GOLD MEDAL AWARD WINNER
The Building of America
Applied Research & Development Facility at Northern Arizona University www.constructionreviews.com
Flagstaff, Arizona
Facts & Figures Owner: Northern Arizona University Type of Project: New academic/ research laboratory facility Size: 60,000 square feet Cost: $26 million Construction Time: November 2004 - August 2007 The Need: A dynamic, ecologically
Applied Research & Development Facility at Northern Arizona University The
Applied
Research Facility
at
the
Center
for
Sustainable
Environments.
executive architect, NAU had two
Development
at NAU
Northern Arizona University (NAU)
Chosen for its prominence on cam-
was to achieve a USGBC LEED®-certi-
The Challenge: Achieving LEED®
(ARD)
and
friendly research laboratory facility
major goals for this project. “The first
is a structural testament to the work
pus, the site was originally a brown-
fied platinum building. The second
laboratory building in a
and ideas the school fosters. Standing
field and storm water detention basin
was to create a signature building that
remote location
three stories high, the facility is only
at the main entry of the campus. This
not only became a landmark gate-
the second building in Arizona to
project provided an opportunity to
way building to the campus, but also
have obtained a platinum certification
clean the surrounding area. According
gave NAU a recognizable architectural
Burns Wald-Hopkins Shambach Architects Executive Architect
from the U.S. Green Building Council
to Richard Bowen, associate vice presi-
identity within the state and nation-
under the Leadership in Energy
dent for economic development at
ally,” she said. “At the same time,
Hopkins Architects Design Architect
and Environmental Design (LEED )
NAU, the reinvented site was used to
we recognize the need for the ARD
program. It’s also one of the
increase the detention basin capacity
to fit within the grain of the campus,
Kitchell Contractors, Inc. Construction Manager at Risk/ General Contractor
highest scoring buildings to receive
and use storm water runoff to create a
and to use local and natural materials
LEED®
at
lake adjacent to the building. Providing
that reinforce the architectural charac-
Brothers Masonry Masonry Contractor
the western gateway of NAU, the
ambient cooling to the building, the
ter of Flagstaff.”
The Structures Group Southwest, Inc. Wood/Steel Subcontractor
ARD facility is appropriately home to
lake also enhances the aesthetics of
university and governmental agency
the property significantly.
certification on a research
Gold Medal AwardWinning Team Members
®
certification.
Located
The facility was envisioned as a “state-of-the-art laboratory [designed]
offices that focus on the environment,
According to Robin Shambach,
to enhance the research mission at
including the National Park Service,
AIA, LEED AP, principal for Burns
NAU by providing a location for
the U.S. Geological Survey and
Wald-Hopkins Architects, the project’s
both the basic theoretical research in
Visit our website: www.constructionreviews.com to view additional Gold Medal Award-winning projects.
Photos courtesy of Timothy Hursley
arizona/nevada edition
gold medal award winner
genetics and genomics, but also to
vested, produced and manufactured,
provide a location for application and
according to Marty Olson, project
translation of the university’s research
director for Kitchell Contractors, Inc.,
into real-world solutions, processes,
the project’s construction manager at
patents and licenses,” said Bowen. The
risk/general contractor. The building’s
top floor of the building is dedicated
concrete includes fly-ash, the waste
to the Center for Microbial Genetics
from coal-fired electric plants. “This
and Genomics and the Keim Lab.
strategy helped to keep this material
According to Burns Wald-Hopkins, this
out of landfills and reduced the need
area comprises research facilities that
for cement, thus reducing the emission
focus on disease-causing bacteria such
of greenhouse gases,” said Olson. And,
as anthrax and the plague.
more than 30 percent of the materials
Encompassing 60,000 square feet,
used in the building include recycled
the ARD is a brick, wood, glass and alu-
content, such as the insulation, which
minum structure. The building forms
was made using recycled denim.
a long arc oriented toward the south
Of course, the innovations don’t
to capture the winter sun in a glass-
end there. The building incorporates
enclosed, three-story gallery that serves
a conservationist approach at every
as a thermal buffer space for the offices
turn, including the long and slender
behind. Louvers and blinds shade the
design of the building, which maxi-
gallery from the hot summer sun while
mizes daylight, thereby minimizing
allowing the sun to warm the building
electrical lighting needs.
in the winter.
Additionally, the building uses a
Utilizing sustainable materials, the
concrete structural frame, which stores
very fabric of the facility is locally har-
heat in the winter while staying cool continued on page 7
Photos courtesy of ©Vance Fox
gold medal award winner
arizona/nevada edition
The Owner’s Perspective with Richard Bowen, Associate Vice President for Economic Development, Northern Arizona University
Q: What is the most innovative aspect of the project (or of the design/construction process, financing, environmental)? What could others learn from? RB: Not only is the building unique in that it has achieved the second highest number of points ever achieved by a LEED® platinum building, 60 points versus 61 points, but it also demonstrates that it is possible to create a fully functional building that is highly energy efficient, enjoyable and healthy to work in, architecturally pleasing, and [that] reduces its short-term and long-term impact on resources and [the] environment. While this building had a 10 percent cost premium primarily for the renewable energy component, the knowledge base and design expertise developed will allow others to build a similar building for a minimum cost premium and with very short payback time for the cost premium. Q: What were the greatest challenges encountered on this project? How, specifically, were they overcome? RB: Finding a design and construction team with sufficient experience and the desire to tackle the challenge of designing a LEED® platinum lab building at a 7,000-foot elevation with the express goal that the building be carbon neutral. When NAU went to the marketplace three years ago to find an architect and contractor, we advertised nationally only to find that most national firms lacked experience in designing highperformance buildings. Hopkins Architects from London had significant experience in Europe designing high-performance buildings and served as a design consultant to an Arizona firm, Burns Wald-Hopkins, which also had actual LEED® design experience. Because canned engineering solutions did not exist and very high goals were set, the architects, engineers and contractor took the challenge and worked closely to create fundamentally different and cutting-edge design and construction solutions that are being used at NAU and throughout the state of Arizona as the base for future high-performance buildings.
Photo courtesy of Northern Arizona University
Q: How did the strengths and experience of the project team contribute to the success of the project? RB: The key to [the] success of this project was the commitment of the entire team to innovation and the goals of the project even during a time of unprecedented construction cost increases. In addition, of special note, the construction manager at risk, Kitchell Contractors, became experts and highly competent in providing design assist and construction solutions, went the extra mile to become experts at the LEED® system, and created cost-effective and efficient procedures for implementation, and [also] taught the subcontractors the LEED® system. Q: If another owner was about to commence work on a similar project, what advice would you offer from your experiences that he/she may not be aware of? RB: Find an experienced team that has a track record of successful completion of high-performance buildings, and hire a LEED® consultant with [a] similar track record. Challenge the team to exceed the performance of any building designed to date, while at the same time continuing to reduce costs. Only then will fundamental change and innovation happen.
South San Francisco St. Flagstaff, AZ 86011 928-523-9011 www.nau.edu
At the Fore of Wood Construction Offering a Team Approach and Complete Involvement in Each Project Known under several different names in the past,
encounter. “The actual fabrication of these glulams
The Structures Group Southwest, Inc. of today prides
was like nothing we have ever done before. Our
itself on innovation and cost analysis in structural design.
workers drilled approximately 30 holes in each
The company was started more than 50 years ago,
glulam column which had to line up perfectly with
beginning in California under the moniker Berkeley
another column to form a double column at each
Plywood. There, it developed a revolutionary new method
location,” Santini says.
for framing roofs on industrial and commercial build-
Unique to its industry, the team always has a structural
ings. This was originally known as the Berkeley Panelized
engineer on staff to provide problem-solving techniques
System and became the foundation for large wood roof
when issues arise. However, the company mainly sets
structures throughout the West Coast.
itself apart due to its focus on details and quality of
After several name changes that eventually
construction. This reputation isn’t easily earned, though,
led to the birth of The Structures Group, the company
and the team continually searches for opportunities to
has continued to build a reputation that hasn’t
save clients money, even if that means more work.
faltered throughout the years. Neal Vandenburgh is CEO of the company and was previously the CEO of
A Past of Workmanship and Glowing Reviews
Simpson Structures. Brian Vandenburgh became president of The Structures Group after working for the company
A long history in woodworking has also allowed the
as a carpenter. In 1994, he earned his engineering
company to grow in timber construction. Using the latest
degree and registration as a professional structural
wood technology, high-profile wood structures can be
engineer before returning to the company.
erected, and exceptional challenges in construction design can be managed with ease.
Attention to Detail and Cutting Costs
During the past 30 years, The Structures Group has worked with general contractor Sun State Builders.
With an exceptional knowledge of structural
Working on approximately 600 jobs together,
engineering, the team is able to look at different systems
Sun State admires The Structures Group for its
and provide cost and strength options at the concep-
masterful foresight. The company is involved in
tual phase of design. For the Applied Research and
many of Sun State’s projects, and is able to
Development Facility at Northern Arizona University,
recognize possible construction and design hurdles
The Structures Group had to bend its normal practices in
well before they actually occur. This type of acute
order to meet Leadership in Energy and Environmental
preparation is what makes The Structures Group a
Design (LEED ) standards. With an expertise primar-
standout company — dedicated to timeliness and
ily in structural roof framing, wood panelized roof sys-
staying within budget.
®
tems and structural steel roof systems, this project was unique for the company on many different levels. According to Joe Santini, sales engineer at The
Kurt Sullivan, vice president of the Douglas Allred Company, worked with The Structures Group on a structurally
unprecedented
building.
According
Structures Group, the company’s main focus — and one
to Sullivan, “the company took the lead on all issues
of its biggest challenges — was creating the columns
concerning the project and coordinated various work
and beams that would welcome visitors, students and
components in a ‘general contractor’ mode,” rather
academics to the facility. “The glulam columns and
than simply carrying out its own specific area of work.
beams
were
not
simple
industrial-grade
Just as The Structures Group builds relationships
beams — they were tapered at one end and beveled at
with its clients, it does the same with its suppliers. After
the other and had an architectural appearance,” he says.
a half-century in the industry, the team has assembled
With no model to refer to, this was a novel task for
a top-notch group of suppliers that provides it with
the project team and critical in setting an aesthetic
only the finest products for the job.
standard, since it would be the first thing people would
— Corporate Profile
The Architect’s Perspective with Robin Shambach, AIA, LEED AP, Principal, Burns Wald-Hopkins Shambach Architects Q: What were some of the drivers behind the design? What design materials or concepts were used? Please note any design innovations on this project, especially those that would be helpful for other owners to learn from. RS: One of the primary design strategies for the building was to integrate multiple design disciplines and seemingly unrelated aspects of design in a manner that permits synergistic benefits to be realized. The goal is to achieve high performance and multiple benefits at a lower cost than for the total of all the individual components combined. Our team developed and integrated green design strategies into the design criteria for building form, function, performance and cost. A key to the successful integrated building design is the participation of people from different specialties of design: general architecture, HVAC, lighting and electrical, interior design, and landscape design. By working together at key points in the design process, our team integrated highly effective solutions to design needs that would otherwise not be found.
Photo courtesy of Timothy Hursley
Q: What were the greatest challenges encountered on this project, either from your firm’s point of view or as a project team? RS: Some of the challenges on this project included resolving differences in traditional construction practices by the international design team, specifically the integration of a European building industry approach of custom-built components into the U.S. model of manufacturer-supplied stock materials. Also, some of the innovations utilized to achieve the platinum certification had never been done in Arizona. For instance, the concrete used for the structural frame had a very high percentage of fly-ash to reduce cement content and lower the carbon dioxide generated. New 40 percent fly-ash mix designs had to be generated and tested by the materials supplier, and the concrete subcontractor had to become familiar with the particular characteristics of the mix designs before casting the entire project since most of the concrete is the final architectural finish. Another example was the use of pervious concrete paving for the parking area. ARD has the first use of pervious concrete in the state of Arizona, and paving of the parking lot was delayed a short time while the contractor achieved the appropriate local licenses.
Q: What were some of the lessons learned from this project? RS: The entire team, design professionals, contractor, tradespersons and, most importantly, the owner, need to be on board and committed from the start of the project to achieve the highest possible level of sustainable design. Some of the strategies are more expensive, but some simply require a new way of occupying the building or a different way of prioritizing design decisions. Doing things because they have “always been done that way,” simply doesn’t work.
Burns Wald-Hopkins Shambach Architects 261 N. Court Ave. Tucson, AZ 85701 520-795-2705 www.burnswald.com
continued from page 3
in the summer, reducing the energy
local utility provider Arizona Public
international design team — more
project, the knowledge of LEED® with
required for heating and air condition-
Service — is used to produce more
specifically, integrating a European
the subcontractors was more limit-
ing year round. On top of the confer-
than 20 percent of the electricity
building industry approach of cus-
ed,” he said, which was a potential
ence unit, a living or green rooftop is
for the building. Due to these and
tom-built components with the U.S.
threat to the schedule. But with semi-
designed to insulate the building, limit
other inspired design techniques,
model of manufacturer-supplied stock
nars and monthly meetings held by
storm water runoff and reduce the
energy consumption is reduced
materials.
Kitchell, the subcontractors were able
heat island effect. According to Olson,
by 89 percent when compared to
energy usage is reduced by more than
similar buildings.
According to Olson, the remote location of the site also posed chal-
to gain vital knowledge that helped them meet the LEED® requirements.
60 percent through a combination
But groundbreaking construction
lenges. For one, many of the local sub-
For Bowen, the main challenge
of natural ventilation, radiant heat-
and design doesn’t come without
contractors had a smaller employee
was finding a design and construc-
ing and cooling, high-performance
challenges. According to Shambach,
base and had a difficult time retain-
tion team with sufficient experience
insulating glazing, and solar shad-
one of the major issues on this project
ing the necessary skilled craftsmen
and the desire to tackle the challenge
ing. Furthermore, a nearby field of
involved the differences in traditional
because the demand was so high.
of designing a LEED® platinum lab
photovoltaic panels — donated by
construction practices among the
“Also, due to the remoteness of the
building. Three years ago when NAU continued on page 11
Photos courtesy of ©Vance Fox
gold medal award winner
arizona/nevada edition
The General Contractor’s Perspective with Marty Olson, Project Director, Kitchell Contractors, Inc. Q: What is the most unique or important feature of the facility (or of the design/ construction process)? MO: …The overall goal of constructing a building that reduces the overall impact to the environment was the most important accomplishment.
Q: What were the greatest challenges encountered on this project and how, specifically, did you overcome them? MO: Cold Temperatures — The cold temperatures mostly affected the concrete. To help resolve this conflict, we employed many different tactics. First, we tented the floor below the pour and placed heaters inside the tent to heat the formwork above. The heating started the day before the pour, ran through the night and throughout the pour. The batch plant used hot water for the concrete mix and the concrete temperatures were measured constantly during the pour. One of the innovations used on this project was to reduce the amount of cement used in the concrete by 40 percent. To offset this reduction and to meet the required design strengths, the amount of fly-ash used was increased in roughly the same proportions. The issue with this method was that high-volume fly-ash concrete has less heat of hydration and therefore increases the cure time, typically requiring six to seven hours. After the concrete was set, thermal blankets were placed on the concrete and the heating from below continued for several days. We also purchased household electric blankets and wrapped them around the cast-in-place columns to keep the heat in while they cured.… Recycling — Recycling of construction waste was another complication that had to be addressed. …Due to the remoteness of the project, the recycling facilities that are available in a large city were not available here. The experience of both the workforce and the waste management company was not recycle-friendly. We had to take a more proactive approach to recycling on this project and brainstorm different venues for recycling. Two innovative solutions: the excess drywall was chipped and used as fill at the photovoltaic site. The concrete wood forms that are typically thrown out were chipped and reused as landscaping.
Q: How did you work with the architect and owner to save time and/or money on the project? How was value engineering applied to your responsibility? MO: The main objective of this project was to attain LEED® platinum certification while remaining within the original budget. Because of this, Kitchell was involved in several value engineering sessions during the design phase to decrease costs by $3 million.
Q: What were some of the lessons learned from this project? MO: The main lesson learned is that with sustainable design it pays to do your research as early in the process as possible. The extensive research we did resulted in several creative solutions and additional LEED® points.
1707 E. Highland Ave., Ste. 200 Phoenix, AZ 85016 602-222-5300 www.kitchell.com
An Ancient Craft with a Modern Approach: Brothers Masonry
Staffing its jobs with only the finest craftsmen, Brothers Masonry Corporation consistently ranks among the top masonry contractors in Arizona. The company was founded in 1983 by Carl Funke, president, and Greg Jonovich, vice president, CFO and general manager. Starting out doing small residential projects, the company gradually began working on small commercial, hospital and church projects. Today it is a full-service masonry contractor specializing in all aspects of the business, offering design input and value engineering. “When a contractor solicits us to bid a job, he deals with the estimator at the start and continues to use the same estimator to act as the project manager,” Jonovich says. This assures clients that there are no gaps in the masonry portion of their investment, and offers them the security of knowing that their financial expectations are met accordingly.
Individualized Expertise for Every Project Greg and Carl work closely with their clients, workers and estimators, providing hands-on attention every step of the way, and take part in everyday, on-site activities. Brothers Masonry has a commitment to growth, perseverance, consistency, honesty and quality, always offering its clients the most skilled and professional workers in the trade. Each estimator has expertise in a particular facet of the masonry industry and is chosen for specific projects that are tailored to these skills and credentials. For the Applied Research and Development Facility at Northern Arizona University, Brothers Masonry erected the structure from brick and glass block. With its skilled craftsmen, Brothers Masonry was able to overcome on-site challenges and work through difficult conditions. Past experiences have helped Brothers Masonry predict almost the exact amount of material it needs for each project. “We have had jobs with as many as 150 different types of materials, shapes and colors. It is rare that we have a shortage or excess of material on any given job,” Jonovich says. This is something the company takes pride in, and is also a valuable feature when considering the project’s budget.
costly impact to the industry are structural changes that are being implemented into most building codes. In order to stay in touch with these ongoing modifications, Brothers Masonry constantly pursues education in local and state requirements. Though it rarely uses sub-subcontractors, Brothers Masonry has found that loyalty and prompt payment are the best ways to maintain competitiveness in the market and create professional relationships. As a major force in the construction industry in Arizona, Brothers Masonry has a goal to encourage growth in its economy through hard work, dedication and by merging the timeless artistry of masonry with the technology of today. By focusing on quality in its industry, Brothers Masonry is looking to advance not only for its company and clients, but for the masonry economy as a whole. — Corporate Profile
Staying Informed with Educated Professionals In the current construction industry, along with the more “sophisticated architectural designs,” there are many stricter insurance and safety requirements for each job than there were 10 years ago. Adding another
www.brothersmasonry.com 3621 East Superior, Ste. 101 • Phoenix, AZ 85040 p. (602) 954-9500 • f. (602) 954-6258
“[The facility was envisioned as a] state-of-the-art laboratory [designed] to enhance the research mission at NAU by providing a location for both the basic theoretical research in genetics and genomics, but also to provide a location for application and translation of the university’s research into realworld solutions, processes, patents and licenses.” – Richard Bowen associate vice president for economic development at NAU
Photo courtesy of Northern Arizona University
Photo courtesy of ©Vance Fox
10
arizona/nevada edition
gold medal award winner
continued from page 7
went to the marketplace to seek out the best project team, it found that “most national firms lacked experience in designing high-performance buildings,” he said. Soon it discovered Hopkins Architects from London, who acted as a design consultant to Arizona firm Burns Wald-Hopkins, although both companies do have experience in LEED® design. The Structures Group Southwest, Inc., the project’s wood/steel subcontractor, also played a key role in achieving LEED® certification for the facility.
Photo courtesy of Timothy Hursley
According to The Structures Group, the company utilized local materials for the columns and beams at the entrance of the building. The glulam columns and beams provided for this project were Forestry Stewardship Council (FSC)-certified and were harvested and manufactured within 500 miles of the jobsite. Brothers Masonry, the project’s masonry contractor, assisted with the building’s extensive glass block and innovative brickwork. According to Greg Jonovich, vice president and CFO of Brothers Masonry, the team used quality masons to overcome on-site challenges and work through difficult conditions. With so many individuals involved, the cornerstone of the project was the dedication and flexibility of each team member. Since its opening, the Applied Research & Development Facility at NAU has become a lifelong tribute to the educational process. “For many years a core expertise of Northern Arizona University has been environmental research, environmental curriculum and application, renewable energy, and environmental public policy,” said Bowen. “What better opportunity for an organization to practice what it preaches than demonstrating that a cost-effective, highperformance, attractive laboratory building that would meet the LEED® platinum rating could be designed and built.” n — Megan Merritt Photo courtesy of Northern Arizona University
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arizona/nevada edition
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