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
| May 16, 2014
BoA, USGBC to offer $25,000 grants for green affordable housing projects
The Affordable Green Neighborhoods Grant Program will offer 14 grants to developers of affordable housing in North America who are committed to building sustainable communities through the LEED for Neighborhood Development program.
| May 16, 2014
HED expands leadership in San Diego
Neville Willsmore, Thomas Christian join leadership team for Harley Ellis Devereaux.
| May 16, 2014
Toyo Ito leads petition to scrap Zaha Hadid's 2020 Olympic Stadium project
Ito and other Japanese architects cite excessive costs, massive size, and the project's potentially negative impact on surrounding public spaces as reasons for nixing Hadid's plan.
| May 15, 2014
Paints, coatings, and sealants: 10 new ways to seal the deal
Color-shifting finishes, dry-erase surfaces, and stain-blocking paints are highlighted in this round up of new offerings in paints, coatings, sealants, and finishes.
| May 15, 2014
Biking to work up by 60 percent, according to Census Bureau report
Many U.S. cities are seeing an increase in bicycle commuters, according to new a U.S. Census Bureau report. While bicyclists still account for just 0.6% of all commuters, some of the nation's largest cities have more than doubled their rates since 2000.
| May 15, 2014
'Virtually indestructible': Utah architect applies thin-shell dome concept for safer schools
At $94 a square foot and "virtually indestructible," some school districts in Utah are opting to build concrete dome schools in lieu of traditional structures.
| May 15, 2014
First look: 9/11 Memorial Museum opens to first-responders, survivors, 9/11 families [slideshow]
The 110,000-sf museum is filled with monumental artifacts from the tragedy and exhibits that honor the lives of every victim of the 2001 and 1993 attacks.
| May 14, 2014
New study shows employees aren't happier working in green buildings
People working in buildings certified under LEED’s green building standard appear no more satisfied with their workplace environments than those in conventional buildings, according to new research from the University of California, Berkeley, and the University of Nottingham.
| May 14, 2014
Construction growth looking up: Gilbane Spring 2014 Economic Report
Construction spending for 2014 should finish 6.6% higher than in 2013, with nonresidential work contributing substantially.
| May 14, 2014
Prefab payback: Mortenson quantifies cost and schedule savings from prefabrication techniques
Value-based cost-benefit analysis of prefab approaches on the firm's 360-bed Exempla Saint Joseph Heritage Project shows significant savings for the Building Team.
