pioneering the delivery of the building envelope
OUR INDUSTRY
We trace our roots to the advent of prefabrication, often referred to as “architecture’s oldest new idea.”
OFFICE LOCATIONS / /
COMPANY PROFILE / /
CALVERTON / NY 1101 Scott Avenue Calverton, NY 11933 p 631 208 3500 info@islandcompanies.com
Island International Exterior Fabricators (Island), a member of the Island Construction Companies, is a privately owned firm that was established in 2000, to exclusively perform the building envelope and cladding technologies work which the company had previously been engaged in during its 40 year history within the Northeast. The Island headquarters, including the primary fabrication and assembly facilities are based on Long Island, in Calverton, New York with New England satellite offices located in Pawtucket, Rhode Island and Boston, Massachusetts.
BOSTON / MA 179 South Street, Suite 600 Boston, MA 02111 p 857 214 7300 info@islandcompanies.com
Our firm employs on average over 400 full-time personnel including engineers, drafters, project managers, accounting personnel, purchasers, superintendents as well as the trades & crafts people engaged both in the fabrication and installation of the assemblies provided by Island. We are a fully self-sustained organization equipped with the in-house skilled design & engineering professionals, state-of-the-art equipment and facilities, as well as the production capacity, installation work force and, most importantly, the financial capacity to complete large scale, complex projects in a timely and efficient manner.
PAWTUCKET / RI 835 School Street Pawtucket, RI 02860 p 401 723 2040 info@islandcompanies.com
Our fabrication operations are performed within six clear span, large volume structures formerly occupied by the United States Navy and Grumman Aircraft Engineering Corporation. These properties are situated on a combined 30 acres of land, where both fabricated and raw materials are stored. The fabrication facilities themselves total over 250,000 sq. ft. of indoor, climate controlled space which enables IEF to operate year round in any weather. This location also features an active runway which makes visiting Island a little more convenient for any client inclined to observe our operations in action. Our repeat customers and clientele include some of the nations leading construction managers, general contractors, owners & developers, architects, designers, and consultants.
INDUSTRY LEADERS / / As one of the nations leaders in unitized building cladding technologies, Island provides all of the services and maintains the necessary resources required to meet the needs of our clients and their projects.
Our services and resources specifically include:
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Preconstruction Design, Engineering and Cost Estimating
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Industry Leading Engineering and Design
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Experienced Project Management Teams
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Complete ASTM Performance Testing Services and Tested Assemblies
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Ongoing Research and Development
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Financial Strength and Capacity for over $150,000,000 Annual Income
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Bonding Capacity of $250,000,000
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Multi-Trade Cladding and Finishing Capabilities
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250,000 Square Foot Climate Controlled, State-of-the-Art Fabrication Facility
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Over 400 Personnel Including Highly Skilled Tradesmen & Crafts Personnel
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Specialized Fleet Cranes, Transportation, Trailers & Handling Equipment
ABOUT ISLAND
We design, engineer and execute highperformance, precision fabricated unitized systems to enclose the buildings of tomorrow.
OUR APPROACH
Success in our business is built on genuine collaboration. From architects to builders our projects are only as strong as our partnerships.
OUR CAPABILITIES / / Specializing in building cladding and envelope design, our expertise spans a wide range of envelope materials and systems, trades skills and construction services. Our capabilities include: OVERHEAD OUTGOING :
Envelope Design
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Facade Consulting
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Material Flexibility
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Facade Engineering
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Project Delivery
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Visual Mock-ups / Prototypes
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Design Assist
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QC/QA Programs
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Installation
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VDC Services
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Facility & Transport
TOOLS + TECHNOLOGIES :
BIM Execution
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Parametric Modeling
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2D/3D Shop Drawing & Fabrication
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Direct-to-Fabrication / CNC
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Digital Scanning of as-built conditions
DESIGN VERSATILITY / / The unitized assemblies and technology offered by Island provide extensive design versatility, flexibility and diversity while providing cost-effective solutions for adaptable performance-driven, architectural building envelope assemblies to the design team, ownership and builder by means of the following diversified cladding materials, applications and technologies: : Aluminum Plate & Composite Aluminum Cladding :
Terra Cotta Cladding
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Specialty Metals including (Stainless Steel, Titanium, Copper, Pressed & Profiled, Perforated)
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Brick Veneer Cladding
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Natural Stone Cladding (Granite & Limestone)
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Glass Cladding
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Phenolic Panel Cladding
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Extruded Fiber Reinforced Cementious Cladding
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Ultra High Performance Concrete
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Energy Absorbing Blast Wall Systems
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Cast Stone
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Glass Fiber Reinforced Concrete Cladding
WHAT WE DO
We deliver project-tailored envelope solutions that enable developers, contractors and architects to realize complex projects.
AND HOW
We give form to vision through our dedication to design and research. Our commitment to excellence fosters innovation.
RESEARCH + DESIGN / / Every project is an opportunity to innovate and expand the breadth and depth of prefabrication as it pertains to delivery, cost, performance, and design. Island conducts research and development in a reactionary manner, utilizing project demands and intent to push the boundaries of the technology. The prefabrication methods employed by Island make research and development more feasible, as time saved from an expedited delivery can be put towards technical experimentation and discovery. :
Advanced Digital Design and Fabrication Techniques
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Facade Physics Optimization
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New Systems Design
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Life-cycle Assessment
SYSTEM PERFORMANCE TESTING / / Research, design development and testing is performed at our facility. ENHANCED THERMAL PERFORMANCE Incorporating insulation outboard in the exterior sheathing effectively ‘jackets’ the entire building envelope. If additional insulation is utilized, this feature significantly enhances the walls thermal performance in order to achieve LEED certification or other building efficiency standards requirements which may be necessary. DEW POINT MANAGEMENT The utilization of an outboard insulated assembly for the building envelope not only enhances thermal performance, but effectively manages the dew point of the exterior sheathing and air-vapor, externally - not within the interior cavity as in traditional assembly systems.
PROJECT DELIVERY
03
50
400+
10
REGIONAL OFFICES
DESIGN ENGINEERS
FABRICATION PERSONNEL
CNC MILLS W/ 3-4-5 AXIS CAPABILITY
3,000
24
20
06
SF OF PANELS INSTALLED PER DAY
HOUR OPERATION
TRUCKS + TRAILERS
300 FT CAPACITY CRANES
BALLET HISPANICO STEPHEN GAYNOR SCHOOL
THE TOWERS CITY COLLEGE OF NEW YORK
148 West 90th Street
340 Saint Nicholas Avenue
ROSE CENTER PLANETARIUM
HARLEM CHILDREN’S ZONE PROMISE ACADEMY
200 Central Park West
MERCEDES HOUSE
770 11th Avenue
CHATHAM 44
35 East 125th Street
HL23
515 West 23rd Street
CassaNY
464 West 44th Street
70 West 45th Street
245 10th AVENUE
GANSEVOORT HOTEL PARK AVENUE
245 10th Avenue
459 WEST 18th STREET 459 West 18th Street
THE STANDARD HOTEL 848 Washington Street
GANSEVOORT HOTEL MEATPACKING 18 9th Avenue
New York /
420 Park Avenue South
SEPTEMBER 11 MEMORIAL MUSEUM PAVILION Liberty Street
BERKLEE COLLEGE OF MUSIC RESIDENCE HALL 168 Massachusetts Avenue
33 HARRY AGGANIS WAY - BOSTON UNIVERSITY 33 Harry Agganis Way
45 PROVINCE 45 Province Street
Boston /
Selected Work /
45 Province Boston, MA
CHALLENGE
How do you sequence the installation of separate rainscreen and curtain-wall envelope systems, without compromising the structural integrity or weatherproofing for the entire façade?
SOLUTION
The design and fabrication processes were closely coordinated by Island to allow for the integration of multiple cladding systems, while ensuring that materials from different manufacturers fit within the [necessarily] tight building tolerances. Island fabricators’ knowledge of and involvement in the design of each component from the beginning enabled the team to develop a custom component that would allow for the panels to remain unfixed yet impermeable to outside moisture.
View from street condition.
45 PROVINCE Boston / MA OVERVIEW
LOCATION /
The façade for 45 Province demanded a type of accuracy that was not common to all panelized systems. The design called for long vertical strips of curtain wall, broken by similar pre-engineered rainscreen panels, which would have to be installed separately. The Boston high-rise tower is clad with German Terra Cotta tiles which were carefully coordinated and designed to fit seamlessly between the long, narrow slices of curtain wall. The extended panel length allowed for a 9-foot ceiling inside of the project’s luxurious, loft-style condos.
Boston, MA
BUILDING SYSTEM The installation of this system was atypical in that the outboard insulated rainscreens were made much longer and narrower than usual. This condition necessitated careful calculation as to how much load could be supported by the slabs, considering they would carry the full weight of the panels. In order to lock the panels into place the system relies on steel alignment pins, which also helps to strengthen its resistance against any lateral loads. Lighter framed extrusions were designed at the perimeters of the panels leaving narrow slits for the curtain wall to later occupy.
PHASE / Completed 2009 ENVELOPE SYSTEM / Outboard-Insulated Rainscreen MATERIAL SYSTEM / Terra Cotta ARCHITECT / Bruner/Cott Architects & Planners BUILDER / Suffolk Construction
Assembly-line panel fabrication.
Intersection at panel joint.
Vertically hung panel installation.
Selected Work /
HIGHLINE 23 New York, NY
CHALLENGE
How do you fabricate panelized cladding for a project with a unique geometry, while preserving the architect’s vision for an iconic building on a highly public site?
SOLUTION
In order to adapt a typical unitized cladding system to the complex façade geometries, cross-channel communication and extensive 3D modeling were necessary in order to execute the construction process. Enlisting multiple manufacturers and suppliers required an integrated panel design and fabrication approach so that they could be properly fabricated and installed on site.
VIEW FROM View of the stamped metalSTREET panels.
HIGHLINE 23 New York / NY OVERVIEW
LOCATION /
The Highline 23 is a residential project that sits adjacent to the popular Highline walkway in New York City, a highly trafficked pedestrian thoroughfare. Its stainless steel punched cladding system is paired with two curtain wall facades which adds to the unique aesthetic and high visibility of the project. The prolific character of the project also became its most challenging design parameter. The building demanded a well-executed finished product, as its undulating metal skin and window-walls coupled with its prime location along the Highline would serve as a main attraction for building enthusiasts and city-goers alike.
New York, NY
BUILDING SYSTEM
Metal Panel
The project’s technical and logistical complexities, required an integrated approach to designing and fabricating panels so as to ensure their proper delivery and installation. Coordination had to occur during the fabrication process, but also had to remain flexible during the installation of the unitized panels. The metal panels were additionally sealed after adjusting their placement, creating a watertight skin on the Highline elevation, while the curtain walls were installed on its adjacencies. Island used alignment pins to not only lock the panels into their correct locations, but also to resist any lateral forces that would act upon them. This system allowed for on-site adjustments and allowed for the flexibility required to construct the panelized façade for project.
ARCHITECT /
PHASE / Completed 2011 ENVELOPE SYSTEM / Outboard-insulated Rainscreen +Curtain Wall MATERIAL SYSTEM /
NMDA BUILDER / T.G. Nickel
Curtainwall panel installation.
1:1 Performance mock-up.
Stamped metal panel installation.
Selected Work /
MERCEDES HOUSE New York, NY
CHALLENGE
How do you deliver a panelized faรงade that allows for the realization of specific intended aesthetics, but is also an effectively sealed and efficiently installed building envelope?
SOLUTION
By working intensively with manufacturers, Island created a custom die that would integrate with the framing system of our panels. This allowed for increased adaptability while ensuring that the frame, weatherproofing, and aggregation strategies would continue to function as designed.
INTERSECTION OF PANELIZED ANDcourtesy CURTAINWALL Photography of JulesFACADES Antonio.
MERCEDES HOUSE (CLINTON PARK) New York / NY OVERVIEW
LOCATION /
The Mercedes House offered the unique challenge of matching the aesthetic and architectural language created by Ten Arquitectos, while maintaining a building system that could be easily produced and systematically delivered. A driving factor in the design of the envelope was the client’s desire to conceal the window frames, allowing the façade to appear as an uncut sheet of glass resting behind a terra cotta rainscreen.
New York, NY
Additionally, the project featured a compilation of elements which contributed to the complexity and execution of typical a panelized façade system. The project is designed as a residential tower, but also incorporates a public showroom and machine shop for Mercedes Benz that are contained within a three-story plinth alongside the building’s street front.
PHASE / Completed 2011 TYPE / Residential ENVELOPE SYSTEM / Outboard-Insulated Rainscreen MATERIAL SYSTEM /
BUILDING SYSTEM
Metal Panel
This was the pilot project for Island’s newly developed V-1 Extrusion Panel Framing System. This system allows the typical outboard-insulated unitized façade to aggregate on site, while creating an immediate watertight four-way intersection at the panel joints. This negates the need for additional caulking on the façade, helping to streamline the erection process for the Mercedes House.
ARCHITECT /
The unitized façade is disguised though the addition of perforated metal screens at the exterior PTEC systems, which are engineered to provide optimum airflow to each unit. By working with the window manufacturer, Island’s engineers were able to create an unusually narrow panel frame to window mullion extrusion, granting further freedom to the designers during the placement of the joints.
TEN Arquitectos BUILDER / Two Trees Builder
Individual panel alignment.
Assembly-line panel fabrication.
Floor-by-floor installation.
Selected Work /
INTERNAL CURTAINWALL
VIA VERDE New York, NY
CHALLENGE
How do you design for and fabricate a unitized facade system that incorporates multiple features added on to the standard wall and window panel assemblies?
SOLUTION
In its overall complexity, the design for the facade at Via Verde presented a challenge and also an opportunity for Island to demonstrate the benefits and facility of on-site fabrication when it comes to streamlining increasingly complex projects. The sunshades and balconies protruding from the face of building were integrated into the design of the unitized panel assemblies themselves, removing the task of having to separately add these features later on, and simplifying the install schedule.
PANELIZED FACADE ELEVATION Photography courtesy of Jules Antonio.
VIA VERDE Bronx / NY OVERVIEW The design of the facade for the Via Verde housing project located in the South Bronx, was unique in that the exterior wall system incorporated features which, had they been constructed by traditional methods, would have significantly increased the time it took to complete the project from start to finish. As a new model for public housing, the architects’ aims were not only complete the project as quickly and economically as possible but to also employ smart-building strategies where the costs and time saved for the client could be reallocated towards other civic and community rebuilding initiatives. BUILDING SYSTEM The facade designed for the Via Verde project features aluminum, cement, and wood panels with panoramic windows, sunshades, and courtyard balconies. The concept, inspired by the integration of nature and the city, carries through not only the organizing plan of the architecture in its tiered series of green roofs and dynamic gardens, but also in its manufacture. The facade system features an outboard insulated rain screen integrating 3 types of rainscreen cladding--extruded fiber cement, phenolic wood and composite aluminum. In addition to the cladding types, the facade also integrates punched window assemblies with the balcony and sunshade features. In using a customized gasketed joinery the project also features a caulkless interface at all panel-to-panel joints.
LOCATION / Bronx, NY PHASE / Completed 2012 TYPE / Residential ENVELOPE SYSTEM / Outboard-Insulated Unitized Metal Panels MATERIAL SYSTEM / Cementitious ARCHITECT / Grimshaw/Dattner BUILDER / Lettire Construction
Main project elevation.
Cruciform panel intersection.
Post panel installation.
Selected Work /
VIEW FROM STREET
NJIT Newark, NJ
CHALLENGE
How do you deliver six enclosed building projects within a period of three months, adhering to an aggressive build schedule?
SOLUTION
Through Island’s method of project delivery, fabrication and installation of assemblies were able to take place simultaneously eliminating the waiting period in between manufacture and construction. The wall assemblies themselves were dualpurposely designed to function as both the superstructure and finish avoided turning to traditional construction methods for project delivery.
FROM STREET View from VIEW the street condition.
NJIT Newark / NJ OVERVIEW
LOCATION /
NJIT will be a 3-acre mixed-use residential housing complex that will include computer labs, project studios, a library, student lounges, student government offices and guest houses. Island implemented a scope package defining a “modular” approach to construction seeing that all major components are fabricated off-site in order to meet the fasttrack project schedule. When completed, the 214,000 square foot complex will add 600 beds to NJIT’s existing inventory of residential housing.
Newark, NJ
BUILDING SYSTEM
ENVELOPE SYSTEM /
Island’s scope of work for the project includes the design, fabrication and installation of all buildings enclosures, which will feature load-bearing interior and exterior panelized wall systems. The envelope systems are outboard-insulated and utilize multiple materials--brick, cast-stone, and aluminum composite. Island’s responsibilities also extended to manage the sourcing and installation of the precast stairs and planks, and fabrication of the structural shear wall systems throughout the buildings.
Outboard-Insulated Panelized Veneer
PHASE / Active TYPE / Academic/Residential
MATERIAL SYSTEM / Brick, Cast-stone, Composite Panels ARCHITECT / Agnew Rincon Architects BUILDER / Hunter Roberts Construction
Panel intersection at window.
Horizontal panel transportation.
On-site installation.
Completed Work /
STEPHEN GAYNOR SCHOOL Completed 2007 / New York, NY / Rogers Marvel Architects / Turner Construction / Outboard Insulated Rainscreen / Metal Panel /
BARCLAYS CENTER Completed 2012 / New York, NY / Shop Architects / Hunt Construction / Outboard Insulated Rainscreen / Metal Panel /
BOSTON UNIVERSITY Completed 2009 / Boston, MA / Cannon Design / Walsh Bros. Inc. / Outboard Insulated Rainscreen / Terra Cotta /
C.E.W.I.T. Completed 2009 / Stony Brook, NY / Mitchell/Giurgola Architects LLP / J. Kokolakis Construction Inc. / Outboard Insulated Rainscreen / Metal Panel /
80 DEKALB Completed 2009 / Brooklyn, NY / Kondylis Architecture / The J Companies / Outboard Insulated Rainscreen / Metal Panel /
ROSE CENTER | HAYDEN PLANETARIUM Completed 2000 / New York, NY / Polshek Partnership / Morse Diesel / Outboard Insulated Rainscreen / Metal Panel /
NATIONAL SEPTEMBER 11 MEMORIAL Completed 2011 / New York, NY / Snohetta / Lend Lease / Outboard Insulated Rainscreen / Metal Panel /
GANSEVOORT HOTEL Completed 2004 / New York, NY / Steven B. Jacobs Group / Levine Builders / Outboard Insulated Rainscreen / Metal Panel /
GANSEVOORT PARK AVENUE Completed 2011 / New York, NY / Stephen B. Jacobs Group / Levine Builders / Outboard Insulated Rainscreen / Metal Panel /
BROOKLYN RENAISSANCE Completed 2007 / New York, NY / William B. Tabler Architects / The Muss Organization / Outboard Insulated Rainscreen / EIFS /
New Considerations /
MODULAR UNITS + BATHROOM PODS.
BENEFITS OF PREP-FABRICATION AND MODULAR CONSTRUCTION / / : Grid system regularized for layout flexibility and manufacturing simplicity. :
Corner modules regularized on common grid system.
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Module layout altered to allow for ADA clearances.
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Wall thickness increased to allow for MEP clearances and increased acoustical separation.
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Independent brace frame in typical in modular construction is replaced with an integral brace frame.
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Integral brace frame does not increase wall thickness.
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Elevator shaft and stairwells fit within the modular system.
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Balconies preserved.
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Module risers connect vertically.
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Tighter installation tolerances are available through factory QA/QC procedures.
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Optimal project production volumes based on increased factory labor productivity rates.
HIGH-END FINISHES BUILT WITH FACTORY QUALITY / / : Mateline positioned to reduce labor intensive work (tile, drywall). : Ship loose pieces to arrive with module, pre-cut and with minor tools needed. : Mateline components double as access for MEP field connections. : Interior millwork, finishes, and fixtures designed to ship fully installed, eliminating additional needs.
MEP SYSTEMS OPTIMIZED FOR MODULAR CONSTRUCTION / / : Installation of module MEP systems in factory maximizes cost savings. : PTAC heating and cooling system. : Tenant comfort enhanced with pressurized hallways. : Low-maintenance and unit-efficiency increased through direct venting of each unit. : Mechanical louvers and outlets integrated into both the facade and the structure.
Bathroom pod, within overall module unit.
Module fabrication process.
MODULAR TOWER
TYPE 4 TYPE 5 TYPE 6
19 FLOOR 17,18 FLOORS
TYPE 3 TYPE 1 TYPE 2
15,16 FLOORS
2-14 FLOORS
Diagrammatic module aggregation.
On-site installation diagram.
87 DIKEMAN In Progress / Brooklyn, NY / SHoP Architects / SCIFAB / Modular Unit Construction /
Structural analysis + diagram.
Systems analysis + diagram.
Our Clients / / Success in our business is built on genuine collaboration. From architects to builders our projects are only as strong as our partnerships.
Hunt Construction Brennan Beer Gorman
Perini Construction
Apollo Realty Goshow Architects
Polshek Partnership
Blumenfeld Development Group Della Valle Bernheimer
Richard Meier & Partners
Cannon Design HKS Architects
SHoP Architects PC
Capstone Development Aurora Contractors
SLCE Architects
CGS Developers E.W. Howell
Stephen B. Jacobs Group
Chatham Builders Two Trees Builder
Structure Tone
CM & Associates TEK
Suffolk Construction
Colony Capital TEN Arquitectos
Tanger
Goldman Sachs T.G. Nickel
The Dermot Group
H. Thomas O’Hara Perkins Eastman Architects
The Mills Group
Lend Lease J. Kokolakis Construction, Inc.
The Muss Group
Morse Diesel Snohetta
Walsh Brothers
Pavarini Construction A. Pappahohn Co.
Whiting Turner
Pavarini McGovern Lend Lease
Joseph Jingoli & Son, Inc.