“When the framing system goes in, you don’t have the ability to cut a stud or to bridge around it, so you have to work with the spacing that is designed.” “The system is laid out very rigidly,” he says. Pigozzi says the trade-off of using the cold-form metal framing system is that the designs needed to be tightly coordinated so that all of the equipment and systems in the rooms would fit properly. The prefabricated system proved to be the most affordable choice, in part because of the speed of installation. The hotel, which was initially designed as structural steel, was redesigned as cold-form metal framing. Photo by Multivista, courtesy of Turner Construction Co.Īlthough cumbersome, Richardson says the process ultimately saved budget and schedule.įor the Family Entertainment Center, crews installed structural steel with glulam timber placed on top of the steel to maintain the wood look. Crews performed repairs during night shifts to limit impact to other parts of the water park.Īlthough most Great Wolf Lodge water parks are glulam timber structures, the Perryville project is steel with protective coatings to shield against corrosion. Repair procedures were developed, performed and inspected in collaboration with the paint manufacturer and the inspector. Great Wolf Resorts hired its own National Association of Corrosion Engineers Level 3 inspector to ensure that the painted metal met quality assurance and quality control requirements. We did realize that there could be some damage that would have to be repaired, but we knew the time savings would be worth it in the end.” “Then we had to come up with special rigging processes so that it wouldn’t destroy the coatings. “We developed a process for how to load their trucks with protection between the so we could get the product up here in the best possible condition,” he says. The decision also came with some risks, however, as the coatings could be chipped in shipping. Richardson estimated that option could save a month in the schedule. “We saw that train coming at us, so we elected to have the contractor spray both the prime coat and mid-coat in its facility.” “The water park is 80 ft tall at its peak, so getting up there to paint would be slow work and it’s out in the elements,” Richardson recalls. Andrew Pigozzi, Principal in Charge, Stantec They are just as complicated as a hospital.” The team had also planned to have crews add the extra coats in the field, but that created its own challenges. Instead, the bar joists were shipped and sent to a paint shop. The initial plan called for the manufacturer to paint the prime coat before shipping, but ultimately that did not fit the schedule. The affordable solution was bar joists and metal decking with three layers of high-performance coatings. Still, pricing at the time was prohibitive enough that the team had to consider a steel option, says Braxton Richardson, senior project manager at Turner Construction. The company particularly likes to specify glulam timber in its water parks because they are warm, wet environments where metal materials are more likely to corrode. With the industry facing widespread shortages of timber, Great Wolf Resort could not get affordable and easy access to one of its favored materials-glulam. Material choices, however, resulted in some of the most significant changes. Photo by Braxton Richardson, courtesy of Turner Construction Co. Structural steel was used for the lobby and family entertainment center, while the six-story hotel used a cold-form metal framing system. We basically had to start over again and create a larger box for the water park.” “That was not feasible because the lateral system wouldn’t have worked. “We looked at trying to salvage the existing structural design and just add another couple of bays,” Pigozzi says. The expanded water park, however, required a full redesign. Pigozzi says the team was able to extend the wings of the hotel to accommodate the extra rooms while keeping the building at the same height. The team began an intense six-month process of redesigning the project, taking into account new challenges around material availability and cost escalations. In light of the favorable outlook, Great Wolf Resorts wanted to restart the project as quickly as possible.
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