGroupJJR, Detroit Structural Engineer: SmithGroupJJR, Detroit Signage Consultant: Inkspot, Chicago, IL Subcontractors • AV – BlueWater Technologies, Southfield • Building Control System – Michigan Environmental Controls and Johnson Controls, New Hudson and Auburn Hills • Carpet and Cork Flooring – Master Craft Carpet Service, Inc., Redford • Concrete Foundations and Flatwork – Broadcast Design & Construction and Amalio Corporation, Mt. Clemens and Sterling Heights • Doors and Door Hardware – LaForce, Troy • Ductwork – McShane Mechanical and Great Lakes Mechanical, Commerce Township and Dearborn • Electrical – Motor City Electric, Detroit • Elevators – ThyssenKrupp, Livonia • Fabric Panels and Markerboards – Integrated Interiors, Warren • Fencing – Riteway Fence Co., Sterling Heights • Fire Sprinkler Systems – Shambaugh & Son and SimplexGrinnell, Southfield and Farmington Hills • Fireproofing – The William Reichenbach Company, Lansing • Framing and Glazing – Trainor Glass and Peterson Glass, Allen Park and Ferndale • Garage Building Renovation – Devon Industrial Group, Detroit • General Trades – Jasman Construction and TurnerBrooks, Whitmore Lake and Madison Heights • Hard Tile – Artisan Tile WBE, Brighton • Interior Signage – West Shore Signs, Riverview • Irrigation – Marc Dutton Irrigation, Waterford • IT – Superior Electric Great Lakes Company and Motor City Electric Technologies, Troy and Detroit • Kitchen Equipment – Stafford-Smith, Inc., Ferndale • Landscaping – WH Canon Company, Romulus • Masonry – Davenport Masonry, Holt • Mechanical Piping – Macomb Mechanical and Mechanical Piping Plumbing Corporation, Sterling Heights and Dearborn • Millwork – Brunt Associates, Inc., Wixom • OH Cranes – Wolverine Crane & Service, Inc., Romulus • OH Doors / Dock Equipment – KVM Door Systems, Clinton Township • Painting – Detroit Spectrum Painting and Eugenio Painting Company, Warren and Grosse Pointe Woods • Paving – ABC Paving and AJAX Paving, Trenton and Troy • Plumbing – Macomb Mechanical and Guideline Mechanical, Sterling Heights and Clinton Township • Pre-Cast Concrete – Stress-Con Industries, Shelby Township • Pre-Purchase Roof Top Units – ThermalNetics, Inc., Auburn Hills • Raised Access Floors – Data Supplies, Inc., Plymouth • Roofing – CEI Michigan and Christen Detroit, Howell and Detroit • Security Systems – SimplexGrinnell, Farmington Hills • Siding – Universal Wall Systems and C. L. Reickhoff Company, Grand Rapids and Taylor • Site and Building Signage – Harmon Sign Company, Novi • Site Work – Blaze Contracting and Angelo Iaftrate Company, Detroit and Warren • Steel – Utica Steel and Casadei Steel, Chesterfield and Sterling Heights • Test Track – Angelo Iafrate Company, Amalio Corporation and AJAX Paving, Warren, Sterling Heights and Troy
92 CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012
WSU CHEMISTRY BUILDING RENOVATIONS & EXPANSION Owner: Wayne State University, Detroit Architect/Engineer: Harley Ellis Devereaux, Southfield Structural Engineer: Desai/Nasr Consulting Engineers, West Bloomfield Twp. Contractor: DeMaria Building Co., Detroit Subcontractors • Abatement – Next Generation Services Group, Ypsilanti • Madison Heights Glass Co. – Madison Heights • Caissons – Rohrscheib Sons Caissons Inc., New Hudson • Carpentry & Millwork – Nelson-Mill Co., Southfield • Concrete Site work – Albanelli Cement Contractors, Livonia • Demolition – 21st Century Salvage Inc., Ypsilanti • Dimension Stone Cladding – Booms Stone Co., Redford Charter Twp. • Doors/Gypsum Assemblies/Ceilings – Great Lakes Ceiling & Carpentry, Ann Arbor • Earthwork/Site Demolition/Site Utilities – Eagle Excavation Inc., Flint • Traction Elevator & Wheelchair Lift – ThyssenKrupp Electric, Troy • Electrical – Center Line Electric Inc., Center Line • Electrical – Maryland Electric Co., Clinton Twp. • Fire Suppression – TriStar Fire Protection Inc., Plymouth • Fixed Audience Seating – Detroit Technical Equipment Co., Troy • Foundations/Interior Slabs-on-Grade – DSP Constructors, Detroit • Glass & Metal Railings – R.S.I., Shelby Twp. • Joint Sealants/Granite Stair & Restoration/Traffic Coating – D.C. Byers, Detroit • Laboratory Casework & Equipment – Farnell Equipment Co., Troy • Landscaping & Lawn Irrigation – Troy Clogg Landscape Associates, Wixom • Masonry – Renovation – Brazen & Greer Inc., Livonia • Mechanical/Plumbing/Controls, Expansion&South Half Renovation – Limbach Inc., Ann Arbor • Mechanical/Plumbing/Controls, North Half Renovation – John E. Green Co., Highland Park • Metal Panels – C.L. Rieckhoff Co. Inc., Taylor • Miscellaneous Specialties – Rayhaven Group, Southfield • Painting – L&R Painting, Highland • Resilient Flooring & Carpet – Master Craft Carpet Services, Redford • Resinous (Epoxy) Flooring – Stonhard, Maple Shade, NJ • Roofing/Built-Up Roof & Vegetated Roofs – ChristenDetroit Roofing, Detroit • Security – Electronic Security Systems Inc., Warren • Signage – MLS Signs Inc., Chesterfield • Structural/Miscellaneous Steel – Casadei Steel Inc., Sterling Heights • Telecommunications – Center Line Technologies, Center Line • Terrazzo Flooring & Ceramic Tile – Artisan Tile Inc., Brighton • Testing & Balancing – Aerodynamics Inspecting Co., Dearborn • Waterproofing/Building Restoration – RAM Construction Services, Livonia “Voice Of The Construction Industry”®
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SPECIAL ISSUE SUBCONTRACTOR LISTS • • • • • • • • • • BERMAN CENTER FOR THE PERFORMING ARTS Owner: United Jewish Foundation of Metropolitan Detroit, West Bloomfield Contractor: Sachse Construction, Birmingham Architect: Neumann/Smith Architecture, Southfield Mechanical/Electrical Engineer: Peter Basso Associates, Troy Theatrical and Acoustics Consultant: Acoustics by Design, Grand Rapids Civil Engineer: Zeimet Wozniak and Associates, Novi Structural Engineer: Desai/Nasr Consulting Engineers, West Bloomfield Landscape Architect: Grissim Metz Andriese Associates, Northville • Asphalt – Asphalt Specialists, Pontiac • Cabinetry, Framing and Drywall – Jasman Construction, Whitmore Lake • Caissons and Drilled Piers – Toledo Caisson Corporation, Ottawa Lake • Caulking – RAM Construction Services, Livonia • Civil Consulting and Surveying – Zeimet Wozniak and Associates, New Hudson • Concrete – Albanelli Cement Contractors, Livonia • Custom Sails and Fabric – Division Nine Products, Inc., Farmington Hills • Custom Signs – Syylmark, Golden Valley, MN • Custom Theater Door – Noise Barriers, LLC, Schaumburg, IL • Demolition – Great Lakes Construction Services, Beverly Hills • Doors, Frames and Hardware – LaForce, Inc., Troy • EIFS – Saylors’s Inc., Ottawa Lake • Electrical – Rich Osterman Electric Company, Clinton Township • Final and Periodic Cleaning – Preferred Building Services, Southfield • Fire Protection – SimplexGrinnell Fire Protection, Farmington Hills • Fireproofiing – William Reichenbach Co., Lansing • Flooring – The Floor Club, Wixom • Foundations – Novi Wall, Novi • Glazing – Modern Mirror and Glass, Roseville • HVAC – Alliance Air Conditioning and Heating, Oak Park • HVAC Controls – Controlled Temperature, Inc., Walled Lake • Landscaping, Inc., Sue’s Landscaping, Inc., Walled Lake • Lockers and Bleachers – Steel Equipment Co., Pontiac • Masonry – Pomponio Construction, South Lyon • Millwork – Sterling Millwork, Farmington Hills • Movable Bleachers – Interkal Telescopic Seating Systems, Kalamazoo • Operable Partitions – Gardiner C. Vose, Bloomfield Hills • Overhead Doors – KVM Door Systems, Clinton Township • Painting – J & B Painting, Livonia • Plumbing – USA Plumbing and Sewer Services, Inc., Ray Township • Polished Concrete Floors – Hoover & Wells, Toledo, OH • Precast Walls – Kerkstra Precast, Inc., Grandville • Roofing and Metal Panels – Esko Roofing and Sheet Metal, Shelby Township
Security – D/A Central, Inc., Oak Park Signage – Signgraphics, Farmington Hills Signage – Stamprite Supersine, Lansing Sitework – Robert Clancy Contracting, Casco Township Steel – Utica Steel, Inc., Chesterfield Telephone and Data – Ultra-Intelesys, Inc., Southfield Temporary Fence – National Rent-a-Fence, Columbus, OH Theater Flooring – Varsity Sports Flooring, Shelby Township Theater Rigging – Beck Studios, Milford, OH Toilet Accessories – Rayhaven Group, Inc., Southfield
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THE UNIVERSITY OF MICHIGAN WILLIAM DAVIDSON PLAYER DEVELOPMENT CENTER Owner: The Board of Regents of the University of Michigan Architects: TMP Architecture, Inc., Bloomfield Hills, in association with Sink Combs Dethlefs, Denver, CO Contractor: Turner Construction Company, Michigan Office, Detroit Mechanical and Electrical Consulting Engineers: Peter Basso Associates, Inc., Troy Structural Engineers: Structural Design Incorporated, Ann Arbor Civil Engineers: Spalding DeDecker Associates, Inc., Rochester Hills Landscape Architects: Hamilton Anderson Associates, Detroit Earth Retention: Soil and Materials Engineers, Inc., Plymouth Consultant Review for Turner: Ruby + Associates, Farmington Hills Subcontractors: • Architectural Woodwork - Rice & Werthmann, Detroit • Asphalt Paving - ABC Paving, Trenton • Concrete - Spence Brothers, Ann Arbor • Concrete Saw Cutting - FMG, Brighton • Demolition - Blue Star, Inc., Warren • Doors, Frames, Hardware, Misc. Specialties, Visual Display Boards, Projection Screens, Fire Protection Specialties, Toilet and Bath Accessories - LaFORCE, Inc., Troy • Drywall Partitions, ACT, Plaster - Arrow Acoustical, Ypsilanti • Earth Retention Excavation - Eagle Excavation, Flint • Earth Retention System - Schinabel Foundation, Cary, IL • Electrical - Conti Electric, Sterling Heights • Elevators - Schindler Elevator, Livonia • Excavation and Utilities - Double E Construction, Millington • Fencing - Shamrock Fence, Southgate • Final Cleaning - PROImage Facility Services, Inc., Redford • Fire Protection - Dynamic Fire Protection, Newport • Floor Hatch, Louvers and Vents - Architectural Building Component, Grand Rapids • Glazing - Universal Glass & Metals, Detroit • Gym Equipment - Dew-El Corporation, Holland • Gym Floor, Basketball Courts - Foster Specialty Flooring, Wixom • Masonry - Boettcher Mason Contractor, Bay City • Mechanical - John E. Green, Highland Park
94 CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012
Metal Wall Panels - Renaissance Sheet Metal, Redford Ornamental Iron (Column Covers and Beam Wraps) Michigan Metal Walls, Wyandotte Ornamental Iron (Railings) - P&P Artec, Wood Dale, IL Ornamental Iron (Stainless Steel Stairs) - Division 5 Metalworks, Kalamazoo Painting - Duross Painting Company, Warren Roller Shades - The Sheer Shop, Shelby Township Roofing - Christen Detroit, Detroit Rough Carpentry, Flooring, Wood Flooring - Turner Brooks, Madison Heights Sauna - McCoy Sauna & Steam, Wixom Sealants and Waterproofing, Epoxy Flooring - RAM Construction Services, Livonia Spray-On Fireproofing - Pontiac Ceiling & Partitions, Pontiac Steel - Utica Steel, Chesterfield Surveying – Washtenaw Engineering Company, Ann Arbor Terrazzo Floor - Artisan Tile, Inc., Brighton Tile - Empire Tile, Eastpointe Toilet Compartments - Rayhaven Group, Southfield Unit Pavers, Landscaping - Margolis Companies, Ypsilanti
DETROIT/WAYNE COUNTY PORT AUTHORITY PUBLIC DOCK AND TERMINAL Owner: Detroit/Wayne County Port Authority (DWCPA) Program Managers: SDG Associates, Detroit Compliance Managers: Mannik & Smith Group, Maumee, OH Contractor: White/Braun LLC, Detroit/Farmington Hills Architect: Hamilton Anderson & Associates, Detroit Engineer 1: Geotechnical, Environmental and Facilities Engineer: NTH Consultants, LTD, Detroit Subcontractors • Architectural Building Products - Advanced Specialties, Clawson • Carpet & Resilient – Conventional Carpet, Inc., Sterling Heights • Cement Work – Albanelli Cement Contractors, Livonia • Communications/Electrical/Security – Dynalectric of Michigan, Madison Heights • Concrete Foundations – Moretti Foundation Co., Inc., Woodhaven • Consulting Engineers – NTH Consultants, Ltd., Detroit • Doors/Hardware – Tupper Door & Hardware, Farmington Hills • Draperies – Drapery Service By Ernest, Inkster • Drywall and Acoustical – Pontiac Drywall Systems, Inc., Pontiac • Elevators - Kone, Inc., Livonia • Fence Work – Future Fence Co., Warren • Fire Protection – Absolute Fire Protection, Mount Clemens • Floor Care & Cleaning - Hydra Clean, Inc., Saline • Flooring, Tile – Artisan Tile, Brighton • Glass & Glazing – Edwards Glass Co., Livonia • H.V.A.C. & Plumbing – Limbach Company, LLC, Pontiac
“Voice Of The Construction Industry”®
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Landscaping - W.H. Canon Co., Romulus Masonry Services - Dixon, Inc., Detroit Metal Siding – C.A.S.S., Inc., Detroit Millwork - Mod Interiors, Inc., Ira Township Monitoring Services- AECOM, Inc., Lansing Ornamental Metals – Industrial Fence & Landscaping, Inc., Detroit Overhead Doors - Overhead Door West, Waterford Painting & Wallcovering – Madais Brothers, Inc., Detroit Paving – ABC Paving Co., Trenton Piling & Marine Work – E.C. Korneffel Co., Trenton Plumbing Specialties – Progressive Plumbing Supply, Warren Restoration & Waterproofing - RAM Construction Services, Livonia Roofing – Roofcon, Inc., Brighton Sign Fabrication – Spectrum Neon, Detroit Site Development & Excavation - Blaze Constacting, Inc., Detroit Structural Steel - Service Iron Works, Inc., South Lyon Surveying - Atwell Hicks, Southfield Video and Appliance Suppliers - ABC Warehouse, Pontiac Workspace Products - Interior Environments, Southfield
H-PROJECT BATTERY MANUFACTURING FACILITY, HOLLAND Owner: LG Chemical of Michigan, Inc., Seoul, Korea Design/Build Manager: Roncelli, Inc., Sterling Heights Architect: Rossetti Associates, Southfield Engineer: Ghafari and Associates, Dearborn Subcontractors • Carpentry - Pontiac Ceiling & Partition, Pontiac • Carpeting - Great Lakes Flooring Covering, Inc., Grand Rapids • Clean Rooms – Hodess Construction, Attleboro Falls, MA • Clean Rooms – Unified, Sauk City, WS • Earthwork - D & R Excavating, Howell • Electrical - Circuit Electric, Byron Center • Elevators - Schindler Elevator, Grand Rapids • Epoxy - Northern Industrial Flooring, Angola, IN • Exterior Metal Panels - Universal Wall Systems, Grand Rapids • Fire Protection - Shambaugh & Son, Fort Wayne, IN • Fireproofing - Reichenbach Company, Lansing • Food Service - Stafford Smith, Kalamazoo • Glazing - Modern Mirror & Glass Co., Roseville • Hard Tile - Artisan Tile, Inc., Brighton • Hardware – S A Morman, Grand Rapids • Landscaping - Landscape Design Services, Holland • Lockers / Toilet Partitions - Rayhaven Group, Kentwood • Masonry - Hicks Masonry, Shelby Township • Mechanical - John E. Green, Detroit • Painting - Eugenio Painting, Grosse Pointe • Paving - Nagle Paving Company, Novi • Roofing - Quality Roofing, Ann Arbor • Stainless Steel / Ductwork - Franklin Holwerda Company, Wyoming
Available online at www.cammagazineonline.com
• • • • •
Structural Steel - Bristol Steel, Davison Superior Wood Products – Millwork, Grand Rapids Utilities - Superior Excavating, Auburn Hills Wetland Landscaping - Backyard Kreations, Inc., Bronson Window Treatments - The Sheer Shop, Shelby Twp.
THE M@DISON BUILDING Owner: Rock Ventures LLC, Detroit Architect of Record/Interior Designers: Neumann/Smith Architecture, Southfield Interior Design Consultants: Doodle Home, Detroit Contractor: Sachse Construction, Birmingham Structural Engineers: Desai/Nasr Consulting Engineers, West Bloomfield; Fitzpatrick Structural Engineering, Ann Arbor Design/Build Mechanical Systems: Ventcon, Allen Park Design/Build Electrician: Current Solutions, Shelby Twp. Acoustics – Acoustic By Design, Grand Rapids Subcontractors • Bathroom Tile & Marble – BYB Tile Marble, Fair Haven • Control Systems for HVAC – Johnson Controls, Auburn Hills • Demolition – Blue Star, Warren • Design/Build Drywall/Metal Studs for Auditorium – Turner Brooks Inc., Madison Heights • Doors/Frames/Hardware Package – Tupper Door & Hardware Inc., Farmington Hills • Drywall/Metal Studs for Core Y Sell System, Toilet Partitions/Accessories – Brinker Team Construction, Detroit • Elevator Systems Kone Inc., Livonia • Fire Protection – John E. Green Company, Lansing • Fire Cabinets & Fire Extinguishers – Eastman Fire Protection Troy • Fireproofing – Russell Plastering, Ferndale • Furniture – Facility Matrix Group, Pontiac • Glass & Glazing – Aluminum Supply Co., Detroit • Glass/Glazing – Modern Mirror & Glass, Roseville • Kitchen Cabinets – Berloni America, Troy • Kitchen Equipment – Gold Star Products, Oak Park • Labor Source for Misc. Construction Labor – Preferred Building Services, Detroit • Low Voltage & Security – GSI, Troy • Millwork/Misc. Barn Wood Installations –Mod Interiors, Ira Township • Miscellaneous/Ornamental Iron & Structural Steel – Ideal Contracting, Detroit • Miscellaneous Concrete/Concrete Stair – Kerson Construction Inc., Lapeer • Painters & Intumescent Fire Coating – Detroit Spectrum Painters, Warren • Retroplate Concrete Floor Systems – Inside Edge Commercial Interiors, Eagan, Minn. • Rooftop Patio Paver System & Waterproofing – RAM Construction Services, Livonia • Surveying – George Jerome & Co., Roseville • Supply & Installed Overhead Doors for Skidmore Studio – KVM Door Systems, Clinton Township
THE UAW/CHRYSLER WORLD CLASS MANUFACTURING ACADEMY Client: Chrysler Group LLC Contractor: Commercial Contracting Corporation, Auburn Hills Architect: Barton Malow Design, Southfield Electrical Engineers: Berbiglia Associates, Farmington Hills Structural Engineers: Desai/Nasar Consulting Engineers, West Bloomfield Mechanical/Plumbing/Fire Protection Consultants: Sellinger Associates, Livonia Subcontractors • A/V Equipment – Exhibit Works-EWI Worldwide, Livonia; Immersion Graphics, Commerce Township • Carpet Tiles, Base and VCT (Bid Pack #1) – Commercial Interior Resources, Commerce Township • Carpet Tiles, Base and VCT (Bid Pack #2, #3) – Shock Brothers Flooring, Roseville • Electrical (Bid Pack #1, #2) – Doublejack Electric, Royal Oak • Electrical (Bid Pack #3) – Motor City Electric & Technologies, Detroit • Epoxy Flooring – Hoover & Wells, Inc., Toledo, OH • Fire Protection – Dynamic Fire Protection, Newport • Footings and Flatwork – Commercial Contracting Corporation, Auburn Hills • Furniture – NBS Commercial Interiors, Troy; American Interiors, Wixom; E&R Industrial, Sterling Heights • Glass Wall/Door Systems & Frames – Glasco Corporation, Detroit • Masonry – Boettcher Masonry, Bay City • Mechanical/HVAC (Bid Pack #1) – Dee Cramer, Inc., Holly • Mechanical/HVAC (Bid Pack #2, #3) – E.W. Ensroth, Warren • Motorized Shades – The Sheer Shop, Shelby Township • Painting (All Phases) – Detroit Spectrum Painters, Warren • Rough and Finish Interiors – Commercial Contracting Corporation Interiors, Auburn Hills • Selective Demolition – 21st Century Demolition, Ypsilanti • Structural Steel Erection – Means Erectors, Saginaw • Structural Steel Fabrication – Commercial Contracting Corporation, Auburn Hills • Terrazzo Flooring – Michielutti Brothers, Eastpointe
CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012 95
SPECIAL ISSUE SUBCONTRACTOR LISTS • • • • • • •
GRATIOT COUNTY WIND PROJECT Owner/Developer: Invenergy LLC, Chicago Civil/Turbine Erection Contractor: Aristeo Construction Co., Livonia Civil Engineering and Surveyor: Metro Consulting Associates, Belleville Foundation Engineer: Barr Engineering, Minneapolis, MN Major subcontractors and suppliers: • Anchor Bolt Supply – Williams Form Eng., Belmont • Cement Stabilization – Wadel Stabilization, Hart • Concrete Supply – Central Concrete, Mt. Pleasant • Embed Ring Fabrication – Millwood Metalworks, Freeport, MN • Environmental Monitoring – AKT Peerless, Farmington • Materials Testing – PSI, Plymouth • Re-steel Fabrication – Hymmco, Saginaw • Re-steel Installation – Whaley Steel, Mio • Site Work & Access Roads – Fisher Contracting, Midland
• • • • • • • • • • • • • • • • • • • • • • • •
NEW MACKENZIE PK-8 SCHOOL Owner/Developer: Detroit Public Schools – Walbridge Joint Venture Architect: SHW Group Engineer: Albert Kahn Associates Contractors: MIG/AUCH, LLC Joint Venture Subcontractors: • Casework/Millwork – Farnell Contracting, Linden • Commissioning Agent – Albert Kahn, Detroit • Earthwork/Site Utilities – Adamo Group, Detroit • Electrical – Detroit Power Systems, Detroit • Electrical – Gillis Electric, Inc., Detroit • Elevators – Thyssen Krupp Elevator Co., Livonia • Evacuation Signage – Fire Safety Displays Co., Dearborn • Existing Furniture Movers – Premier Relocations, Novi • Expansion Joints/Spray Foam – RAM Construction Services of MI, Livonia • Fencing – Industrial Fence/Landscaping, Inc., Detroit • Fire Protection – Dynamic Fire Protection, Inc., Newport • Fire Protection Specialties – International Building Products, Livonia • Food Service Equipment – Great Lakes Hotel Supply Co., Detroit • Foundations – Novi Wall, Novi • Furniture – Airea, Farmington Hills • Furniture – School Specialty, Inc., Bay City
• • • • • • • •
Furniture Management – FaciliNet Services, Inc., Southfield Glass and Glazing – Union construction Serv. Inc., Detroit Gym Equipment – Holland Desk & Chair, Grand Rapids Gyp, LG, EIFS Acoustical – Vetbuilt Building Group, Detroit HM, WD, Finish Hardware – Detroit Rolling Door/Gate, Inc., Detroit Horizontal Louver Blinds – The Sheer Shop Inc., Shelby Twp. HVAC/Plumbing – J.M. & Sons Plumbing Company, Brighton HVAC/Plumbing – Klear-View Mechanical Systems, Detroit HVAC/Plumbing – Systemp Corporation, Rochester Hills Interior Concrete – Albanelli Cement Contractors, Livonia Landscaping – WH Canon Company, Romulus Markerboards & Tackboards – Advanced Specialties, Clawson Masonry – Davenport Masonry, Inc., Holt Masonry – Grunwell-Cashero Co., Detroit Material Testing Agency – ABE Construction Services, Detroit Material Testing Agency – Testing Engineers & Consultants, Inc., Detroit Metal Lockers – International Building Products, Livonia Metal Roofing/Panels – Custom Architectural Sheet, Detroit Modified Bituminous Roof – Royal Roofing Co., Inc., Orion Office Furniture – Facility Matrix, Pontiac Operable Partitions – Gardiner C. Vose, Inc., Bloomfield Hills Overhead Coiling Doors – KVM Door Systems, Inc., Clinton Twp. Painting – Future Maintenance, Inc., Livonia Playground Equipment – Playworld Midstates, Clinton Twp. Projection Screens – Advanced Specialties, Inc., Clawson Resilient/Carpet Flooring – Shock Bros Floor Covering, Roseville Scoreboard – Holland Desk & Chair, Grand Rapids Signage – ASI Modulex, Troy Site Concrete & Asphalt Paving – Detroit Recycling, Detroit Stage Curtains – Tobins Lake Sales, Whitmore Lake Structural & Miscellaneous Steel – Ross Structural Steel, Detroit Technology – LaBelle Electric, Macomb Technology – Learning Consultants Inc., Detroit Technology – Wiltec Technologies, Ann Arbor Telescoping Bleachers – Interkal, LLC, Kalamazoo Tile – Artisan Tile & Marble, Brighton Toilet Accessories – Rayhaven Group, Southfield Toilet Partitions – Rayhaven Group, Southfield Wire Mesh Partitions – Acme Wire & Iron Works, Detroit Wood Flooring – Star School Flooring, Hastings
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Auger Cast Piles – Berkel & Company Contractors, Inc., La Grange, KY Carpet & Resilient Tile – MasterCraft, Redford Cast Concrete Paving Brick Pavers – Mid-Michigan Turf Care, Inc., Owosso Civil (Steam Tunnel) – Fishbeck, Thompson, Carr & Huber, Inc., (FTCH) Grand Rapids Commissioning – Peter Basso Associates, Inc., Troy Earthwork/Site Utilities – TCI Inc. of Michigan, Eaton Rapids; The Niemi Corp., Ypsilanti; Mersino Dewatering Services, Davison; Lowe, Eaton Rapids Electrical Systems, Trailer Electric – Superior Electric, Lansing Elevators – Schindler Elevator, Lansing Fire Protection – Jackson Automatic Sprinkler, Spring Arbor General Carpentry, Millwork, Doors – Christman Constructors, Lansing General Trades - Bruce’s Sweeping, LLC, Grand Ledge Glass/Glazing, Curtain Wall & Aluminum Entrances – Calvin & Company, Flint Hard Tile – Artisan Tile, Brighton Industrial Hygiene Services – Fibertec, Holt Lab Casework/Fume Hoods/Washers & Dryers/Sterilizers Cold Room – Detroit Technical Equipment, Troy Masonry – Schiffer Mason Contractors, Holt Mass Demolition – Pitsch Company, Grand Rapids Mechanical Systems – Gunthorpe, East Lansing; Dee Cramer, Holly; Siemens Building Technologies, Inc., Plymouth Ornamental Metals – Couturier Iron Craft, Comstock Park Overhead Doors – Michigan Overhead Door, Burton Painting – Lake State, Lansing Plaster/Drywall/Acoustical/Insulation – William Riechenbach, Lansing Rebid Earthwork – Merlyn Contractors, Novi Roofing, Metal Panels & Column Enclosures – CEI, Howell Site Concrete, Curbs & Concrete Paving – Fessler & Bowman, Flushing Structural Concrete – Grand River Construction, Inc., Hudsonville; Ambassador Steel Fabrication, LLC, (resteel) Lansing Structural Steel, Deck, Stairs – Valley Steel Company, Saginaw; Steel Erectors, Grand Blanc Survey – KEBS, Inc., Haslett Temp Asphalt/Asphalt Patch – Spartan Asphalt Paving Company, Lansing Temp Fencing – Dewitt Fence Co., Lansing Terrazzo – Fabris Pearce, Burton Testing – Soil and Materials Engineers, Inc. (SME), Lansing Waterproofing/Dampproofing – RAM Construction Services, Livonia Window Treatments – MSC Blinds & Shades, Bronson Won Door – Won Door Corp, Salt Lake City, UT
Subcontractors and professional consultants listed are identified by the general contractor, architect or owner.
MSU MOLECULAR PLANT SCIENCES BUILDING Owner: Michigan State University, Lansing Architect: SmithGroupJJR, Detroit Contractor: The Christman Company, Lansing Subcontractors and Consultants: • Architectural Specialties – Payne Rosso, Lansing
96 CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012
“Voice Of The Construction Industry”®
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ADVERTISERS INDEX ARC/Dunn Blue ................................................................67
Desai/NASR........................................................................32
McCoig Materials ............................................................46
Ace Cutting Equipment ................................................67
Detroit Carpentry JATC..................................................79
Metro Consulting Associates ......................................81
Aluminum Supply Company/Marshall Sales ........26
Detroit Terrazzo Contractors Association ..............33
Michielutti Brothers ........................................................17
Amalio Corporation ........................................................16
DiHydro Services..............................................................45
Michigan Regional Council of Carpenter ..............61
Aoun & Company ............................................................32
Doeren Mayhew ..............................................................17
Motor City Electric ..........................................................23
Bricklayers and Allied Craftworkers
Edwards Glass ..................................................................49
Next Generation Services Group ..............................29
Union Local #1 ............................................................59
Excel Dryer ....................................................................9, 91
North American Dismantling Corp. ..........................39
Broner Glove and Safety ..............................................58
Executive Vehicle Sales, Inc. ........................................85
Oakland Companies ......................................................35
CAM Administrative Services ........................................3
Facca Richter & Pregler, P.C...........................................48
Oakland Metal Sales, Inc. ..............................................10
CAM Affinity ......................................................................97
Ferndale Electrical..........................................................IFC
Operating Engineers Local 324-JATF..........................7
CAM Comp ........................................................................65
Fishbeck, Thompson, Carr & Huber, Inc. ..................91
Plante Moran, PLLC ........................................................47
CAM ECPN ............................................................................9
G2 Consulting Group ....................................................55
Plunkett Cooney ..............................................................41
CAM Magazine ................................................................98
Glazing Contractors Association ..............................IBC
R.L. Deppmann Co. ........................................................73
CAM Tradeshow ..............................................................93
Goldstein, Bershad & Fried, P.C. ..................................64
R.S. Dale Co. ..........................................................................4
C.A.S.S. ................................................................................57
Hartland Insurance Group, Inc. ..................................11
Rick's Portables ................................................................72
C.E.I. ......................................................................................89
IBEW Local 252 ................................................................33
SMRCA ................................................................................55
C.F.C.U. ..........................................................................50, 51
Intentio Innovations ......................................................73
Sani-Vac Service ..............................................................39
Cochrane Supply & Engineering................................38
Jeffers Crane Service, Inc...............................................35
Spartan Specialties..........................................................44
Collins, Einhorn, Farrell & Ulanoff, P.C. ......................56
John Deere ........................................................................27
Sullivan, Ward, Asher & Patton, P.C.............................72
Commercial Contracting Corporation ....................75
Kem-Tec ..............................................................................48
Testing Engineers ............................................................67
Connelly Crane Rental Corp. .......................................21
Klochko Equipment Rental ..........................................54
Valenti Trobec Chandler, Inc. /
Cummins Bridgeway ......................................................21
Kotz, Sangster, Wysocki, P.C. ........................................BC
Griffin Smalley & Wilkerson ......................................5
D. J. Conley..........................................................................60
MIG/AUCH ..........................................................................85
Zervos Group ....................................................................91
DKI, Inc. ................................................................................20
MasonPro, Inc. ..................................................................15
DRC Contract Cleaning Restorative Drying ..........20
McAlpine and Assoc. ..............................................68, 69
CAM Magazine is a monthly publication covering construction news throughout the state of Michigan, highlighting interesting construction projects, personnel news and industry happenings. In-depth feature articles focus on a variety of industry trade segments and on key management and economic issues, keeping pace with the Michigan construction scene. Since 1985, CAM Magazine has been known as the “Voice of the Construction Industry”. Now, in addition to being printed and mailed to over 3,600 industry professionals each month, thousands more are able to access the entire magazine online, complete with link-thrus to participating advertisers' company websites. This has dramatically increased the circulation and exposure of our award-winning magazine and our advertisers – we are now worldwide! Call or e-mail to find out how CAM Magazine can help put your company in front of an unlimited number of construction professionals each month.
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98 CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012
“Voice Of The Construction Industry”®
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CAM MAGAZINE OCTOBER SPECIAL ISSUE 2012 99
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CONSTRUCTION COUNSEL Kotz Sangster knows the construction industry. When you need practical, service-oriented lawyers who can answer your questions, we are the law firm to call. We understand the types of risk you face on each project, and we add value to your business by helping you develop and implement effective risk mitigation strategies. However, in the event litigation is required, we are also aggressive, experienced litigators who protect your business interests.
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“Voice Of The Construction Industry”®