Design & Build = With Metal: Jacob K. Javits Center Expansion & Renovation

Jacob K. Javits Center = Expansion=20 & Renovation

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Ceco Building Systems Involved = In The=20 Ultimate Construction Challenge: Downtown New York City Convention = Center=20 Expansion & Renovation

Combine virtually every construction and logistics challenge = =E2=80=93 the=20 renovation of an existing building, expanding that building, plus = tunnels,=20 traffic, the responsibility of keeping a booming business in continuous=20 operation, and place it right in Manhattan =E2=80=93 and you have the = Jacob K. Javits=20 Center expansion and renovation project.

One of the nation=E2=80=99s premier convention facilities, the Javits = Center is=20 located at 34th Street and 11th Avenue, on the west side of Manhattan. = Completed=20 in 1986, the Javits Center has hosted thousands of trade shows, = conferences and=20 special events, including many of the top 200 tradeshows. The Center's = 760,000=20 square feet of exhibition space can be divided into nine self-contained = halls,=20 enabling accommodation of trade shows and conventions of all sizes. = Average=20 attendance is 3.5 million a year.

However, the facility hadn=E2=80=99t been expanded or renovated in 25 = years, and it=20 was in dire need of more space. Aiding in that revitalization were=20 custom-designed metal building systems from Ceco Building Systems.

According to Kevin Taylor, project manager for Construction Manager = Tishman=20 Construction Corporation of New York, a contractor with an international = reputation, the enormous convention center had to be fully renovated and = expanded while remaining open and completely operational. To do that, = Javits=20 Center North and its connector were constructed and sequenced to be = completed=20 prior to the renovation to supply show space that will be taken out of = service=20 during the renovation in nine phases.

To fulfill the needed expansion, a new building was designed and = constructed:=20 Javits Center North, a 98,000-square-foot structure with 160-foot clear = span for=20 shows, and The Link, a 260-foot-long connector of the main Javits Center = to the=20 new Javits North building. The renovation of the main Javits Center is = still=20 ongoing and includes fa=C3=A7ade and roof replacement, the replacement = of rooftop=20 mechanical units and the repair, replacement and upgrade of several = building=20 systems and interior components.

Site Preparation

Javits Center North covers almost an entire New York City block and = is=20 situated outboard of the original Hudson River shoreline. As a result, = the=20 subsurface conditions were rather poor, consisting of variable fill = (placed in=20 the 1700s and 1800s) and river sediment, according to Marc Gallagher, an = engineer with Langan Engineering and Environmental Services, Inc., which = provided geotechnical, civil and environmental engineering along with = survey=20 services for the expansion project. =E2=80=9CA large building would = typically be placed=20 on expensive pile foundations to limit long-term settlement,=E2=80=9D he = explained.=20 =E2=80=9CHowever, because the fill has been in place for a significant = time and the=20 building is quite tolerant of some settlement by its nature - a = temporary long=20 span steel building - the concern about long-term settlement was = somewhat=20 mitigated. Also, the owner understood the issue and accepted placing the = building on large spread footings, and the potential settlement, thereby = eliminating piles and saving substantial costs.=E2=80=9D

The site/civil design included new storm water detention systems = inside,=20 under the floor slab, and outside the building. It entailed new electric = vaults,=20 new streetscaping, and a new plaza with retaining walls. The proximity = of the=20 plaza and building to the existing Lincoln Tunnel, which was only = several feet=20 below West 39th Street at its shallowest, made the design of utilities = and the=20 structural system a challenge, and mandated close coordination of design = and=20 construction work with the Port Authority of New York and New = Jersey.

The Expansion And Renovation

The Ceco portion of the Javits Center North expansion was a = design-build=20 project requiring a considerable amount of homework by project members = before=20 the start-up. The project team was led by the Convention Center = Development=20 Corporation, a New York State agency, Tishman Construction, serving as = the=20 Construction Manager, Architectural Team Javits II Architecture (a joint = venture=20 between FXFowle Architects and A. Epstein & Sons International, New = York,=20 NY), and Racanelli Construction (Melville, NY), a leading general = contractor,=20 construction manager and design-build firm, serving as the prime = sub-contractor=20 for the custom-designed building and other key components. In addition = there=20 were separate mechanical, electrical, plumbing, structural concrete and=20 architectural finish contracts.

A Ceco Building Systems authorized builder, Racanelli enlisted the = design=20 assistance of Ceco=E2=80=99s Eastern service center. =E2=80=9CThis = project perfectly fits our=20 design and manufacturing capability,=E2=80=9D said Ceco President Roger = Burlingame. =E2=80=9COur=20 specialty is custom-designed integrated steel structures, and the Javits = project=20 was just the type of challenge in which we excel.=E2=80=9D

According to Racanelli Construction Marketing Director Carmine = Martuscello,=20 in order to ensure that every detail of the project was addressed, he = and Ceco=20 Building Systems representatives flew to Indianapolis to view the = manufacturing=20 of the particular red wall panels ordered for Javits Center North.

Notwithstanding extensive preparation, the expansion entailed a huge = amount=20 of work since it was a fast-track job. Racanelli Construction=E2=80=99s = role was to=20 implement this approach. The complexity of the project demanded the = expansion be=20 done quickly so that it was complete in time to support the renovation = schedule=20 for the main Javits Center.

Some team members had to be acclimated to the custom-designed = building world.=20 =E2=80=9CWhile understanding the building type, we weren=E2=80=99t = particularly familiar with=20 Ceco's specific building systems,=E2=80=9D commented Larry Dalziel, = architect and=20 project manager with Javits II Architecture. Tishman project manager = Kevin=20 Taylor agreed. =E2=80=9CThere was a learning curve =E2=80=93 there was a = lot of special=20 attention paid to scheduling.=E2=80=9D

The speed of the project and the unfamiliarity with custom metal = buildings=20 weren=E2=80=99t the only challenges, however. Adhering to stringent = building codes=20 maintained by the City of New York was understandably challenging. Add = to that=20 the fact that part of the Link was built above the Lincoln Tunnel, which = brought=20 an entire set of logistics to work out, including a mere five-foot = clearance=20 because of the tunnel below. Weather wasn=E2=80=99t always cooperative, = either. The=20 expansion project began in March of 2009 and was completed in July 2010. = During=20 this time New York City endured the worst snow in the area in 50 years, = and in=20 March, the most rain in 50 years. The substantial grade change, = approximately an=20 11-foot drop over the 675-foot length of the lot, also proved = challenging.

Each project member had his own set of challenges. David Ennis of = EPoc=20 Partnership, the firm that designed the building as Associate Architects = of=20 Javits II Architects, mentioned budget constraints and the aggressive = schedule=20 that had to be adhered to as well as the requirement of water = tightness.

=E2=80=9CThe main Javits Center roof has always leaked,=E2=80=9D = Ennis added. =E2=80=9CPart of the=20 renovation was to replace the roof, and the new building had to be more = closely=20 analyzed for water tightness.=E2=80=9D Also, Javits North is 260 feet = from the main=20 Javits Center and is 160-feet, column free in width, with a minimum = clear height=20 of 25 feet, and about 500 feet long. Finally, the Link needed to allow = 45-foot=20 wide by 20-foot high clear access over an existing City sewer main.

As if these circumstances were not enough of an undertaking, adjacent = to the=20 renovation site churned another project: the City of New York was in the = midst=20 of extending its MTA subway line #7 and building an additional station = near West=20 34th Street.

Regarding the renovation portion of the project, =E2=80=9Cit was the = perfect storm,=E2=80=9D=20 commented Jeff Smithline, director of Transportation Engineering and = project=20 manager with Sam Schwartz Engineering. Part of the scope of the MTA's = subway=20 extension is to rebuild the elevated portion of 11th Avenue directly in = front of=20 the Javits Center. =E2=80=9CWith the reduced footprint caused by the = simultaneous Javits=20 renovation and subway construction, my job was to develop a plan to keep = the=20 Javits Center operational for events and conferences. Accommodating the = buses,=20 shuttles, taxis, pedestrians and personal vehicles generated by the = events=20 became a challenging task.=E2=80=9D

We had to figure out how the Center could still function and operate = at full=20 capacity while all this work was going on,=E2=80=9D Smithline added. = =E2=80=9CThe Javits Center=20 had to continue to provide good service to their customers and visitors, = and we=20 worked closely with city engineers, the bus companies and with Javits = operations=20 and security personnel.=E2=80=9D

Tishman=E2=80=99s project manager Kevin Taylor said that delivery = logistics played a=20 big role in the expansion portion of the project. A unique challenge = involved=20 pouring the large concrete floor of the new building. Each day during = this phase=20 as many as 50 to 75 concrete trucks had to be strategically brought into = the=20 construction area. These deliveries had to be scheduled around Javits = events.=20 =E2=80=9CWe needed to be very careful of our scheduling of deliveries, = so we worked=20 closely with operations people and their =E2=80=98move-in=E2=80=99 and = =E2=80=98move-out=E2=80=99 dates for=20 shows.=E2=80=9D

Ceco=E2=80=99s custom-designed building systems allowed the Javits = Center expansion=20 to proceed smoothly and on budget. According to Dalziel, the combination = of cost=20 and aesthetics associated with a metal building permitted the use of the = necessary clear span, column-free space, repeated from bay to bay.

"One of the biggest challenges was the fact that there was an = incredible=20 amount of site conditions and site constraints and programmatic = requirements for=20 which a custom-designed metal building is perfectly suited to = handle,=E2=80=9D added=20 Ennis.

Ceco materials used in constructing Javits Center North and = =E2=80=9CThe Link=E2=80=9D=20 connector included DoubleLok 24-gauge Galvalume standing-seam roof = panels;=20 insulated panels (R13 wall and R30 roof); and unpainted PBR 24-gauge = Galvalume=20 wall panels. The Link also sported 26-gauge interior liner wall panels = in Custom=20 Red with a Kynar finish. The Link included the installation of three = massive 45=E2=80=99=20 wide by 20' tall glass sliding doors, the largest in Manhattan.

Kevin Taylor commented on the speed of the expansion building. = =E2=80=9CLooking back,=20 custom-designed construction goes faster than conventional steel. We = just had to=20 adjust our planning accordingly. Everyone is very, very happy with it. = It=E2=80=99s a=20 unique building, and Racanelli Construction did an excellent job. We = look=20 forward to working with them again. Ceco also was very good =E2=80=93 = very=20 responsive.=E2=80=9D

=E2=80=9CIt was a pleasure working with Tishman = Construction,=E2=80=9D commented Martuscello.=20 =E2=80=9CIt was our first experience with them, and we enjoyed it. It = was also great=20 working with the architectural team.=E2=80=9D

=E2=80=9COverall, the (expansion portion of the) project turned out = quite nice,=E2=80=9D=20 commented Dalziel. =E2=80=9CThe team worked very well = together.=E2=80=9D

The renovation portion of the project is ongoing with a scheduled = completion=20 date in 2013.

About Tishman Construction

Tishman Construction is a construction management firm headquartered = in New=20 York City with operating units in Newark, Boston, Chicago, Las Vegas, = Los=20 Angeles, Philadelphia, Washington, DC, and Abu Dhabi. Tishman provides a = wide=20 range of construction and construction-related services for projects of = varying=20 scope, budget, schedule and complexity. Tishman Construction=E2=80=99s = services include=20 Construction Manager as Agent; Construction Manager at Risk; and = Owner=E2=80=99s=20 Representative. Some of Tishman=E2=80=99s current projects include One = World Trade=20 Center in New York City for the Port Authority of New York & New = Jersey; the=20 U.S. Department of Homeland Security Headquarters - Phase 1 in = Washington, DC;=20 and the Philadelphia Convention Center Expansion.

About Racanelli Construction

Since its founding over six decades ago, Racanelli Construction in = Long=20 Island, New York, has been responsible for new construction and = renovation=20 across a broad range of market segments, completing projects that = include=20 corporate headquarters, industrial complexes, hospitals, assisted living = facilities, university and college facilities, retail stores, hotels,=20 restaurants, houses of worship, self storage complexes, condominiums and = townhouses. With years of industry-specific expertise, extensive = resources and a=20 reputation for integrity, Racanelli is recognized as one of the = region=E2=80=99s leading=20 providers of preconstruction planning, project management, design/build, = and=20 general contracting services.

About Ceco Building Systems

3D"Ceco_Building_Systems_ Ceco=20 Building Systems, a leading division of NCI Building Systems, designs = and=20 fabricates attractive, energy-efficient, = =E2=80=9Cfunction-oriented=E2=80=9D metal buildings.=20 Ceco is well-known for its =E2=80=9Cnonstandard is standard=E2=80=9D = design philosophy, allowing=20 each project to be designed and manufactured to meet specific space and = function=20 requirements. For more information, visit http://www.cecobuildings.com/.

About NCI Building Systems

NCI Building Systems, Inc., (NYSE:NCS) is one of the largest = integrated=20 manufacturers and marketers of metal building components and = custom-designed=20 metal building systems in North America. The company offers one of the = most=20 extensive metal product lines in the building industry, under well = recognized=20 brand names.

The content on Design And = Build With=20 Metal relates to metal roofing (standing and batten=20 seam, shake, tile, shingle, corrugated and=20 screw-down roofs); metal wall products (ribbed, smooth=20 faced, metal composite and curtain walls); metal buildings (pre = engineered=20 steel, wood post frame, hangars and self storage); insulation; = doors; paint=20 coatings; and many related products (including roof accessories like = snow=20 guards, screws and vents). The site covers metal construction = products=20 using all types of substrates: steel, copper, aluminum, zinc, stainless = steel,=20 Corten, Terne, Galvalume, Zincalume, galvanized, tin and more.=20 Environmental (green) issues, such as sustainability and cool = initiatives,=20 are also covered. Project, news and product submissions are = welcomed...see=20 information in About Us section

Development by Aardvark, Inc.=20

Jacob K. Javits Center = Expansion=20 & Renovation

Click images to enlarge. Ceco Building Systems Involved = In The=20 Ultimate Construction Challenge: Downtown New York City Convention = Center=20 Expansion & Renovation

Click images to enlarge.

Ceco Building Systems Involved = In The=20 Ultimate Construction Challenge: Downtown New York City Convention = Center=20 Expansion & Renovation