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 | Aug 22, 2023
2023 Giants 400 Report: Ranking the nation's largest architecture, engineering, and construction firms
A record 552 AEC firms submitted data for BD+C's 2023 Giants 400 Report. The final report includes 137 rankings across 25 building sectors and specialty categories.
Giants 400 | Aug 22, 2023
Top 175 Architecture Firms for 2023
Gensler, HKS, Perkins&Will, Corgan, and Perkins Eastman top the rankings of the nation's largest architecture firms for nonresidential building and multifamily housing work, as reported in Building Design+Construction's 2023 Giants 400 Report.
Higher Education | Aug 22, 2023
How boldly uniting divergent disciplines boosts students’ career viability
CannonDesign's Charles Smith and Patricia Bou argue that spaces designed for interdisciplinary learning will help fuel a strong, resilient generation of students in an ever-changing economy.
Apartments | Aug 22, 2023
Key takeaways from RCLCO's 2023 apartment renter preferences study
Gregg Logan, Managing Director of real estate consulting firm RCLCO, reveals the highlights of RCLCO's new research study, “2023 Rental Consumer Preferences Report.” Logan speaks with BD+C's Robert Cassidy.
Shopping Centers | Aug 22, 2023
The mall of the future
There are three critical aspects of mall design that, through evolution, have proven to be instrumental in the staying power of a retail destination: parking, planning, and customer experience. This are crucial to the mall of the future.
Affordable Housing | Aug 21, 2023
Essential housing: What’s in a name?
For many in our communities, rising rents and increased demand for housing means they are only one paycheck away from being unhoused. It’s time to stop thinking of affordable housing as a handout and start calling it what it is: Essential Housing.
Healthcare Facilities | Aug 21, 2023
Sutter Health’s new surgical care center finishes three months early, $3 million under budget
Sutter Health’s Samaritan Court Ambulatory Care and Surgery Center (Samaritan Court), a three-story, 69,000 sf medical office building, was recently completed three months early and $3 million under budget, according to general contractor Skanska.
Healthcare Facilities | Aug 18, 2023
Psychiatric hospital to feature biophilic elements, aim for net-zero energy
A new 521,000 sf, 350-bed behavioral health hospital in Lakewood, Wash., a Tacoma suburb, will serve forensic patients who enter care through the criminal court system, freeing other areas of campus to serve civil patients. The facility at Western State Hospital, to be designed by HOK, will promote a holistic approach to rehabilitation as part of the state’s vision for transforming behavioral health.
Vertical Transportation | Aug 17, 2023
Latest version of elevator safety code has more than 100 changes
A new version of ASME A17.1/CSA B44, a safety code for elevators, escalators, and related equipment developed by the American Society of Mechanical Engineers, will be released next month.
Adaptive Reuse | Aug 16, 2023
One of New York’s largest office-to-residential conversions kicks off soon
One of New York City’s largest office-to-residential conversions will soon be underway in lower Manhattan. 55 Broad Street, which served as the headquarters for Goldman Sachs from 1967 until 1983, will be reborn as a residence with 571 market rate apartments. The 30-story building will offer a wealth of amenities including a private club, wellness and fitness activities.
