Tapestry on the Hudson, a repurposed historic 6.5‐story building constructed in 1899, converted into 67 multi‐family, mixed income, residential apartments
In the design plans, of the $22.2 million Tapestry on the Hudson preservation and restoration project of the old 6.5‐story “Mooradian Building” in the City of Troy, was the construction of a new elevated green space deck and playground. The elevated deck preserved valuable parking spaces for the building’s residents as well as providing a beautiful view of the Hudson river.
Due to the over budget original steel deck design, Oldcastle Infrastructure of Selkirk, N.Y. was selected to manufacture precast concrete components to compose the elevated deck. Working closely with the architect, engineer and general contractor, Oldcastle Infrastructure developed a turnkey, precast solution that provided many benefits. The use of precast reduced costs, saved time, and lowered future maintenance requirements compared to exposed steel.
Their precast design had to overcome various challenges such as working around existing underground sewer structures and a sloping grade that impeded headroom below, the top of deck elevation was fixed by the handicap ramp maximum slope from the existing building and tight access for the trucks and a crane. In addition to a limited budget.
To provide the deck superstructure, Oldcastle Infrastructure’s scope included the manufacturing and installation of precast‐prestressed beams, precast columns, prestressed composite IT and L‐beams (several with cantilever on one end towards the river), precast spandrels with moment frame connections, elematic precast hollow‐core slabs, precast stairs and landings and precast walls.
It took Oldcastle Infrastructure field operations only five days to erect the deck superstructure.
Tapestry on the Hudson, a repurposed historic 6.5‐story building constructed in 1899, was converted into 67 multi‐family, mixed income, residential apartments. Additionally, the transformation included the restoration of a concrete seawall, construction of an elevated green space deck, new vertical transportation systems, repairs to the building structure, upgrades to the building envelope systems, solar and other green infrastructure investments while preserving the historic features throughout the building.
Project Name: Tapestry on the Hudson
Location: Troy, NY (along east bank of the Hudson River)
Owner: Community Builders Inc.
Architect: Dave Sadowski – Community Builders Inc.
Engineer‐of‐Record: The Chazen Companies
Contractor: UW Marx Construction – Troy, NY
Precast Producer: Oldcastle Infrastructure – New York
About Oldcastle Infrastructure
Oldcastle Infrastructure is the clear choice for building products and services for North American infrastructure projects. We are a leading provider of engineered product solutions nationwide to a number of market sectors including: Water, Communications, Energy, and Transportation.
www.oldcastleinfrastructure.com
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Adventure Aquarium in Camden, NJ uses EASI‐SPAN building for new Penguin Habitat. The panels have ThermoMass R‐10 insulation in the walls and R‐32.5 insulation in the roof. The Penguin’s will be happy to have a new home!
About Oldcastle Infrastructure
Oldcastle Infrastructure is the clear choice for building products and services for North American infrastructure projects. We are a leading provider of engineered product solutions nationwide to a number of market sectors including: Water, Communications, Energy, and Transportation.
www.oldcastleinfrastructure.com
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Using precast concrete custom made wall panels and hollow core plank, Oldcastle Infrastructure Newnan, Ga., working in conjunction with CNS Communications, LLC, constructed the newly upgraded emergency generator runway light control building at Buffalo’s International airport.
Owner of Buffalo International Airport, the Federal Aviation Administration contracted CNS Communications, LLC to provide an upgraded FAA Approach Lighting Systems (ALS) generator building for one of the gates at the airport.
After review, the owner and CNS Communications selected a precast wall panel system as the best option for the airport location and awarded the precast contract to Oldcastle Infrastructure of Newnan, Ga. (Project Leader), Easton, Pa. and Selkirk, NY to design, engineer, produce and outfit the new ALS building.
After manufacturing the custom precast wall panels, the 32‐foot by 44‐foot (ALS) generator building was constructed by erecting and connecting each 6‐inch thick, insulated, precast wall panel, including interior concrete partition wall for the different sectors which included electrical controls, workshop and generator room. The building’s final exterior dimensions were 44’0” Long x 32’0” Wide x 11’11” High.
To enclose the roof, 8‐inch thick, precast concrete hollow core plank was specified, making the building a very durable, safe and secure structure for the airport.
In addition to the precast products, Oldcastle Infrastructure outfitted the building with all interior wall, floor and ceiling finishes as well as doors and openings, HVAC/Environmental systems, exhaust / intake air system, lighting, and alarms.
Vice President – Regional General Manager Gene Drake, P.E. stated, “We took a lot of pride in this project because it demonstrated the cooperation, reach and varied core competencies of several Oldcastle Infrastructure units. While our Newnan, GA, plant was the project leader, our Easton, Pa., plant made the wall panels, our Building Systems Division plant in New York made the roof panels and the construction management was handled by our Modular Group. Four units from four different states pulled together to complete one outstanding project which demonstrated a degree of expertise and coordination that not many companies could offer.”
About Oldcastle Infrastructure
Oldcastle Infrastructure is the clear choice for building products and services for North American infrastructure projects. We are a leading provider of engineered product solutions nationwide to a number of market sectors including Building, Water, Communications, Energy, and Transportation.
www.oldcastleinfrastructure.com
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After several years of diligent determination, Cape May County will finally get the new correctional center they have been waiting for and will be utilizing prefabricated jail cells to do it.
Contracted by General Contractor Hall Construction Co., Oldcastle Infrastructure Modular Group of Telford, Pa. is designing, engineering, manufacturing and fully‐outfitting the precast concrete rear chase cell and dormitory style cell modules that will house approximately 320 inmates in the new $37.3‐million correctional center.
Facilities Director AnnMarie McMahon stated in the Cape May County Herald, “the use of modular units will help with quality control and the schedule to construct the facility. They are factory constructed and delivered to the site, so before we know it, there will be significant progress once we begin. The modular units get delivered with plumbing fixtures and interior fixtures already in place so it’s just a matter of stacking them and constructing around them.”
“This significantly saves in on‐site construction time. And since they are constructed at a factory, there is more quality control. The strength of the concrete is almost double the strength of masonry construction,” McMahon added.
After producing the precast cell modules at their Telford, Pa. facility, Oldcastle Infrastructure Modular fully outfits the cells with all furnishings and system tie‐ins, including HVAC, plumbing, electrical, doors, frames, toilet, sink and bunk. In all, ninety‐six, 2‐inmate, precast concrete, rear‐chase cell modules and sixteen, 8‐man, dormitory style cell modules will be produced.
The rear chase configuration was chosen because it allows the maintenance personnel to have access to the mechanical systems without having to disrupt the prison population’s daily routines.
“After the jail cells are complete, they are shipped to the jobsite,” said Sandy Kester, Project Manager for Oldcastle Infrastructure Modular. “It takes under 10 minutes to make one cell secure as the crane rolls on to hoist another. That’s one reason construction can advance quickly.”
The 85,000‐square‐foot correctional center features housing for 320 inmates, a medical area that will be able to house inmates, in addition to a laundry facility which will enable the jail to do most of the laundry items for the Crest Haven Nursing and Rehabilitation Center and the animal shelter, reducing costs. The correctional center will also include a separate juvenile housing unit as an alternate bid package.
The start of the project on Crest Haven Road was Aug. 1, 2016. Target completion is scheduled for the beginning of August 2018.
Construction is being performed by Hall Construction Co. and Hill International is overseeing the project for the county.
About Oldcastle Infrastructure
Oldcastle Infrastructure is the clear choice for building products and services for North American infrastructure projects. We are a leading provider of engineered product solutions nationwide to a number of market sectors including: Water, Communications, Energy, and Transportation.
www.oldcastleinfrastructure.com
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At Calpine’s York 2 Energy Center in Peach Bottom Township, Pa., a precast concrete restroom from Easi‐Set Buildings was the preferred building solution. The restroom—manufactured and installed by Easi‐Set Buildings licensed producer Oldcastle Infrastructure, Easton, Pa.—provides superior R‐values and explosion‐proof qualities to keep workers safe, if an accident ever occurs at the facility.
The 28‐megawatt center is a dual‐fueled, combined‐cycle electric generating facility. Using clean‐burning natural gas, the combustion turbines were also designed to run on ultra‐low‐sulfur diesel fuel oil when necessary. The project began commercial operation this year to provide additional reliable power to the region.
The restroom is a single unisex ADA‐compliant building, measuring 8’‐10” wide x 12’‐0” long x 9’‐4” high, with one toilet and one sink. The building has insulated reinforced concrete walls with a simulated split‐faced block external appearance. The walls were manufactured by Oldcastle Infrastructure to be 8” thick having a 5,000‐psi strength at 28 days. That equates to a R‐13 value for the walls and R‐19.5 for the roof. Stainless steel was selected for the toilet and sink. All electrical components are NEMA 4 rated. A crane from general contractor CB&I, Charlotte, N.C., was used to hoist the restroom into place within the structure. The install took just one day.
“Each Easi‐Set Buildings licensed producer offers customized precast concrete buildings for its customers because each project has such unique requirements,” says Moffette Tharpe, managing director of Easi‐Set Worldwide. “Licensed producers are production‐trained in their own facilities by Easi‐Set Buildings’ personnel to ensure that quality custom solutions are always the top priority.”
About Oldcastle Infrastructure
Oldcastle Infrastructure is the clear choice for building products and services for North American infrastructure projects. We are a leading provider of engineered product solutions nationwide to a number of market sectors including: Water, Communications, Energy, and Transportation.
www.oldcastleinfrastructure.com
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Considering the old jail is at least 100 years old, Sullivan County knew years ago, it was essential to build a new, more modernized facility. Subsequently, after talking about it for decades, the Sullivan County lawmakers gave the approval to move forward with construction of a new jail.
“We’re going from an 18th century to a 21st century correctional center,” said Sullivan County Undersheriff Eric Chaboty. “We skipped the 20th century. We researched so many other jails across the state, and we adopted the ideas that worked.” (Excerpt from recordonline.com – Times Herald‐Record)
Plans called for a jail of more than 155,000 square feet, with 256 single cells and more than 300 beds, at a new location just outside Monticello on Old Route 17. The new $79 million jail in Sullivan County, New York consists of a new two‐story, 300‐bed correctional facility featuring 70 sq. ft. and 100 sq. ft. precast concrete, front chase cells with integral precast concrete bunks.
Contracted to supply the prefabricated concrete cells for the six housing units, Oldcastle Infrastructure manufactured the front‐chase cells at their Oldcastle Infrastructure Telford, Pa. precast plant and shipped them to the job‐site. A total of 164 precast cells, measuring 70 square‐feet, and 92 precast cells, measuring 100 square‐feet, were manufactured for the new jail.
Built in the factory, the modular precast concrete units were outfitted with all furnishings and system tie‐ins, including HVAC, plumbing and electrical fixtures, doors, windows and frames. Because modular units are built in a controlled environment, issues such as weather and temperature don’t hamper the construction process as compared to CMU or steel. As the job site was prepared, precast cell modules were delivered to the job site in Monticello, NY, as needed, for immediate erection. The expedited product delivery and fast erection of the precast cells shortened construction timelines.
The Sullivan County Sheriff’s Office Complex, which includes the new jail, started last October and is currently on time and within budget. The complex is being designed to allow for future expansion and more efficient operations. It will house not only the jail, but also the civil, patrol and administrative divisions.
If construction continues on schedule, the project is expected to be completed by September 2018.
Design Consultants: Mark Kukuvka, of LaBella Associates
General Contractor: The Pike Company, Rochester NY
Engineer: Pennoni
About Oldcastle Infrastructure
Oldcastle Infrastructure is the clear choice for building products and services for North American infrastructure projects. We are a leading provider of engineered product solutions nationwide to a number of market sectors including: Water, Communications, Energy, and Transportation.
www.oldcastleinfrastructure.com
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On January 10, 2017, John Jones, Oldcastle, Inc. Executive Vice President and LEED Green Associate, accepted the 2016 National Association of Home Builders (NAHB) Pillars of Industry Award for Best Green Building Concepts on behalf of Blue Sea Development Company for Prospect Plaza Site 1, located in Brooklyn, New York.
Oldcastle Infrastructure Building Systems and Blue Sea Development Company are honored to be the recipient of this prestigious award.
“This year’s competition for Best in Green Awards was truly impressive, with more entries than ever before,” said NAHB Chairman Ed Brady, a home builder and developer in Bloomington, Ill. “The winners represent the best of the best in environmentally friendly building, development, and remodeling, showcasing the latest in high‐performance building practices and sustainable living.”
Oldcastle Infrastructure Building Systems provided the precast concrete building system which includes hollowcore and prestressed concrete slabs, precast concrete beams, interior and exterior wall panels, solid slabs, and precast stairs and landings used to construct a four story walk up, townhouse‐ style buildings, and a five‐and‐a‐half story elevator building. Additionally, they supplied a prefabricated composite metal panelized wall system for the exterior of the building which included shop installation of windows within the prefabricated system.
Moreover, Oldcastle Modular, certified as an off‐site fabricator by the New York City Department of Buildings, Office of Technical Certification, and Research (OTCR), supplied 117 modular, fully out‐fitted bathroom pods for the new housing facilities.
“We are excited and very proud to be a part of this award winning New York Community project and partnering again with Blue Sea Development Company who are committed to building green and sustainable communities and homes,” stated David Wan, Regional Manager of Engineering at Oldcastle Infrastructure Building Systems. “The benefits of using these modular technologies together accelerates the construction schedule, provides a safer job site, as well as providing a sustainable quality building.”
Prospect Plaza is comprised of 364 units with 80 units of NYCHA public housing, and included space for a new supermarket, a community facility, a rooftop greenhouse, and a new recreation area.
NAHB Prospect Plaza Site 1 – Best Example of Green Building Concepts – Winner
PROSPECT PLAZA SITE 1
Location: Brooklyn, N.Y.
Submitted By: Blue Sea Development Company
Developer: Oceanhill
Architect: Dattner Architects
Marketing Firm: Cornell Pace
About Oldcastle Infrastructure
Oldcastle Infrastructure is the clear choice for building products and services for North American Infrastructure projects. We are a leading provider of engineered product solutions nationwide to a number of market sectors including: Water, Communications, Energy, and Transportation
www.oldcastleinfrastructure.com/
Download Full Press Release
