Few colleges or universities have embraced prefabrication more wholeheartedly than Valparaiso (Ind.) University. The Lutheran-based institution completed a $27 million residence hall this past summer in which the structural elements were all precast. The modular bathroom pods were manufactured in and shipped from New Jersey.
“The primary motivation for prefab was an accelerated schedule,” says Andy Frank, Construction Executive with Mortenson Construction. Much of the structural and exterior work on the 85,000-sf building was completed before the start of winter, which was critical in an area prone to blinding snowfalls fed by nearby Lake Michigan.
Manufacturing precast flooring planks and exterior panels that mimic limestone and brick masonry in a climate-controlled plant saved two to three months on the construction schedule, says Frank. The modular bathroom units, made by AmeriPOD, Dayton, N.J., shaved another month off the construction timetable of the suite-style residence hall. The time savings enabled the building to be ready for the fall 2014 semester.
FGM Architects and Mortenson collaborated on the design-build project using 3D BIM modeling to deliver a Collegiate Gothic structure that blends in with the prevailing campus architectural style. One of the critical factors in the construction process was leaving wall openings large enough for the bathroom pods to be transported from a staging area at one end of each floor through the building to their final position. Workers rolled the bathroom units through each floor to a preformed depression, where they were lowered by jacks into place.
Frank attributes the success of the prefab approach in part to the type of project. “When you have a large number of users involved in programming the building”—such as an academic building shared by multiple departments—“you’re going to need a longer design process,” he says. Housing projects tend be more suitable for prefab because they usually have a limited number of stakeholders—in the Valparaiso project, primarily residential life officials and some students.
Related Stories
Giants 400 | Oct 6, 2017
Top 90 K-12 architecture firms
Stantec, DLR Group, and PBK top BD+C’s ranking of the nation’s largest K-12 sector architecture and AE firms, as reported in the 2017 Giants 300 Report.
Giants 400 | Oct 5, 2017
On wings of gold: Alternative financing schemes are propelling the high-flyin’ air terminals sector
The $4 billion renovation of New York City’s LaGuardia Airport is the first major U.S. aviation project delivered using a public-private partnership (P3) model.
Giants 400 | Oct 4, 2017
Top 40 airport construction firms
Hensel Phelps, Turner Construction Co., and Skanska USA top BD+C’s ranking of the nation’s largest airport sector contractors and construction management firms, as reported in the 2017 Giants 300 Report.
Giants 400 | Oct 3, 2017
Top 30 airport architecture firms
Jacobs, Corgan, and Gensler top BD+C’s ranking of the nation’s largest airport sector architecture and AE firms, as reported in the 2017 Giants 300 Report.
Multifamily Housing | Sep 27, 2017
Pickleball, anyone?
Two-and-a-half million Americans are playing the game with the funny name.
Architects | Sep 25, 2017
Blending past, present, and future at a research center
The four-part mission of a garden of scientific research helped drive the design for the Beijing New Material Research & Development Center.
Architects | Sep 22, 2017
Design giants merge: FKP joins CannonDesign
The deal strengthens CannonDesign’s pediatric healthcare expertise, establishes presence in Texas and Ohio.
40 Under 40 | Sep 22, 2017
Meet the 40 Under 40 Class of 2017
These AEC stars are making their mark in business, philanthropy, and in their communities.
40 Under 40 | Sep 21, 2017
Meet the 40 Under 40 Class of 2017
These AEC stars are making their mark in business, philanthropy, and in their communities.
Office Buildings | Sep 20, 2017
Five Stantec offices move into one Fifth Avenue location
The new location provides the firm with 40,000 sf of space.