With Consigli’s pre-fabrication and self-perform experts, the project team identified a viable, cost-neutral solution for the building’s exterior wall panels to save on schedule. Upon presentation to and approval from the University, Consigli planned and executed the pre-fabricated exterior wall panels to condense a traditionally six-week building enclosure timeframe into just two weeks with its own self-perform craftspeople.

Design

Engaging the right design partners confirms accurate design details of pre-fabricated building elements and mitigates the risk of rework once materials leave the warehouse.

Consigli engaged a third-party delegated design team to review and confirm details for connections on the exterior wall panels. Excel Engineering, a specialty engineering firm with expertise in cold form steel, was hired to detail the panels and confirm all structural details. Excel converted the façade into panels that could be transported from Consigli’s pre-fabrication facility to the jobsite as they were ready to be installed.

Pre-fabrication

In addition to improved quality control and productivity, implementing pre-fabrication strategies on higher education projects takes work off campus and minimizes on-site construction activity.

Self-perform at Pre-fabrication Warehouse

At Consigli’s regionally based pre-fabrication shop, self-perform crews assembled 130 panels totaling 15,000 sq. ft. to enclose the residence hall addition. For eight weeks, five self-perform craftspeople precisely fabricated all exterior wall panels in sequence of how they would be placed on the building. This process brought approximately 1,800 hours of labor hours off of the University’s campus and into the warehouse, reducing on-site construction traffic and supporting a quieter job site in the process.

The well-lit, heated, ground-level space at the warehouse provided an ergonomic working environment—one that a construction site cannot always guarantee among the noises of intrusive trades on site, especially amid February weather in New England. When preparing the panels for load and delivery to site, the project team employed a project-specific quality assurance checklist developed and implemented by Consigli’s Quality department to safeguard the quality of every panel. All dimensions and details were reviewed on multiple occasions, and once each panel passed inspection, the panel was loaded on the flatbed to leave for the site. Panels were loaded onto four flatbed trucks for just-in-time deliveries so the panels could be picked and flown directly onto the building upon arrival to the job site.

Delivery & Installation

Parallel processing of material fabrication and installation supports faster, higher-quality construction by simultaneously managing multiple trades.

Pre-fabricated Exterior Wall Panel Install

While the crew in the pre-fabrication shop fabricated panels and loaded the trucks, six Consigli craftspeople at the jobsite received and unloaded the panels to be flown and placed on the building. Consigli’s simultaneous workflow—also known as parallel processing—maximized time both on site and in the warehouse. The Consigli field team had pre-checked the concrete foundation wall perimeter at the jobsite to ensure it was flat and level to quickly and accurately receive the first-floor panels set to rest on top of it.

The fast-tracked, two-week installation in February allowed the project team to enclose the exterior and start heating for interior tradework throughout the winter. And, because the building was enclosed and work was moved indoors, the construction site quickly quieted for the campus community, especially for the students in the adjacent dormitory.

The benefits of Consigli’s hands-on ownership of the pre-fabricated exterior wall panels went beyond the accelerated project schedule. Exterior wall system pre-fabrication ensured a quality product was fabricated and installed efficiently and with the campus’s best interest in mind—from decreased on-campus activity to the maintenance of a clean, safer and substantially quieter construction site.

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“Our culture is built on drive, humility and accountability,” said Josh Sylvester, Director of Operations – CT. “We focus on building three things: great people, great projects and great relationships.”

Consigli’s achievement was acknowledged by the Hartford Business Journal through an article highlighting its commitment to fostering a strong culture, generous benefits and opportunities for development for its employees.

“Consigli has always fostered a company culture that feels more like family and prioritizes staying true to who we are as genuine builders above all else,” said Alondra De Leon, Senior Project Manager. “The best places to work are made of the people who create environments where you can be your best, truest self, and Consigli provides that for us.”

The feature also emphasized Consigli’s efforts in the community, including its longstanding relationship with New Haven Promise, and its direct investment in its people as an employee-owned business.

In addition to benefits supporting the physical and mental health of employees and their families, Consigli also provides its employees with paid volunteer time, generous 401K matching, fitness reimbursement and wellness incentives, summer Fridays, parental leave and a culture that encourages work life balance. Various Employee Resource Groups (ERGs) also work collaboratively and thoughtfully to foster a diverse, equitable and inclusive environment for all employees.

The Best Places to Work in Connecticut is a survey and awards program, conducted through a Hartford Business Journal and Workforce Research Group partnership, that honors employers in Connecticut that are making their workplaces great.

To read the full feature on Consigli, click here.

To view the full list of the 2024 Best Places to Work in Connecticut, click here.

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Consigli was ranked first in the large-firm category. The “Best Places to Work” awards recognize the most admired workplaces in Connecticut.

“We take great pride in this achievement because it speaks to the culture that we have worked hard to build and maintain over the last 117 years,” says Joshua Sylvester, Director of CT Operations for Consigli. “To maintain such a strong culture in this industry, especially with the unpredictable environment we continue to operate in, is particularly meaningful.”

Developed more than 12 years ago by the  Hartford Business  Journal and the Best Companies Group, a third-party research firm that manages similar programs all over the country, the recognition requires companies to go through a workplace assessment process, including employee surveys and a full inventory of company benefits, policies, and offerings.

“Our people are our greatest asset,” said Ed Oloff, Director of CT Operations for Consigli. “We are excited to celebrate this achievement with them.”

The comprehensive review allowed for an in-depth analysis of each company’s strengths and weaknesses and ultimately determined the companies most deserving to make the list.

Click here for the Hartford Business Journal’s full article on Consigli!

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In this video series, Consigli looks at components of net zero carbon construction and implementation with our partners. Our first feature is Hotel Marcel, a certified historic renovation that repositioned a former office building into a hotel, targeting Net Zero Energy, Passive House and LEED Platinum certifications.

Sustainable Energy Production

Looking at operating costs over a five-year period, the investment in net zero operations ultimately pays for itself.

As a net zero energy building, the hotel generates 100% of its own electricity, heat and hot water with a rooftop solar array and solar parking canopies—totaling over 1,000 solar panels—with no fossil fuels used for the building’s power or heat. Hotel Marcel is its own energy island, supported by a battery-equipped solar microgrid to power the hotel, feed power to the grid during peak times and maintain power to the building during grid outages. The building’s Energy Use Intensity (EUI) rating is projected to be 34 kBtu per square foot, which is 80% less energy than median EUI for hotels in the United States.

Building Electrification

Technology, like lighting through an ethernet system, allows what was historically one of the least energy-efficient building operations to greatly reduce energy use and operational costs.

Hotel Marcel houses all-electric kitchen and laundry facilities—some of the largest energy-use areas in hotel operations—and utilizes low-voltage Power over Ethernet (PoE) technology to significantly reduce energy use across the entire building. Building-wide PoE powers and controls all lighting and window shades, enhancing operational control and reducing lighting energy use by over 30% compared to conventional lighting systems.

High-efficiency Mechanical Systems

The right mechanical systems can reduce monthly heating and cooling expenses while fostering improved indoor environments through ventilation and exhaust air heat transfer without direct air mixing.

Carefully selected mechanical systems at Hotel Marcel, specifically Variable Refrigerant Flow (VRF) air-source heat pumps and Energy Recovery Ventilation (ERV), support energy-efficient heat recovery and improved indoor air quality in the hotel. The VRF systems at Hotel Marcel can recover heat from cooled spaces for use in heated spaces and vice versa, enabling multiple indoor zones to operate on the same system from the same main compressor unit. The ERV recycles heat energy from the building’s exhaust air to pretreat outside air, reducing load on the HVAC unit and the required capacity of the mechanical equipment. ERV operations are essential for achieving great indoor air quality in high-performance, airtight buildings like Hotel Marcel.

Airtight Envelope Design & Moisture Control

Historic restorations requirements and regulations are not an end-stop for sustainable construction. Innovative building strategies can maintain a building’s historic integrity and deliver solutions for a more sustainable future.

Key to an energy efficient building is a well-insulated envelope with interior and exterior insulation, especially when targeting Passive House. However, at Hotel Marcel, the historic concrete façade could not be modified. Through interior spray foam insulation, the project team created an airtight, high-performance envelope while leaving the exterior untouched, aside from minor caulking improvements. Great care was taken in selecting an environmentally preferable spray foam with low embodied carbon and minimal off-gassing. Coupled with the installation of high-performance window, multiple layers of spray foam insulation ensure an airtight envelope protected from the impacts of outdoor moisture.

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“To be recognized as a “Best Place to Work” after 2020 says a lot about the strength of our team members here at Consigli. We are proud of what our people have been able to accomplish and for the positive work environment we have created here in Connecticut,” said Mike Walker, Director of CT Operations for Consigli Construction. “We strive to support our employees and build a positive company culture and are thrilled with this award.”

Consigli was ranked in the large-firm category. The Best Places to Work awards recognize the most admired workplaces in Connecticut. Developed more than eleven years ago by the Hartford Business Journal and the Best Companies Group, a third-party research firm that manages similar programs all over the country, the recognition required companies to go through a workplace assessment process, including employee surveys and a full inventory of company benefits, policies, and offerings. The comprehensive review allowed for an in-depth analysis of each company’s strengths and weaknesses and ultimately determined the companies most deserving to make the list.

Consigli was a strong contender for this award because of its employee-centric benefits plans and company perks, including paid volunteer time, gym membership reimbursement, and employee stock ownership plans. The company’s focus on creating a culture of accountability and safety, supporting the health and wellness of its people and their families, and maintaining a healthy work/life balance also contributed to this recognition.

Consigli has also been named a “Top Place to Work” in Massachusetts by The Boston Globe for the last 12 years. Its Portland, Maine office has been recognized by Mainebiz as a “Best Place to Work” for the last 14 years. Consigli has also won Best Place to Work Awards in New York and Washington, D.C.  In 2020 The company was recognized as a top employer in all states where it has offices.

Click here for the Hartford Business Journal’s full article on Consigli. 

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The new 55,000 sq. ft. Bobby Valentine Health & Recreation Center isn’t your typical athletic facility—it has a 35’ climbing wall, a golf simulator and a 5,000 sq. ft. six-lane bowling center, along with exercise and weight training rooms, a basketball court, an indoor track and a spin center. Consigli’s self-perform crews installed the 14’ concrete foundation walls.

The completion of the Bobby Valentine Health and Recreation Center marks Consigli’s fourth project on the SHU campus, and we are underway with our fifth and sixth—the West Campus Lobby and a new 197,000 sq. ft. Upper Quad residence hall.

Read more on the team win in Connecticut Building Congress here: https://www.cbc-ct.org/page-1859848

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“We have a fantastic team here in Hartford, which makes Consigli a wonderful place to come to and work each day,” said Dan McConaghy, Consigli’s District Manager for Southern New England. “Our peoples’ commitment to building outstanding projects and supporting their local community is something to be admired. This award belongs to all of them.”

Consigli was ranked in the large-firm category. The Best Places to Work awards recognize the most admired workplaces in Connecticut. Developed more than ten years ago by the Hartford Business Journal and the Best Companies Group, a third-party research firm that manages similar programs all over the country, the recognition required companies to go through a workplace assessment process, including employee surveys and a full inventory of company benefits, policies, and offerings. The comprehensive review allowed for an in-depth analysis of each company’s strengths and weaknesses and ultimately determined the companies most deserving to make the list.

Consigli has also been named a “Top Place to Work” in Massachusetts by The Boston Globe for the last ten years. Its Portland, Maine office has been recognized by Mainebiz as a “Best Place to Work” for the last 12 years.

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Some of the most challenging elements of getting performing arts spaces just right are keeping sound where it’s supposed to be—and not letting it travel anywhere else, the craftsmanship required to meet high levels of architectural detail, and team communication!

When building a performing arts space – things to consider for successful projects include:

Utilizing Building Elements to Keep Sound Where It Belongs
In buildings that house performing spaces where there can be a number of different adjacent uses, it’s essential to keep sound where it belongs. There are a number of measures that can be taken to achieve a high STC (Sound Transmission Class) rating, which designates a material’s ability to resist airborne sound transfer, such as multi-layer floors, preventing vibration, sealing all possible acoustic penetrations, isolating walls, and reflective ceilings.

In addition to keeping the sound of music where it’s intended, reducing potentially distracting noise from mechanical systems is also important. Sound dampening, acoustical insulation can be used inside and out on mechanical systems. Oversize ductwork allows for slower airflow and results in a quieter system. MEP/FPs can be isolated from the building structure using vibration isolation hangers and neoprene waffle pads.

When working on Wellesley College’s Pendleton Hall on a renovation and addition, the millwork in the salon and rehearsal hall was used both for its aesthetics and acoustic purposes: it has a layer of insulation, acoustic panels, and a layer of wood slats. The slats in the walls allowed exhaust air to pass through this millwork system to keep the volume at desired levels in the space, while still providing comfort and humidity control.

Paying Close Attention to Architectural Details
Performing spaces demand a high level of customization, detail, and quality. Using 3D modeling and mockups in the field (see our Emerson Colonial Theatre renovation) ensures our builder’s ability to meet these expectations, as does fully understanding the architect’s design intent and staffing our projects with the right craftsman to carry out their vision. Some specific examples from our recent experience include:

Modeling
To ensure the complex mechanical systems would fit within the space while working on Yale’s Adams Center for Musical Art, our builders performed a laser scan of the existing building and then electronically added pieces of the mechanical system into the job. That study resulted in adjusting the ceiling height to better accommodate the mechanical systems.

On Wellesley’s Pendleton Hall, the project’s predominant building material was concrete because of its acoustic properties. However, the design called for the concrete treatment to look like wood, complete with shadow lines. It was important to find the right tone and texture, so our team custom-made the concrete in batches and created “tombstone” samples to ensure each batch blended seamlessly and met the architect’s goals.

Craftmanship
Similarly, Wellesley’s Pendelton Hall project had a number of linear elements that required careful attention by our team. The architect wanted to ensure that anywhere someone looked inside the building, the linear properties converged properly. From the lights to the soffits, to the wall mullions, all had to be perfectly aligned on the proper horizontal or vertical plane to create the desired aesthetic. Our expert team of craftsman took the time to understand the desired outcome and delivered.

Team Coordination & Co-Location
Coordination between the design and engineering team and all construction trades requires patience and commitment on intricate construction projects.  A construction management tool, co-location— establishing a shared physical location where all members of a construction project team collaborate– helps ensure team communication across all trade specialties and creates a forum for discussing careful planning and coordination. Seemingly a simple concept, it’s critical in our highly detailed projects and only truly works with foresight and commitment. As an example; to ensure all of the trades were closely coordinated during our work on Yale’s Adams Center for Musical Arts, our team co-located twice a week with the design, engineering team, and subcontractors.

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“Simply put, our company’s success is a result of our people,” said Mike Walker, director of Connecticut operations at Consigli. “Being recognized as the best place to work is something we are very proud of and speaks to the incredible culture we have at Consigli.”

Consigli was ranked number one in the large-firm category. The Best Places to Work awards recognize the most admired workplaces in Connecticut. Developed more than ten years ago by the Hartford Business Journal and the Best Companies Group, a third-party research firm that manages similar programs all over the country, the recognition required companies to go through a workplace assessment process, including employee surveys and a full inventory of company benefits, policies and offerings. The comprehensive review allowed for an in-depth analysis of each company’s strengths and weaknesses and ultimately determined the companies most deserving to make the list.

Consigli has also been named a “Top Place to Work” in Massachusetts by The Boston Globe for the last nine years. Its Portland, Maine office has been recognized by Mainebiz as a “Best Place to Work” for the last 11 years.

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Camp Courant is the oldest and largest free summer day program in the nation. This program provides Hartford area youth, ages five-12, with the opportunity to develop positive relationship skills in a safe fun environment during the summer months.

Sylvester has been involved with Camp Courant since his days as a counselor and continues to consult on various capital projects. In 2016, he spearheaded the renovation of the camp’s pool, which now allows for the inclusion of all campers, including disabled children. Sylvester has also consulted on various yearly capital upgrade projects including building renovations, basketball court improvements, and building structural repairs.

Consigli has been supporting Camp Courant on numerous levels for many years, including sponsoring campers and providing counsel on large capital projects. In September, Consigli received the Corporate Award at the annual Buddy Bash event, honoring a company that has gone above and beyond in its support of the camp

“Camp Courant is thrilled to have Josh join the Board of Directors,” said Camp Courant Executive Director & CEO McKinley Albert. “As a former Camp Courant counselor, Josh understands the impact that summer programming has on Hartford’s young people. Josh is profoundly dedicated to his work at Consigli, and we know he will bring the same sense of enthusiasm, commitment and passion to Camp Courant.”

“At Consigli, we encourage people to give back to the communities they live in,” said Consigli President Matthew Consigli. “Josh is a perfect example of this. Josh believes strongly in the mission of Camp Courant and we know he will be an invaluable resource to the board.”

“We look forward to continuing working with Josh and the entire Consigli team,” said Albert. “Together, we will provide the best summer experience possible for over 1,000 of Hartford’s youth.”

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