800 Barrel Addition – Completed 2014
Two Hearted Fermentation Additions – Completed 2015
Kaiser Aluminum Corporation, a producer of high-quality fabricated aluminum products for aerospace, custom automotive and industrial applications, recently redeveloped 264,000 square feet of the former General Motors stamping plant in Kalamazoo, Michigan; an $80 million state-of-the-art billet casting and extrusion facility. Components of the project include: addition of a 4000 Ton extrusion press line, a 6000 Ton extrusion press line, a cast house, new office spaces, and loading docks.
This project involved some unique challenges related to building the concrete equipment foundations. The former General Motors Stamping plant in Comstock Township had press pits 18 feet below the main floor level. The challenge for Kaiser Aluminum and Byce was to support the heavy equipment at the main floor level above the basement. Consequently, the 6000 Ton and 4000 Ton Presses required foundations, approximately 25’deep x 50′ long x 18′ wide, which needed to be constructed at the basement level and rise up through the main plant floor. Stretcher equipment foundations have loads of up to 200,000 pounds in uplift requiring mass concrete foundations to resist the uplift. To control the heat of hydration generated temperature differential within these large concrete sections, a mass concrete mix design with 70% slag replacement of cement was utilized. To support some of the extrusion equipment, existing 54″ plate girders were re-utilized. These plate girders previously supported General Motors stamping presses.
Another significant challenge was increasing the floor live load up to 2,000 pounds per square foot as required by Kaiser Aluminum during their 2009 plant build out. The prior floor structure designed by Byce & Associates, Inc. in 2004 was designed for 600 pounds per square foot by way of a 6″ concrete floor slab on a metal deck, supported by existing W12x40 beams @ 30″ O.C. that were rotated 90 degrees and laid sideways. In order to reuse the hundreds of W12 beams from GM’s original floor, the beams were laid sideways to allow the new floor to line up with the surrounding slab on grade after the GM wood flooring was removed.
The challenge in 2009 was reinforcing this floor to 2,000 psf. Byce developed a design that involved installing new 10,000psi concrete beams between the existing sideways steel beams. Self-consolidating concrete (Concrete with a slump of 26 inches) was pumped down through the existing 6″ concrete floor to create new concrete beams between the existing flat laying steel beams.
The construction for the Radisson Plaza Hotel expansion included 6 stories of 8 inch thick Post Tensioned Concrete, flat plate floor slabs, supported by 4 stories of a structural steel frame.
Through the $44 million expansion and renovation, the Radisson Hotel became one of four hotels in Michigan that have received a four star rating. The building encompasses 650,000 square feet of hotel space, four restaurants, multiple conference centers and meeting rooms.
The scope of the renovations and expansion to the original building included: construction of a nine story guest room tower above the original two story portion of the building, installation of a new curtain wall over the existing facade, and renovation to the majority of interior spaces.
All new structures are in a way, a new invention and certainly have their own set of unique design requirements. The design of this structure was no exception and required several notable innovations in order to construct the new nine story tower above the existing two story concrete structure.
One innovation developed on this project is what architect Mike Simpson called a “Table” concept. At the guest tower, twelve (12) of the Twenty Five (25) concrete columns that extended from the 9th floor roof down to the 4th floor could not continue directly to the foundation, due to constraints of the existing two story concrete structure beneath. To accommodate these constraints, we proposed a “Table” concept at the fourth floor as a way to transfer the load of the 12 discontinuous columns. This table essentially stilts 60 feet tall around and through the original structure and supports the concrete structure housing the guest rooms above. At the table level, a typical column transfer beam consisted of three (3) – 40″ deep wide flange beams spanning 50 feet. This concept allowed for fixed columns located beneath the fourth level and allowed for some design flexibility in the column layout above.
As each new floor was constructed, more and more dead weight was added to the fourth floor “Table” structure. This added weight induced deflection in each transfer beam. To compensate for the accumulation of deflection in the concrete structure during each additional floor placement, a system of jacks was installed at the discontinuous columns at the fourth floor. The jacks were raised after each floor was constructed to keep all the floors near level.
Currently in design is the Stormcloud Brewing Company’s Production Facility Expansion in Frankfort, Michigan. Stormcloud Brewing Company, voted “Michigan’s Best New Brewery” in August 2016, has been in operation for 3 years brewing Belgian Inspired Michigan Made Beer and cooking up locally inspired food. Byce & Associates, Inc. is providing Architecture, Interior Design, Mechanical, Electrical and Structural Engineering Services. The new 10,000 square foot facility will include a dedicated brewing, fermentation, and bottling areas as well as, cold storage and shipping and receiving. Office space and a small tasting room and mechanical area will be provided. The design intent focuses around connecting the new facility to the existing brew pub as a way for Stormcloud to maintain its roots in Downtown Frankfort. Look for completion in 2017.
The Association of Licensed Architects (ALA) has awarded the design team with the Silver Medal for the Newell Rubbermaid Design Center. The design team included Byce & Associates, Inc. as design architect, AVB, Inc. as design builder, and Perkins + Will as interior designer/branded environments. The annual Design Awards Program showcases the power of design by the members of ALA.
The Newell Rubbermaid Design Center is a 40,000 square foot consumer product design and innovation center, intended to enhance the creative process through the continuum of design and across a spectrum of consumer products in adaptable spaces, including Product Innovation Labs, Immersion Rooms, Rapid Prototyping and Product Usability Labs all supported by Huddle Rooms, Creative Zones, and a light filled, vibrant open office. For more information on Newell Rubbermaid visit: https://byce.com/project/newell-rubbermaid/
Impact Label is moving to a new 30,000 square foot facility located in Galesburg, which contains a mixed use of corporate office spaces and production spaces. Within the building are five private offices, open office environments for up to 16 workstations, two large conference rooms, a break room with outdoor seating, an art department office and production space, a second floor mezzanine that contains a fitness room and records storage, and 21,700 square feet of printing production space. Materials for the building included a single sloped metal roof, vertical metal sidings, split face CMU veneer and aluminum storefront systems. To maximize natural lighting throughout the building, large storefront systems were used, while interior and exterior lighting was provided as LED throughout the building.
Byce & Associates, Inc. is a planning, design, and engineering firm providing architecture, interior design, mechanical, electrical, structural, and civil engineering, building commissioning and project management services to industrial, correctional, healthcare, educational, commercial and institutional facility clients.
Tracy Ezell, AIA joins Byce & Associates, Inc. as a Senior Architect / Project Manager. Tracy holds a Bachelor of Architecture degree, as well as a Certificate of Business Administration from the University of Detroit. He has 26 years of professional experience in the Architecture field.
To reclaim The Park Club’s historical relevance, the building is currently undergoing a renovation. The improvements include the front wrap around porch, front entry stairs, and internal stairs that take you from the first floor to the third floor. The overall goal of this initiative is to assist in addressing current deficiencies, improve operational effectiveness, and set a course for future enhancements. Our team was called on for the historical renovation to provide improvements that match and support The Park Club’s business model, strategies, and objectives.
Our team is currently performing Architectural and Engineering Services for the 2015 Expansion and Addition of Bell’s Brewery, Inc. in Galesburg, Michigan. The expansion will include a new Packaging/Bottling Hall, Logistics Warehouse with Keg Cooler, a Point-of-Sale Warehouse, Employee Support Services Spaces, as well as an 800 Barrel Fermentation Addition and Two Hearted Fermentation Addition.
The Employee Support Services building is split into two sides, north and south. The north side is geared towards health and wellness, including a fitness center and wellness clinic, while the south side will be an employee entrance, including locker rooms and break room. Included in the Logistics Warehouse are recessed docks for shipping/receiving, a large keg cooler, and space for the storage of product.
Our team is working closely and collaboratively with Walbridge as the construction manager, to assure that it meets the parameters, expectations, and standards of Bell’s Brewery, Inc. For more information and photos check out our website: https://byce.com/project/bells-brewery-inc-2015-expansion-and-renovation/