The Douglas Company renovated the 630 Lofts building in Traverse City, Michigan, which contained 39 apartment units and retail/office space. The renovation of the 100-year-old building presented many unique challenges due to environmental issues, the thickness of the masonry walls, and meeting historic tax credit requirements. The Douglas Company's solutions included specialized environmental abatement, developing techniques for installing windows, doors, and mechanical systems in thick walls, and customizing finishes and systems to make the project cost-effective while meeting historic standards. Lessons learned included modifying exterior grades to prevent water issues and utilizing early involvement to help expedite the project.

1. The Douglas Company
Lead-Build-Succeed

2. “From Trashed to Treasured”
630 Lofts
Traverse City, Michigan

3. Your Facilitator
John Broer
– Director, Business Development

4. Your Presenter
Ron Siebenaler
– VP, Construction

5. A bit of history

6. A bit of history

7. A bit of history

8. Discussion Points
• Description of the project
• Unique challenges we faced
• TDC’s solutions – Process & Execution
• What we learned - Take-Aways

9. Description of the project

10. Description of the project
• 47,209 square feet
• 39 units (total)
• 3 studio
• 20 one-bedroom
• 16 two-bedroom
• Garden Level - 9,315 sf retail, office,
community space
• Floors 1,2,3 – 9,315 sf (each)
• Attic – 9,949 sf

12. Description of the project
• Project Pricing:
– Contract $8,552,532
– Site $547, 481
– Environmental $339,774
– Demo (structural) $194,500
– Building Const. $7,412,776 ($157.02/sf)
– Bond $ 58,000

13. Description of the project

14. Description of the project

15. Description of project

16. Description of the project

17. Description of the project

18. Description of the project

19. Description of the project
Lofts
Apartments
Office, Common Space, Future Retail

20. Unique Challenges
• Dealing with a 100+ year-old building
– Environmental abatements (asbestos, lead, soils)
– Masonry walls (18-24” thick)
– Basement head clearance (ductwork, pipes)
– Walls, floors, and windows
– Water damage
– Historic Tax Credit Requirements
– Unforeseen conditions

21. Unique Challenges
• Environmental Abatements
– Lead – walls, trim, and ceilings
– Asbestos – piping, duct, flooring
– Soils – Lead, other metals
• “Due Care Plan” to handle, remove,
and dispose offsite

22. Unique Challenges
• Masonry Walls
– Exterior repairs, tuckpoint, cleaning
– Interior repairs
– Unique support developed to cut in
new project door openings
• 18-24” thick walls
– Salvaging bricks – 14,000

23. Unique Challenges
• Basement Head Clearance
– Only 7’4” clearance after
removal of all mechanicals
– Removed concrete floor
and lowered 8” to achieve
clearances

24. Unique Challenges
• Walls
– Thickness presented issues with:
• New openings
• ME&P installations
• Door installations and trim
– Existing plaster walls
• Refurbished and skim coated
• Large-radius corners

25. Unique Challenges
• Floors
– Handled in two ways
• Refurbished existing maple floors
• Overlaid colored/polished concrete
floors – attic, basement, other spaces
– Many areas had to be structurally
reinforced

26. Unique Challenges
• Windows
– Historic Tax Credits required
complete replacement with
historically accurate systems
– Windows over 8-9’ tall in most
locations

27. Unique Challenges
• Doors and Trim
– Had to replicate existing door and
trim profiles
– Not found in typical building supply
store
• 12” base, 4” chair

28. TDC Solutions
• Preconstruction Services
– Budget Estimating Process
– Civil Design Services

29. Budget Estimating Process
• Initial Budget Estimate
• Schematic Estimate
• Final Estimate

30. Civil Design Services
• Site Investigation
• Prelim Site Design
• Final Civil Design

31. TDC Solutions
• Environmental
– Soils remediation on site
– Asbestos abatement
– Lead abatement
• Historic Tax Credit issues
– Windows
– Doors and trim
– Plaster
– Exterior (brick, railings, site)

32. TDC Solutions
• Fire separation
– Floor/ceiling assembly
• Drywall on RC channel
• Suspended DW ceiling under 7” for
mechanicals
• Prevented need for sprinklers
– Mechanical shafts
• Utilized shaft wall
• Specialty Hilti systems at
mechanical penetrations

33. TDC Solutions
• Walls and ceilings
– All surfaces req’d plaster to meet
historical standards
– Utilized a USG Level 5 finish with
drywall compound – more cost-
effective than plaster

34. TDC Solutions
• Walls and ceiling
– Ceiling assembly created to
eliminate need for sprinklers but
still have room for mechanicals
– Attic level vaulted ceilings
achieved with open cell ISO
insulation and vapor barrier paint
• Provided R-40 insulating value and
maximized ceiling heights

35. TDC Solutions
• Door systems
– Developed lintel
installation technique

36. TDC Solutions
• Window systems
– Used a custom window assembly
by Kolbe & Kolbe
• Double-glazed with applied grilles
and internal spacers
• Req’d to meet historical standards
• Unique grid patterns
• Every window measured and
custom-built
• Provided historic look with energy-
efficient operation

37. TDC Solutions
• HVAC Systems
– Recommended a VRV system for
heating and cooling
• More cost-effective than boiler/chiller
system
• Operational efficiencies very high
• Effective to use in building lacking
ductwork
• Individualized controls
• Ability to heat/cool simultaneously

38. TDC Solutions
• Site work
– Abatement/removal of
contaminated soils
– 15’ zone around building
• Impermeable barrier
• Stone and topsoil

39. TDC Solutions
• Site work
– 5’ concrete to shed water
– New parking lot
• Worked around 100-year old
trees
• No storm outlet for low lying
areas
– French drain system created
per TDC recommendation

40. What we learned
• Modification of grades at
perimeter exposed
foundation to water
penetration
• Concrete floor system
desired by owner created
ADA access issues
– Wood floor systems more
economical, would have
prevented issue

41. What we learned
• Early involvement really helped
expedite the schedule
– Had good knowledge of the
project
– Able to work out details early and
in advance of starting

42. What we learned
• Aggressive purchasing
afforded the owner savings
which he incorporated into
the project
– Granite counters
– Security system
– Intercom/door access system
– Custom closet systems
– Ceramic shower surrounds

43. Contact Information
• The Douglas Company – 419-865-8600
• Ron Siebenaler –
rsiebenaler@douglascompany.com
• John Broer –
jbroer@douglascompany.com
• www.douglascompany.com

44. The Douglas Company
Lead-Build-Succeed