Best of 2004-Hospitality

Gaylord Texan Resort & Convention Center
Submitted by: Centex Construction Co., Dallas
Location: Grapevine

Key Players:
Owner: Gaylord Entertainment, Nashville
General Construction: Centex Construction Co., Dallas
Architect: Hnedak Bobo Group Inc., Memphis
Civil Engineer: Carter & Burgess, Dallas
Structural Engineer: Uzun & Case, Atlanta
MEP Engineer: J&A Mechanical Inc., Grapevine

The Gaylord Texan Resort and Convention Center located on Lake Grapevine is just minutes from Dallas/Fort Worth International Airport. The project, which broke ground in March 2001 and debuted in April, includes a 1.3 million-sq.-ft. hotel with 1,511 rooms, a 786,000-sq.-ft. convention center, numerous restaurants and retail space.

The $515 million complex was designed with extensive stonework, themed landscaping and replicas of the Alamo and the San Antonio Riverwalk to illustrate the Lone Star state in every detail.

The project features three atriums totaling 4.5 acres of intricate glass-and-steel structures that represent the Riverwalk, the Hill Country and Palo Duro Canyon.

The Centex team had 26 months to transform 57 acres of former North Texas farm country into more than 2 million sq. ft. of resort space that included simulated rivers running through the air-conditioned, themed-atrium spaces.

Centex's immediate solution was to assemble a large team of preconstruction and operations experts to guide the life of the project. Early involvement during preconstruction proved invaluable.

The columns supporting the ballroom level are 33 ft. tall and include a large amount of reinforcing steel. Rather than placing concrete from the top of the form, the team placed the concrete from the bottom by attaching a pump-hose coupling directly to the bottom of the column form. A column-hung forming system was then utilized to place the ballroom concrete floor.

The ballroom level boasts 24-ft.-tall ceilings adorned with chandeliers and crown molding.

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Best of 2004-Renovation/Restoration
University of Texas Frank C. Erwin Jr. Special Events Center

Key Players:
Submitted by: Hensel Phelps Construction Co., Austin
Owner: The University of Texas System, Austin
General Contractor: Hensel Phelps Construction Co., Austin
Architect/Engineer: Heery International Inc., Atlanta

Hensel Phelps was the general contractor for about $38 million worth of improvements and renovations to the 17,725-seat Frank C. Erwin Jr. Special Events Center, originally built in 1977 to house basketball games for the University of Texas at Austin. Upgrades included meeting current fire and life-safety requirements.

The project was broken into two phases and was completed in March.

During stage one, new arena seating arrangements were provided to create a more exciting basketball environment by moving fans closer to the court. The courtside seating brings fans 7 ft. from the court as compared to the original 20 ft.

Concession stands, new restroom facilities and 28 luxury suites were constructed during stage two. The new skyboxes provide suite holders access to private wet bars, catering, an in-suite television, private restrooms and special parking accommodations.

Hensel Phelps had to demolish and relocate existing concourse concession stands and restroom facilities to make way for the 28 luxury skyboxes. The project featured several unusual design and construction techniques from the lavish, customized finishes in the suites to the various food service venues.

The project doubled the concession stand capacity and tripled restroom facilities. Hensel Phelps implemented a rigorous, job-specific quality control plan that included control of onsite construction, detailed mock-ups, offsite inspections, shop drawings and submittal reviews.

ADA and life-safety improvements included the addition of a new code-compliant fire alarm and sprinkler system. All exterior doors were replaced and the curtain wall removed and relocated outward to enlarge the main concourse. Additional exits were added from the arena floor including the east stair exit, which required a tunneling operation to occur inside the building.

Best of 2004-Public Building
Austin City Hall and Public Plaza
Submitted by: Hensel Phelps Construction Co., Austin
Location: Austin

Key Players:
Owner: City of Austin
General Contractor: Hensel Phelps Construction Co., Austin
Architect: Antoine Predock, Albuquerque
Associate Architect: Cotera + Reed, Austin
Structural Engineer: Datum Engineering Inc., Austin
MEP Engineer: ACR Engineering Inc., Austin

The city of Austin selected Hensel Phelps to build the new $33.3 million City Hall and Public Plaza overlooking Town Lake. The team of the fast-track project, which broke ground in January 2003, worked toward a Silver LEED certification.

Completion was set for November.

The tight site in the heart of downtown Austin required strict material controls and traffic planning.

Dominated by landscaping, the green building incorporates limestone, copper, glass, water and shaded areas. The terraces and limestone balances resemble the natural features of the Texas Hill Country and are prime locations for viewing the activities of the Public Plaza below.

The completed project will feature water that flows from the front steps of the building to splash over limestone rocks in the exterior plaza. There a limestone amphitheater and stage will host special events and cultural performances. Trellises of photovoltaic and copper mesh panels will shade spectators.

The team devised two exceptional construction innovations to save money without sacrificing quality or aesthetics.

The first was a copper roof system originally designed by Bill Zaner, who has patented a beautifully paneled roof with a built-in system to enable water to be captured and flow to the ground. Hensel Phelps worked with the supplier and subcontractor to devise a panel system that still retained the copper appearance but without the complex draining system, saving more than $1.5 million.

The second was the exterior skin. The original design called for a tiered system of limestone, beginning with 12-in.-thick blocks of limestone and stepping up by increments of four. The resulting weight of the limestone, large pieces and difficulty of cutting made the skin expensive.

Hensel Phelps devised a plan to cut the limestone into 4-in.-thick blocks and tiered concreted masonry units with the limestone blocks, retaining the same appearance of the original design but at a far less cost.

Best of 2004-Health Care
Round Rock Medical Center Cardiac Catheterization Lab/C-Section Suite
Submitted by: DPR Construction Inc., Austin
Location: Round Rock

Key Players:
Owner: St. David's HealthCare Partnership, a partnership between HCA, Nashville, and St. David's HealthCare System, Austin
General Contractor: DPR Construction Inc., Austin
Architect: Perkins & Will, Dallas
Civil Engineer: Baker-Aicklen & Associates Inc., Round Rock
Structural Engineer: L.A. Fuess Partners Inc., Dallas
MEP Engineer: Smith Seckman Reid Inc., Nashville

The $3.45 million project at the Round Rock Medical Center included the addition of a 5,000-sq.-ft. cardiac catheterization addition, 450-sq.-ft. caesarean section room expansion and the build-out of 29 medical/surgical patient rooms totaling 9,600 sq. ft. The project began in February 2003 and was completed the following February.

Construction took place alongside, above and within occupied hospital areas. Preserving a sterile environment through proper infection control procedures was of foremost importance.

DPR's infections disease control program, which incorporates traditional occupied hospital building procedures enhanced with practices developed in semiconductor cleanrooms, includes step-by-step processes for creating pretask plans, performing the work and documenting steps taken.

To ensure areas adjacent to construction remained clear of dust or debris, DPR utilized negative air machines to create a vacuum in the rooms under construction, ventilated contaminated air out of the building and used gauges to constantly monitor the rooms' air pressure. The project manager developed a custom alarm system that rang whenever there was a change in pressurization, allowing the team to make adjustments before there was any possibility of contaminated air entering occupied areas.

The new Cardiac Catheterization Lab portion of the project was built to replace a temporary unit on the hospital campus. The project manager had to pinpoint the exact day of turnover two months in advance so the hospital could arrange for no downtime.

DPR used three-week rolling schedules, updated daily, to carefully track field activities, ensuring work was complete and ready to pass inspection. The project was turned over to the hospital several days prior to the mobile unit being taken offsite.

Best of 2004-Sports/Entertainment
Texas A&M Bright Football Complex
Submitted by: SpawGlass, Houston
Location: College Station

Key Players:
Owner: Texas A&M University System, College Station
General Contractor: SpawGlass, Houston
Architect: O'Connell Robertson & Associates Inc., Austin
Structural/Civil Engineer: Jaster-Quintanilla LLP, Austin
MEP Engineer: O'Connell Robertson & Associates Inc., Austin

The 125,000-sq.-ft. Bright Football Complex at Texas A&M University was built next to Kyle Field, the largest stadium in the Big 12 Conference.

The largest facility of its kind in the nation, the $27 million Bright Complex houses a locker room, athletic training room, rehabilitation complex, meeting rooms, coaches' offices, players' lounge and academic area.

With 15,000 sq. ft. of space, the new athletic training room is more than four times larger than the previous facility. The Hagner Auditorium seats more than 250 teammates, coaches and staff.

On the second level, an entire 28,000-sq.-ft. area provides academic services such as computer facilities, quiet study areas and counseling sites. SpawGlass constructed a 50-station computer lab, study lounges and eight classrooms in the academic center.

A center core three-story concrete shaft wall is the focal point of the complex. The glass-like "Spatula Stui" finish applied to the concrete wall has the appearance of maroon and white marble. The main wall and stainless steel grand stairway were all constructed on the same radius to create a unified look. The main wall entrance has .75-in. solid wood paneling with a finish consistent throughout the facility.

Among the challenging aspects of the project were the arched windows and precast eyebrow arches that came in three pieces on a radius. Each window had to be individually measured and the glass custom cut.

The etched glass with A&M seal and 12th Man statue in the main entry were shipped from Canada and arrived broken. The new shipment, weighing 800 lbs., was a challenge to install. Lifts were taken apart and brought in for the installation 30 ft. above the ground floor.

Bow string trusses spanning 130 ft. over the lobby required constant supervision. Extensive MEP coordination with subcontractors was required.

The hydrotherapy pools are suspended over concrete columns with table tops. The pools' size and potential for damage prevented drying in the building, so walls had to be left out until the pools were installed.

Best of 2004-Multifamily Residential
Waterway Lofts
Submitted by: D.E. Harvey Builders Inc., Houston
Location: The Woodlands

Key Players:
Owner: Threshold Interests Ltd., Houston
Architect: Ziegler Cooper Architects, Houston
Structural Engineer: Hanes Whaley Associates Inc., Houston

Waterway Lofts is a 100,000-sq.-ft. six-story poured-in-place flat-slab building with a basement, lobby and pool. The exterior, featuring a Kawneer glass system and brick, envelopes 36 units of high-end residential lofts overlooking The Woodlands Waterway.

Interior finishes include marble, granite, wood floors and faux finished walls. The single-level underground garage provides parking for 72 cars.

Located one block from the Cynthia Woods Mitchell Pavilion and walking distance from The Woodlands Mall and a variety of restaurants, the project is the first multistory urban residential property on The Woodlands Waterway.

Because the project was primarily residential, D.E. Harvey's role progressed beyond the typical tasks associated with a general contractor. D.E. Harvey staff became somewhat of an owner's representative by acting as a liaison between the tenants and their consultants and the owner. Onsite staff and subcontractors worked with the tenants' contractors so that the move-in dates would progress efficiently.

Each unit of the project had to be customized. The customizations were made during all phases of construction, some coming into play after the building was substantially completed.

Due to the difficulty in the design of the brick building, D.E. Harvey went above already high standards of quality control, despite the cost by adding another consultant on the project that specialized in waterproofing. The onsite team provided mock-up models of several residences to ensure quality and efficiency in the actual construction process.

The project site was constricted and more than 300 yds. from the street. It was also surrounded by woodlands, and the only access to the site was via a utility easement. The two streets flanking the site and a nearby bridge were simultaneously under construction, and another residential project began across the street during the project, leaving the team only one way in and out of the jobsite.

Best of 2004-Airport
Continental Airlines Terminal E Interiors at George Bush Intercontinental Airport
Submitted by: SpawGlass, Houston
Location: Houston

Key Players:
Owner: Continental Airlines, Houston
General Contractor: SpawGlass, Houston
Architect: Corgan Associates Architects, Dallas
Structural Engineer: Scientech LLC, Houston
MEP Engineer: Carter & Burgess, Houston

Continental Airlines' new 23-gate, 661,000-sq.-ft. terminal at George Bush Intercontinental Airport helps define the airline's image. The SpawGlass team was responsible for style, comfort and efficiency factors during the 30-month, $17.5 million interiors construction project.

Features of the interiors package included architectural metal panels, precast stone veneer panels, drywall, paint, hardware, carpet, stairs, vinyl-composition tile, ceramic tile and concourse cluster seating. Also, all Federal Aviation Administration security hardware for gates was included.

The centerpiece of the terminal is the four-story "ellipse," which houses the Continental Airlines President's Cub. The space includes an atrium open from the concourse level to the roof with a panelized architectural perforated metal screen in front of storefront windows on each level and an exposed elliptical steel truss.

Every high wall in the massive space is covered by a custom fabricated acoustical panel to help absorb and control noise on the concourse and the third level. A patented outer coating provides the acoustical properties and also a more durable finish.

SpawGlass was responsible for the engineering, fabrication and installation of most of the stairs in the terminal. The stairs were fitted with ornamental handrails and a modular railing system with glass panels. The stringers were clad in brushed stainless steel, which was cut onsite.

Indirect lighting saves energy while providing uniform light. The flooring is epoxy terrazzo throughout the heavy traffic areas with carpet in waiting areas.

Terminal E more than doubled Continental's international gate capacity, making it ultimately capable of processing 4,000 passengers per hour. Almost every piece of equipment is linked to a building management system, which in turn is linked to an automated facility maintenance management system. The terminal is equipped with state-of-the-art plasma monitors displaying up-to-the-minute flight information. Another automated system in the terminal known as COBRA matches passengers and their luggage.

Best of 2004-Education K-12
Richardson High School-Additions and Renovation
Submitted by: Cadence McShane Corp., Dallas
Location: Richardson

Key Players:
Owner: Richardson Independent School District, Richardson
General Contractor: Cadence McShane Corp., Dallas
Architect: PBK Architects Inc., Dallas
Structural Engineer: R.L. Goodson, Dallas
Electrical Engineer: Basharkhah Engineering Inc., Fort Worth

Richardson ISD significantly improved Richardson High School. The project was funded via a bond and included an expansion of 114,000 sq. ft. and renovations totaling 285,000 sq. ft., integrating ninth-graders into the existing high school.

This "freshman programming" project includes new classrooms, science classrooms, a fine-arts department, new gymnasium, locker rooms and field house. A new culinary arts department, library, multimedia room, band room, black-box theater and renovated art rooms, administration parking and landscaping were also added.

Richardson ISD awarded the $23.2 million project to Cadence McShane Corp. in September 2002. The company immediately began making preparations to ensure a timely completion.

A major factor in planning considerations was how to intertwine on-going construction during classes. The plan was to complete all the new work except for the fine arts arena by starting in March 2003 and completing by mid-December. This would allow the school to make use of the new classrooms and offices while interior renovation could begin in January.

The new fine-arts addition was completed in early March. Shortly thereafter the old band hall was converted into a black-box theater facility. Renovations were completed in mid-August.

Since some of the renovation work involved upgrades in the school's power grid and HVAC systems, great care was paid to student safety. Ultimately the HVAC, power, lighting, ceilings, fire alarms, flooring and PA systems were replaced with newer equipment. All restrooms were upgraded to meet ADA requirements.

Although the ISD stipulated a 21-month period for completion of the project, Cadence McShane was able to finish in just 18 months.

Best of 2004-Private Building
Valero Energy Corporate Campus Expansion
Submitted by: SpawGlass, Houston
Location: San Antonio

Key Players:
Owner: Valero Energy Corp., San Antonio
General Contractor: SpawGlass, Houston
Architect: Rehler Vaughn & Koone Inc., San Antonio
Structural Engineer: Haynes Whaley Associates Inc., Houston
Civil Engineer: Pape-Dawson Engineers Inc., San Antonio
Mechanical Engineer: Blum Consulting Engineers, Dallas

Te Valero Energy Corporate Campus is headquarters to one of the nation's top oil refining companies. The facility itself, surrounded by sprawling Live Oak trees, is a limestone and glass three-level building with a standing seam metal roof and a glass rotunda in the center flanked with two newly constructed wings on either side.

When Valero acquired Ultramar Diamond Shamrock in 2001, it wanted to unite all of its 2,400 employees in one location and called on SpawGlass to undertake the challenge of enlarging and renovating the old UDS campus.

The ultimate goal of the project was to create a three-floor, 678,000-sq.-ft. Class A facility with significant renovations to the overall exterior. Ground was broken in February 2002 on the $92 million renovation, with a 28-month completion period.

Minimal disruption to Valero employees onsite was achieved through careful planning by SpawGlass, which split the project into separate phases. From excavating trees at the site to performing new construction and improving infrastructure in the facility's data center, each phase was treated as a different project although all costs were consolidated into single pay applications for the owner.

To make room for new construction, 33 trees were carefully excavated and hoisted by crane to be replanted in a new area on the campus. Then, two separate SpawGlass crews created two new wings, while other crews were busy constructing two new three-level parking garages, adding 1,380 new spaces.

A big job was updating the voice and data center for the renovated facility. This had to be done early in the building process as additional equipment had to be installed to accommodate the needs of the new corporate campus. SpawGlass also obtained a recertification of the FM 200 fire suppression system vital for protection of the sensitive gear in the data center.

Best of 2004-Higher Education/Research
Rice University Nanofabrication/Clean Room Lab Facility
Submitted by: McCarthy Building Cos. Inc., Addison
Location: Houston

Key Players:
Owner: Rice University, Houston
General Contractor: McCarthy Building Cos. Inc., Addison
Architect/Engineer: Lockwood Greene Engineering & Construction Inc., Dallas

Rice University in Houston selected McCarthy to fulfill the renovation of its Nanofabrication/Cleanroom Lab Facility in Abercrombie Hall, which is an expansion of Rice University's nanotechnology research program. The project offered McCarthy and its design partner, Lockwood Greene, the opportunity to develop unique solutions to the goal of taking a 67-year old existing facility and transforming it into a state-of-the-art clean-room environment supporting the study and research of nanotechnology.

The physical size of the facility was small, only 3,000 sq. ft., but the job had a degree of complexity. To accomplish the task, it was necessary to demolish interior structures and completely renovate existing outdated laboratory spaces, converting them into Class 100 and Class 1000 clean room laboratories, a conference area and office space. Restroom facilities and building exterior were upgraded at the same time.

All construction had to be coordinated to minimize disruption to ongoing laboratory and classroom activities. McCarthy performed construction after hours, on weekends, nights and holidays. Following clean-construction protocols, offsite prefabrication of many components enabled just-in-time delivery of many project materials. Limited space required strict control of construction material deliveries.

The construction of the new facility will allow nanotechnology researchers to study minute mechanisms and configurations the size of only a few atoms. The emerging area of research will potentially have profound and positive impacts in the fields of medicine, technology and agriculture.

Best of 2004-Industrial (Light)
Woodgrain Millwork Manufacturing Facility
Submitted by: Harrison Walker & Harper, Paris
Location: Greenville

Key Players:
Owner: Woodgrain Millwork, Greenville
General Contractor: Harrison Walker & Harper, Paris
Architect: Alton Parker & Associates, Dallas
Field Engineer: Stovall & Associates, Greenville

Woodgrain Millwork is one of the world's largest international millwork companies. Its origins date back to 1954, with its first plant in Cedar City, Utah. The company produces high-end doors, with Home Depot being a primary customer and about 70 percent of business coming from custom orders.

By 2002, Woodgrain was outgrowing the building it occupied. After several months of searching and negotiating, Woodgrain accepted an offer from Greenville Industrial Centre, a new industrial park that was in the process of being developed, to build a new 123,000-sq.-ft. manufacturing facility.

Work began on Woodgrain's new building simultaneously with the development of the Greenville Industrial Centre. Intricate coordination with the owner, city of Greenville, the architect and the site contractor allowed both projects to be completed in record time. The $3.7 million Woodgrain Millwork's Atrium Patio Door project, completed in five months, became the first tenant of the Greenville Industrial Centre.

The manufacturing facility occupies 10 of the development's 95 acres with an option to add eight more. Support areas include a high-tech presentation/conference room, a break room, storage rooms and a large cafeteria that serves double duty as an employee training room.

The most striking features are two large freestanding tilt-wall accent panel entrances. Towering 28 ft. tall and 10 ft. from the exterior walls, they add depth and texture to the exterior façade. The warehouse/manufacturing is laid out to maximize efficient workflow for two shifts of employees. Truck docks are equipped with state-of-the-art dock equipment.

Best of 2004-Masonry
Baylor University Science Building
Submitted by: Brazos Masonry Inc., Waco
Location: Waco

Key Players:
Owner: Baylor University, Waco
General Contractor: The Beck Group, Dallas
Architect/Engineer: HarleyEllis, Pontiac, Mich.

Masonry is at the heart and soul of the Baylor Science Building project. All of the exterior walls are concrete masonry unit backup. The exterior sports an impressive blend of modular velour and modular scratch-face Baylor Red brick, with cast stone and custom concrete masonry unit white banding providing contrast.

The project presented a major scaffolding challenge. For the block work, frame scaffold was utilized, working from floor to floor on the inside. The damproofing crew used suspension scaffolding and a boatswain's chair, while the veneer crew worked from a heavy-duty crank-up system. Coordination between the systems and the specific crews was an everyday priority, with 504,000 sq. ft. of scaffolding at heights of more than 60 ft.

Crews installed 180,000 gray CMU. The details around the wing section windows made use of three sizes of CMU in a complicated step-in and step-out pattern. This design was necessary to accommodate the cast stone/custom concrete masonry unit/brick exterior. The architect used 31,000 custom CMU , 5,100 sq. ft. of cast stone and 1,000,000 modular face brick in an accent banding pattern for the exterior.

At one point, the crew size reached 96 onsite employees. Making efficient use of staffing, equipment, material and time, Brazos Masonry was able to complete the $3.7 million contract in about a 15-month timeframe.