News

New GFRC manufacturing facility for Building Blocks

New GFRC Manufacturing Facility

Kissimmee, FL – The new Building Blocks GFRC manufacturing facility is up and running. It is a 7-acre site near Orlando, Florida. The site is close to our Florida markets. It also supports easy shipping throughout the East Coast and the Midwest. The plant employs highly trained technicians in a team-based, continuous learning environment.

 

We use glass fiber reinforced concrete (GFRC) for new construction in four distinct applications: cladding, curtainwall, formwork, and unitized wall systems. Our unitized wall system combines GFRC cladding, Schüco windows, and ThermaFiber insulation into a complete prefabricated wall. This system provides a dry floor immediately upon installation. It also delivers superior performance throughout the life of a building.

 

Building Blocks is set to introduce a proprietary mix of GFRC to the market with the establishment of a new production facility. Preliminary tests show that the improved GFRC offers lower vapor permeability and less expansion than existing GFRC mixes. This reduces tolerance requirements and delivers an even higher performance facade material.

 

We continue to furnish terra cotta from Boston Valley Terra Cotta for both restoration and new construction projects.

 

Chicago skyline in black and white

Jimmy Lee Joins the Team

Jimmy Lee

Jimmy Lee

Chief Operating Officer

Kissimmee, FL – Jimmy Lee joins the Building Blocks team as Chief Operating Officer. He is formerly the President of GFRC Cladding and Vice President of GFRC 360. Previously, he worked with Harmon Contract W.S.A and Curtain Wall Design and Consulting. Jimmy is over 30 years in the high rise cladding industry.

 

His expertise in prefabricated and unitized systems spans a variety of materials from precast, GFRC, and granite to metal panel systems. Jimmy is known for design wall systems that solve client challenges. He prizes effective design and the preservation of architectural aesthetic.

Adrian Smith + Gordon Gill logo

AIA Education at Smith + Gill

Chicago, IL – Building Blocks will deliver two continuing education programs at Adrian Smith + Gordon Gill this spring. The first focuses on the high-performance capabilities of glass fiber reinforced concrete (GFRC). It defines the manufacturing, system capabilities, and design. Similarly, the second session expands on GFRC fundamentals. It specifically covers recladding and overcladding projects.

 

Building Blocks is an American Institute of Architects (AIA) approved provider of continuing education. As a result, we give Lunch & Learn presentations for practicing architects. We teach sessions about GFRC and terra cotta. See more information about the AIA CEU courses we offer here.

Boston skyline in the evening

Facades+ Boston Conference

Boston, MA – Building Blocks will attend the Facades+ Boston conference next month. The one day program features a morning symposium and afternoon workshops. Industry leaders including Elkus Manfredi Architects, Walter P. Moore, and Thornton Tomasetti host these sessions. The conference is hosted by the Architect’s Newspaper.

 

Facades+ Boston

June 6, 2017

 

MIT Samberg Conference Center

50 Memorial Drive

Campbridge, MA 02142

Facades Plus Boston graphic
AIA education at SOM

AIA Education at SOM

Chicago, IL – Building Blocks will host a Lunch & Learn session at the Chicago offices of Skidmore, Owings & Merrill next week. The session focuses on the high-performance capabilities of glass fiber reinforced concrete (GFRC). It defines the manufacturing, system capabilities, and design. The session also illustrates the value of GFRC for complex facade skins. Similarly, it discusses the role of GFRC in facade innovation. We look at some of today’s best architecture and how it uses GFRC.

 

Building Blocks is an American Institute of Architects (AIA) approved provider of continuing education. As a result, we give Lunch & Learn presentations for practicing architects. We teach sessions about GFRC and terra cotta. See more information about the AIA CEU courses we offer here.

Design assist for glass fiber reinforced concrete GFRC facade on Versailles Contemporary building

Design Assist Interview with Architect Zack Cooley

Chicago, IL – Two years ago, Building Blocks worked with Brandon Haw Architecture in a design assist process for Versailles Contemporary. It is the final addition to the Faena District in Miami Beach. Zack Cooley was the technical design lead for the project. He previously worked at Diller Scofidio + Renfro. Brandon Haw formed Brandon Haw Architecture in 2014 after concluding a 26-year career at Foster & Partners.

 

Versailles Contemporary is an eighteen-story condominium. The high-rise is located between Roy France’s classic Versailles Hotel and the Faena House. It is the last parcel of the Faena District in the Collins Avenue Historic District of South Beach. The Faena District was developed by Alan Faena. Versailles Contemporary was “designed to create open space around the original landmarked Versailles structure,” to “maximize views of both the ocean and the western sunsets,” and to hold “a harmonious relationship with its historic and contemporary neighbors” according to Brandon Haw Architects.

 

The undulating white facade features rounded glazed corners and extensive cantilevered balconies that, “float above the ocean’s horizon.” These oversized, light-as-air balconies are a perfect design for glass fiber reinforced concrete (GFRC). Building Blocks was brought into the project for a design assist phase. Design assist helped the team at Brandon Haw Architecture maximize the design flexibility that GFRC added while managing constructability and cost.

 

Kevin Miske of Building Blocks recently sat down with Zack Cooley from Brandon Haw Architecture to recap the project, review the design assist methodology, and discuss the value of early subcontractor involvement to creating complex building skins.

 

Kevin: As the architect, what made you think that design assist for this project is going to be beneficial?

 

Zack: We go a certain distance in our drawings and then as we’re drawing through things and proposing things we develop lists of questions. We try to answer them ourselves but knowing what we don’t know is important in that process. So, for us to engage in design assist as quickly as possible we make the thing more real more quickly. Our knowledge of all systems and all details can be limited. Bringing in people who have years and years of experience on a certain system really helps our documents along.

 

Kevin: Have you worked in design assist with other subcontractors?

 

Zack: Yes, we have. My experience is that when the design assist is a bit more loose it tends to be less successful than the formal, intensive way that we engaged you. In fact, we’ve had subcontractors work in a form of design assist without charging anything. In hindsight, we should have put something on the table for their time because we didn’t get the full attention like we did your attention. Building Blocks stands out as a very successful working process for us.

 

Kevin: So, what do you think about doing this at-risk versus fee-based with a give back once it goes to contract?

 

Zack: I think your idea of a give back program…where we engage in the process and there’s a monthly fee, but it’s credited back if awarded the job, that would get over the hump on the ownership side. Being able to really quantify the savings for a client is difficult.

 

Kevin: There’s also secondary value beyond just the material cost.

 

Zack: Yeah. It benefits the design, too. More complexity doesn’t necessarily yield a better design. It was great with Alan because he’s gone through [design assist] on other projects so he understands the value. You have certain CMs and GCs that, until you go through it, you don’t really understand the value.

 

Kevin: On Versailles, the deliverable on the design assist process was allowing the design team to get to 100% CD. A knowledge transfer that allowed you to answer some of the questions you had at 100% DD, correct?

 

Zack: We’re always sprinting to draw. We’re producing and designing at the same time. So, if we know bringing somebody on board that: 1) is going to contribute the knowledge and get me from A to B more quickly, and 2) actually take part in the production, sharing details, helping develop details – that’s a win-win. As we reach the end of CD and DD we look for any way to get there quicker. It’s a no-brainer for us.

 

Kevin: Reflecting back on the design assist process for Versailles, what do you think worked really well and what do you think could have been done better?

 

Zack: The live work sessions were great; screen sharing, spinning around the model, drafting. There’s nothing better than a session where you discover problems and instead of saying, “Oh okay, we’ll walk away and address these problems and come back to it next week,” you have the tools out and draw through it right there in the meeting. It is a huge benefit for the project when you have people who are willing to play in the sandbox.

 

Kevin: Do you think there were any issues with us being remotely located?

 

Zack: Well, that was my thing that “could have been better.” If you’re in the same room it’s always better, but I’ve never worked on a project where everybody on the team is in the same city. It didn’t really matter because we could Skype.

 

Kevin: There is some benefit to being together. It’s something I would like to look at when we have our next design assist opportunity; to go to the architect’s office and work there with them. I think it’s a more focused effort.

 

Zack: It would be nice to somehow bake the physical mockup into the design assist process. We go through design assist, the drawings are finished, then there’s a big period where the GC is brought on board. Some way to seamlessly transition from design assist into a mockup where there isn’t this stopping point.

 

Kevin: The GC doesn’t have the benefit of everything we’ve been through, and then they are the one driving the mockup and it slows everything down.

 

Zack: It’s like starting from scratch a little bit.

 

Kevin: Because of that delay, especially like Versailles which was a very long delay, you start forgetting all the little pieces of knowledge that you earned during design assist.

 

Zack: You have to somehow convey all of that to the GC. They weren’t with you learning the lessons and you have to somehow bring them up to speed. On the Broad Museum in Los Angeles, which I worked on at Diller Scofido+Renfro, it was a bit earlier because the GC was decided early in the process. We entered design assist in DD, about the same time we did for Versailles. There wasn’t that re-education process. In fact, the mockup process was a bit more seamless because the GC did have the buy-in.

 

Kevin: With having the GC involved, we’re getting closer to an Integrated Project Delivery where the general contractor, the architect, and the engineer engage all of the critical subs that have dependencies on each other early enough that they help influence the design. For an IPD, you’d have to have a general contractor who is really leading that.

 

Zack: It’s a project-wide design assist, which is the ideal scenario.

 

Kevin: I can’t understand why our industry is so reluctant to take on more collaborative relationships. Design assist is really the precursor to getting to an IPD process. I hope that the industry continues to move in that direction.

 

Zack: For us, it’s all about the clients. We work for the clients. Sometimes we have clients who have gone through design assist before and they understand the value. They know they’ll save money and time. It’s all about expectations. Other times we work with clients who aren’t as familiar with design assist and think about it as a step by step process. They prefer to hire an architect, then pass it to the engineers, then to the contractors. They may be attracted to a more incremental process because they’re not committing to everything up front. If you have a client who prefers the a la carte process, it’s hard to convince them to do design assist. If you have a client or a third party adviser who has done it before, it’s much easier.

 

Kevin: Do you think it would be helpful to engage in technical design discussions earlier?

 

Zack: It depends on the project. If you understand what the broad strokes are and you know what the systems are early enough. Once those decisions are made, then the sooner the better. Even early DD if you have the systems finalized. Sometimes you don’t. For example, on Versailles we were talking about several options on the cladding, so it wouldn’t have been appropriate to start with you.

 

Kevin: On Versailles, it started off as precast, is that right?

 

Zack: We were entertaining precast seriously. Someone said it would be cheaper as precast and then we realized several weeks into it that that wasn’t the smartest path.

 

Kevin: So, do you think the outcome of improved cost, schedule, RFI’s, constructability, and quality were achieved with design assist over a design-bid-build process?

 

Zack: I mean, the cost was dead on. When we were going through those VE efforts, well after CDs were finished, it wasn’t really questioned. Everybody was comfortable with where we landed. Having that off the table whenever you’re dealing with so many other issues, to say that this issue is well resolved and we have a high degree of confidence in it is really beneficial. I think we nailed that. What do you mean by schedule?

 

Kevin: Getting to 100% CD faster.

 

Zack: Yeah, yeah. Well, that definitely, but also some of those details wouldn’t have been where they ended up. It definitely gets you there quicker.

 

Kevin and Zack agreed that by the end of the design assist process, Versailles was more comprehensive and ready to transition to the next stage than a project typically is at that point. A major factor was the design assist process. It was also thanks to Brandon Haw Architecture’s well detailed DD set. Most DD plans have only about 50% of the required information for accurate costing but theirs were more developed.

 

Design assist was responsible for keeping the costs of this project consistent from initial budget on February 23, 2015 until contract on April 16, 2016. Generally, when a project progresses from DD to CD, costs increase as more requirements and complexity are identified. Design assist subverted the norm by maintaining the same costs from one stage to the next. The design assist process requires a more collaborative relationship between architects and their contractors. The results are a more thorough, well considered design that is executed on a faster timeline.

 

Facade tectonics forum in Chicago

Facade Tectonics Forum in Chicago

Chicago, IL – Building Blocks will attend the Facade Tectonics Forum in Chicago next month. The morning event is in three distinct parts: the impact of fenestration on thermal performance, digital workflows, and wind effects on tall buildings. Sessions are led by professionals from Skidmore, Owings & Merrill, Thornton Tomasetti, Schüco, and Gensler. The forum is hosted by the Illinois Institute of Technology and the Facade Tectonics Institute.

 

Windy City Skins:

Building Facades Where The Hawk Wind Blows

May 23, 2017

 

IIT Herman Hall

3241 South Federal Street

Chicago, IL 60616

Facade Tectonics logo

Register here to attend.

Hogan challenges

Hogan Challenges from Mice and Fish

Evanston, IL – The O.T. Hogan Building is part of the Northwestern University campus. It is one of three buildings dedicated to the study of biological sciences. The building’s Brutalist architecture features an unusual four-leaf clover-like footprint. It was designed in the 1960’s by Walter Netsch during his tenure at Skidmore, Owings & Merrill. Furthermore, it is an excellent example of his Field Theory; rotating squares to create complex geometries. Limestone panels and aluminum window wall twists around the center.

 

Building Blocks is contracted to replace the exterior window walls of the sixth floor. This entire floor is greenhouse pods. As a result, the unique geometry of Hogan provides an engaging project. Furthermore, an unexpected challenge presented itself after the windows were selected and installation planning began. The unusual challenge has nothing to do with the building itself and has everything to do with what goes on inside it.

 

The biological sciences department house their mice and fish in the Hogan building. The breeding habits of these animals are sensitive to the vibrations and audio frequencies produced by window replacement. As a result, the installation schedule this summer was arranged to allow a work stop from 8:30 am to 10:00 am every day. This prevents the building improvements from disrupting the mice and fish or altering the results of scientific studies underway.

 

Chicago City Hall restoration

Chicago City Hall Restoration Begins

Chicago, IL – Building Blocks is working with IW&G  on the Chicago City Hall facade restoration. We will replace an estimated 600 pieces of terra cotta on the century-old building. Nearly half of the replacement pieces are for a band above the 11th-floor windows. Building Blocks previously worked on the separate but identical Cook County building a decade ago. Consequently, knowledge gained from the Cook County project will help the team stick to their aggressive schedule for the Chicago City Hall restoration.

 

Chicago City Hall and Cook County Building

New York skyline in the evening

Presentation at Facades+ New York City

 

New York, NY – Building Blocks will again speak at a Facades+ conference, this time in New York City. Kevin Miske, President of Building Blocks, joins Jared Della Valle of Alloy and Alberto Franceschet of Permasteelisa. They will discuss reclad planning processes and projects in a session titled, Overclad and Reclad in NYC: New Materials in Rehabilitation ProjectsThe Architects Newspaper hosts the Facades+ New York conference.

 

Facades+ New York City

April 6-7, 2017

 

Register here with our code for discounted admission.

Discount code: DDNYC17