Featured Projects

Materials that Work Just Right…Every Time

“There is no other way to describe it – it’s a big, structural box,” says SSW Engineer Michael Cox. He’s describing the medium-sized retail store called Bi-Mart. As a stand-alone structure selling general household items, Bi-Mart stores are nestled into smaller-sized communities throughout Oregon, Idaho and Washington.  

A big box it may be, yet simple structures have structural complexities and the Bi-Mart stores have their own unique qualities. “As opposed to box buildings constructed of steel joists and deck, Bi-Mart uses exposed engineered wood joists and beams to provide aesthetic appeal,” explains Bill Sharp, Senior Project Manager for Sletten Construction Company. “Big box stores don’t use these types of materials very often.” Sletten has constructed two Bi-Marts in Southern Idaho over the last year, and RedBuilt™ materials have been used to construct more than 20 Bi-Mart stores.

“Beyond the look and feel of the open-web trusses and I-joists, we specify engineered wood from RedBuilt™ because we know exactly what we’ll get,” explains SSW Engineer Michael Cox. “They also provide all the front-end coordination between the framer, contractors, specifiers and transportation scheduling.”

“It all begins with using the design software RedSpec to configure lateral loads and check calculations. Bi-Mart will only use RedBuilt™ for its structural members because of our great confidence in the calculations,” says Cox. “RedSpec just works and it’s easy to use.”

“RedBuilt™ products – I-joists, open-web trusses and glulam beams – are delivered to us pre-cut and ready for installation. There is no field cutting, which saves on labor and jobsite waste,” says Sharp. “We may have a little bit of play in the hangers, yet not one item has had issues.”

“Even though the structure might be a simple box, you want all the members to fit right,” says Cox. “RedBuilt™ products are the most cost-effective and have the best calculations then any of their competitors. They provide materials that just work.”

Economic Innovation: New CrossFit Center Features All-wood System

CrossFit Duratus is unique for many reasons – starting with its name. Duratus is Latin meaning to “endure” or “harden”. Appropriate for a fitness gym. Yet, CrossFit Duratus is not a typical gym in its product offering nor its physical structure. Rather, CrossFit Duratus is a unique all-wood building combining cross-laminated timber (CLT), with RedBuilt’s RedLam LVLRed- I joists and Red-M open-web trusses.

“This is an innovative building for its all-wood structural components,” explains General Contractor Mike Bradley of Beacon Builders. “Yet it didn’t start that way. The owner came to me requesting the most economical option; which I suggested was pre-engineered steel with exposed stick pin insulation.”

After learning more of the owner’s wishes for natural lighting along with functional requirements such as the ability to attach exercise racks to the walls, Bradley with Structural Engineer Logun Rasmussen, were able to determine that the combination of wood was environmentally friendly and the most economical.

“The true benefits of the building came from a collaboration of function, design, and economical feasibility,” says Bradley. “This included a reduced framing schedule that resulted in a seamless construction plan.”

Cost and construction schedule were essential.  It took a three-man crew – one skilled and two unskilled laborers – just three weeks to frame the 8,000 square foot building and a 1,200-square foot mezzanine. Bradley explained that the ability to frame the structure with the current labor constraints was key to the buildings cost basis along with the cycle time of the framing schedule.

“The secret is always labor,” says Bradley. “What I love about building with wood is the wood-to-wood connection and our ability to use a versatile labor force. For example, the RedBuilt Red-I joists are lightweight – which allows them to be installed with just two people. Laborers accustomed to wood framing have a broader scope of skills that are transferable.”

Rasmussen of GLR Engineers explains that the all-wood system had several other benefits. “Our connection design was simple,” says Rasmussen. “Simple because all the materials play well together using typical clips and lag bolts.”

“Selecting a system of economy was the key to this project,” describes Rasmussen. “While we were new to CLT, using other familiar wood product manufacturers made the process predictable, and the mix of products created an appealing and unique structural look.” 

“By using RedBuilt trusses and CLT, we were able to create an all-wood frame where the performance was the same as a steel structure,” says Rasmussen. “The Red-M open-web trusses have the needed strength and capacity while also being the most economical with 8-foot on center spacing – more than twice as wide than what is typical. The Red-M’s at 8’ really open up the space to make it feel open and allow for faster erection time with less labor.”

“While we’ve each had extensive experience with RedBuilt’s engineered wood products, we were a bunch of rookies in using CLT,” explains Bradley. “The owner wanted to use all wood. Logun and I were excited to use this kind of product mix and we’d do it again. ”

“Go Big” with the Vietnam Town Center

“Go big or go home,” is a motto that Mark Muhn lives by in all aspects of his life. In his framing business, he is relentless in going after new work and challenging the status quo. The Vietnam Town Center, Phase II was no exception.

Located in San Jose, California, The Vietnam Town Center is a village-themed combination of shopping and dining within a commercial plaza. The construction took place in two phases; the second phase was much bigger than any other framing job Muhn had done. Yet, this framing contractor from Morgan Hill, California has a passion for construction and doesn’t take “no” for an answer.

Phase two of project includes 120 commercial condos with a grocery store pad – this equates to five, one and two story structures with an average 40,000 square feet per building. The first levels are designated for retail; the upper levels are suited for professional offices.

To bid on the project, Muhn worked for the first time with Shame’s Construction, the project’s General Contractor. The bidding process for the job was complex, long and cumbersome. Consequently, other framers bidding on the work dropped out of the process. Muhn stuck with it and continued to answer questions while leveraging the expertise of RedBuilt in solving design challenges…particularly around the beams.

The job encompasses 600 beams of different lengths with varying design specifications. Initially specified as parallel strand lumber, Muhn together with RedBuilt was able to provide the structural engineer with a substitution utilizing RedLam® LVL Beams. In total, there are 29,071 linear feet of RedLam LVL beams in the project – that’s about five and a half miles. Additionally, the job uses 30,000 linear feet of 24” Red-W® open-web trusses, 24” on center for the second floor systems – that’s another five and a half miles!

“Sourcing beams and open-web trusses through one supplier worked favorably for RedBuilt,” says Muhn. “Minimizing the number of manufacturers to engage with saves time and we need to save time wherever we can.”

RedBuilt’s pricing on both beams and open-web trusses is another aspect that got Muhn’s attention. “RedBuilt was able to supply the whole project at the contracted price point. And, they provided all the shop drawings to ensure all pieces were accounted for and on spec,” explains Muhn. “There are comparable products on the market, yet the people at RedBuilt worked with me to ensure we had all the pieces specified correctly, provided a good price, and delivered on time…can’t beat it.”

Three of the five structures at the Vietnam Town Center are in the construction phase. The other two will begin after a parking structure is completed. This gap of time doesn’t slow Muhn down.

“I have a contract for another project in San Jose and I’m using RedBuilt again,” says Muhn. “They get an A+ for following through on doing what they said they will do. The only way I’m able to take on projects the size of the Vietnam Town Center is by working with companies like RedBuilt.”

X-Shaped School Creates Unique Framing Challenges

The Lower School for Oregon Episcopal School (OES) in Portland, Oregon has replaced an old structure with a new one. One that is X-shaped and was designed to have large flexible classrooms, group collaboration spaces, state-of-the-art science labs and art studios, performance space, and ample access to the outdoors. This unique design for the 45,000 square foot structure now provides learning space for the more than 350 children in Kindergarten through 5th grades.
The architectural vision provided by Hacker Architects created a unique-shaped building set together with complex angles. Wood was selected for its economical benefits, along with the desire for aesthetic appeal with exposed material.
Based on past project successes, Skanska general contractors hired Russ Brotnov and his crew at Carpentry Plus, who specialize in complex wood structures. Skanska and Carpentry Plus had worked on several other projects – including schools – together within the Vancouver area.
“The OES job was big and had the potential to be messy,” says Brotnov. “The X shape of the three-story building dictated that every truss measured a different length.” Specified with open-web trusses, the ceiling trusses were a RedBuilt® Red-S™ series with RedLam™ LVL chords. Red-I™ I-joists were used in hallways and bathrooms with RedLam LVL for beams and headers.
The exposed trusses attached to steel beams and headers with flush mount bearing clips, which were welded on at an angle. Thus, the trusses needed to measure exactly – within a 1/8 of an inch. Every piece had to be manufactured precisely…otherwise it wouldn’t fit.
“There was very little tolerance within the drawing details that caused concern for the tight fit, with lots of angles,” explains Brotnov. “Questions and answers were exchanged between the engineers and RedBuilt as the manufacturer. Together we explored what does and doesn’t work for lengths and loads and how to solve it. RedBuilt was a reliable resource and worked to ensure the architectural vision became a reality.”
Beyond the challenge of ensuring that the truss length was precise, the biggest challenge was in mapping the mechanical.
“This school was a model project to make the duct and piping run through the exposed trusses and fit where they needed to go,” explains Brotnov. “We were successful in getting all the ducts through the trusses due to the frequent interaction between the various teams. With multiple conference calls and 3D modeling we were able to fine-tune the mechanical needs. Then, each truss was labeled to match plan and staged sequentially for installation. On the jobsite the materials were well-marked and grouped separately so we could easily find the needed materials at the right time.”
“There was an extensive amount of design help RedBuilt supplied to coordinate truss web layout versus ducting runs. This was critical to the success of the mechanical design and installation,” says Brotnov. “RedBuilt delivered on their promise of customer service and anything a manufacturer can do to get the order right saves me time and money.”

Innovative use of wood products at Western Oregon University

The 6,000 students at Western Oregon University now have a new College of Education Building called the Richard Woodcock Education Center. The building is unique for several reasons…one of which includes the use of cross-laminated timber. The stand-alone two-story, 57,000 square-foot building houses 13 classrooms, 3 computer labs, meeting areas and 86 offices. The building opens to students in the fall of 2016.

The structure of the building uses a wide mix of wood products, and is the first completed multi-story building in Oregon to utilize cross-laminated timber. In fact, according to a Western Oregon University press release, the building received a designation from Oregon Governor Kitzhaber to promote “innovative use of wood products as a green building material, which encourages innovative uses of wood products and increases markets for Oregon wood products.”

“Following the Governor’s executive order, the Richard Woodcock Center is unique in utilizing nearly every kind of wood product on the market,” says Structural Engineer Ed Quesenberry of Equilibrium Engineers.  “Working with Mahlum Architects, we developed a structural system that utilized cross-laminated timber (CLT) in wall and floor applications in the open ‘collaborative hubs’ at the two main entrances to the building, Lock Deck and exposed glulams in one large multi-purpose classroom, and more traditional joist and stud wood framing elsewhere.”

The Education Center primarily consists of classrooms and faculty offices. The classrooms are big, open spaces, while the offices are smaller. Quesenberry explains that this room layout required the use of open-web wood joists for the 30-36 foot-long spans over the first-floor classrooms and wood I joists over the smaller offices to maintain cost efficiency. Additionally, they needed to keep the floor-to-floor height to a minimum to provide economy for exterior cladding while allowing enough room for HVAC and other mechanical systems to be distributed throughout the building.

The final solution includes 7,752 lineal feet of RedBuilt Red-S open web trusses with laminated veneer lumber chords that span 31 to 36 feet over the classrooms, and 9,718 lineal feet of Red-I65 joists spanning up to 20 feet over the offices and corridors. The design team addressed the concern of noise transfer between the second and first floors by adding three inches of concrete on top of the second floor sheathing. No problem. The Red-S open web trusses and Red-I joists provided the load capacity to support the heavier floor weight, even with the longer spans.

“Together with our RedBuilt tech rep, we worked through all the different areas of the building and developed the optimal framing solution for the entire second floor,” says Quesenberry. “The collaboration was great and made good sense since RedBuilt offers design services for their products. Since they  know their product the best, we were confident that the design we developed would work well.”

“Based on our back and forth discussions with RedBuilt, we knew we had the most economical system,” explains Quesenberry. “Our Rep presented options to increase on-center spacing and use larger I-joists for cost savings. He did the economical analysis to get the best floor possible. I would have had a hard time getting all that information on my own, so we really leveraged that collaborative relationship with the manufacturer. That’s what I really enjoyed. He helped determine the most economical connection details, which is important when there are interfaces between different joist systems like we had on this building. Together we went through the drawings to find different opportunities to incorporate framing efficiencies in to our documents. Our Rep knows what works and what doesn’t. It just made sense to bring in the expert and partner in the design process.”

Furthermore, Tech Reps help ensure proper installation on the job site. This is just more added benefit in working with a service-focused manufacturer such as RedBuilt.

Tapered Open-Web Trusses Provide a Roof with Style

Specialty’s Café serves made-from-scratch breakfasts, lunches and baked goods. Yet this 7,000 square foot dine-in or take-out café provides guests with more than just good food.

“The building is unique from a design standpoint for its use of exposed wood trusses, glass, and steel,” says General Contractor Neil Hardin. “It offers a West-coast type of design creating a unique Midwest look.”

To achieve the sloped roofline, RedBuilt’s tapered Red-H™ open-web trusses with RedLam™ LVL chords were specified. The 13 trusses are 72” deep at one end and 24” at the other. While at the manufacturing plant, additional effort was made to ensure no finger joints were revealed within the chords as the trusses are in an exposed application.

“As a design-build project, you need efficiency,” explains Hardin. “RedBuilt was efficient, accommodating and delivered the product per expectations. The trusses were ready for installation without any customizing. This doesn’t happen often, usually there is something I have to adjust.”

“I’ve gotten other jobs based on this one,” says Hardin. “Other opportunities presented themselves because of our timely construction on this project. Keeping to strict schedules goes a long way in developing credibility and RedBuilt was a key partner in our success.”

Scissor Trusses Offer Aesthetic Appeal

Main Street is a well-traveled, tree-lined street in Watertown, a community on the outskirts of Cambridge, Massachusetts. A corner that was previously a gas station is now an appealing one-story 4,500 square-foot retail building.

“The building owner wanted to think outside the box and transform this site to help attract upscale tenants,” says architect Douglas Annino. “A RedBuilt scissor truss roof system – left exposed – was an aesthetically pleasing characteristic that fit the intent.”

After reviewing three product series with different on-center spacings, the architect was able to evaluate the budget and select the best option. “Our RedBuilt customer service was very good. We don’t get this kind of service from other manufacturers,” says Doug. “It makes a huge difference in my decisions when I can actually talk with someone about design options with up-to-date information on costs and availability.”

Doug selected RedBuilt’s Red-S™ trusses at 4’ on center, 35 feet in length. 38 of the trusses completed the 4,500 square-foot retail building. The trusses were left exposed to create a light, open-air interior with the warmth of a wood planked ceiling and the exposed wood flanges of the trusses.

“This is the second job where I’ve worked with RedBuilt and I look forward to the next,” says Doug. “The product looks good and you can’t beat the service.”

High Strength-to-Weight Ratio:
Just What The Doctor Ordered

Sandpoint, Idaho is a mountain town of less than 10,000 people, on the shore of Lake Pend Oreille. Originally a logging town, it has become a tourist destination—and with population growth comes demand for medical services.

Bonner General Health needed to expand; thus a medical office building was built next door to the existing hospital. Construction of the new facility, however, had its own unplanned emergencies.

As beautiful as it may be, Sandpoint is on an alluvial floodplain of fine, glacial clay that sits in a seismic zone. Original designs called for heavy construction materials of steel and brick on the exterior. “We needed to trim weight from the building to minimize the cost penalty it would have had as a result of the seismic analysis,” says construction manager Jim Williamson.

“Our original plan was to build with steel,” says building owner Chris Meyer. “But the soil conditions presented a different set of circumstances.” A lighter solution was needed, but would a wood frame building be possible? “RedBuilt helped us find solutions at the right cost along with meeting the requirements of engineering,” Chris confirms.

The solution ultimately came from several angles: switching to Red-I™ joists with their impressive strength-to-weight ratio, adding soil stabilization features into the foundation design, and switching part of the building from brick to stucco and an exterior insulation finishing system.

“This is definitely the biggest wood frame building that I’ve ever done,” says Williamson. “Not only did wood give us a more economical structure, but we could more easily source our labor needs with wood framing, too.”

Beyond soil conditions, tenant use also constrained the design. As a medical center, the following considerations needed to be included:

  • High ceiling heights to allow for medical machine placement
  • Complex ventilation and plumbing requirements, including options for anticipated future needs
  • Maximized column spacing to allow for unobstructed rooms and large, flexible spaces
  • Minimal floor vibration
  • Connection by overhead walkway to the Bonner General Health regional hospital

“We needed room for all of that plumbing and mechanical in the floor space,” says Williamson. “The solution came from a careful layout and a collaborative effort between the engineer and the RedBuilt team. We did a lot of up-front value engineering to ensure our design was optimized.” The result?

  • 28″ deep Red-I90™ series I-joists, with 3½″ wide flanges, at 16″ on center for both floors and the roof. Care was taken in the proper installation of the floor joist hangers, hung from 4″ wide steel beams.
  • Even 30 to 32 foot I-joist spans still yielded an acceptable FloorChoice™ performance rating. The goal was to keep the joists shallow, with minimal floor vibration. Vibration would be further dampened by lightweight concrete topping and a gypsum ceiling.
  • RedLam™ LVL columns were used throughout the walls to resist shear and wind loads, and accommodate expansive exterior windows.

After a three-month delay in redesigning the building and stabilizing the soil, the construction team was under a tight time constraint. “RedBuilt understood our needs and constraints, and they were really on top of the ordering process,” says Williamson. “We don’t get big surprises with RedBuilt—no one likes those kinds of surprises.”

“RedBuilt was responsive and creative in solving our challenging structural issues,” says building owner Chris Meyer of Parkwood Business Properties, a family-owned real estate developer. “RedBuilt proves with their warranty that they are a company that stands by their products. As a long-term building owner, we invest in our structures’ sustaining value. And we like working with companies like RedBuilt because we share the same vision.”

Through a collaborative team effort, the unforeseen delays were overcome and the medical building opened in the summer of 2015. The three-story structure is a 50,000 sq. ft. multi-tenant building, home to rehabilitation therapy, women’s health and wound care clinics, blood drawing services, and multiple physicians’ offices.

Kelson Orthodontics’ New Office Blends Classic with Contemporary

Kelson Orthodonics was growing and needed an additional location for its family-owned business. As a second-generation orthodontist, Dr. Chris Kelson wanted the office to blend old with new, integrating his father’s 35 years of experience with modern dental science.

“The new office’s contemporary design has a high level of sophistication and includes modern features such as exposed steel, glass, concrete and stucco,” says Peter Rockwell, principal at Glancey Rockwell & Associates—the architectural firm behind the building. “Dr. Kelson has a keen eye and sharp sense of design, which gave us the freedom to design a jewel of a building in a small, 5,000-square-foot package.”

The building’s structural components not only serve a functional purpose, they also add a touch of dramatic flair to its design. Wood framed walls and steel bracing accommodate large spans of glass, and wood floor and roof trusses make up the balance of the building’s structure.

According to Rockwell, the design required a specific system that could accommodate multiple conditions. “We looked at wood, masonry and steel solutions, but it became clear that wood was the right choice,” he says. “It was easy to work with, satisfied the aesthetic concerns and structural qualities—and it was cost effective.”

Despite the building’s complicated nature, wood offered a smooth solution for constructing the office. Some of the forms the owner designed required built-up rib framing similar to a fine wooden canoe in order to get the soft shape desired. The use of wood provided softness and texture to the exterior accents, stairs, vaulted ceiling and reception area—offsetting and complementing the hard stucco and gypsum finishes.

The building’s framing is a combination of platform-framed two-story section and balloon-framed lobby space braced with steel to accommodate large open window spans. For the roof structure, the Glancey team used 24” Red-L™ open-web barrel trusses at 32” on-center, assembled to a 90’ exterior radius. The rounded roof complements the building’s interior curves.

“The truss webs were made from cold-formed tubular steel,” says Rockwell. “And steel pins were used to connect wood chords and flat-punched ends on steel webs.” Matching the truss curvature were two 2x6 wood truss outriggers that overhung four feet on high and low ends. Each set of outriggers was factory built and field installed.

The team at Solitude Homes, who acted as the general contracor and framers for the office, assembled the roof on the ground in two pieces. They put them together as modules with wind-bracing and bridging before crane lifting them into place fully sheathed.

Aside from the roof, Rockwell says a variety of wood species can be found in other parts of the building, including zebrawood stair treads, oak veneer doors, mahogany cladding on the trusses and maple finishes at the reception desk. The office’s large sunshade soffits feature weathered wood planking, which provide a pleasant texture and color, while complimenting the weathered wood siding.

In the end, Dr. Kelson got the modern, classic-looking office he wanted. And now the building is complete, his patients have a stunning, state-of-the-art orthodontic structure—and another reason to show off their new smiles.

2750 Richter: Installing exposed trusses and solving a skylight dilemma

When the team at Worman Resources Inc., a development and construction company in Kelowna, British Columbia, started designing a two-story, mixed-use building in a trendy neighborhood in Kelowna’s South Pandosy District, they knew they wanted to include exposed trusses.

Because they’d used RedBuilt trusses on many of their commercial, residential and mixed-use projects since 2010, choosing RedBuilt for this building was a no-brainer.

“We like the look of the trusses as an “unfinished piece” within our buildings,” said Shane Worman, owner of Worman Resources. “We wanted the Richter project to have a more open loft feel. We like the combination of steel and wood and the aesthetic that brings to the building.”

Worman’s team used RedBuilt™ Red-M™ open-web trusses at 48″ on-center for the roof of the commercial portion of the building, and Red-I™ joists at 16″ on-center for the roof over the stairs. They installed Red-L™ open-web trusses at 48″ on-center for the floor and roof over the building’s residential section.

“All the RedBuilt trusses are exposed along with all the mechanical ducting, sprinklers and electrical conduits,” said Worman. “We can get great spans out of them and run HVAC between trusses that we just can’t accommodate with I-joists.”

Worman also likes that the trusses are a straightforward product to work with. “They can be installed with conventional wood framing methods and don’t require specialty trades,” he said. “And they install quickly in the wider spacing.”

Along with supplying the trusses, RedBuilt helped solve a problem caused by two large skylights — spanning a substantial portion of the trusses’ length — where decking was not present to provide top-chord lateral restraint.

“To solve the skylight issue we provided metal cross-bracing to stabilize the trusses,” says RedBuilt engineer Jeff Jack. “Our team designed a cross-brace system to ensure lateral stability of the trusses where decking was not directly applied.”

At 23,200 square feet, the Richter building is about a block wide and three blocks deep. Construction began in October 2013 and wrapped up in December 2014. Residential tenants moved in that same month. Businesses in the commercial part of the building include a veterinarian clinic and a spa/salon, as well as physical therapy and real estate offices.

In the end, Worman said exposed trusses became a selling feature for commercial tenants who like the non-traditional warehouse look. In fact, some tenants added their own touches to the truss design. Owners of the salon stained the truss chords and painted the steel webs black for added drama.

On the residential side of the building, the Worman team painted the trusses above the kitchen white to create a clean, modern look that tied in with the European kitchen design. For added aesthetic appeal on the roof of the commercial section, they included exposed 2x6 decking over the trusses to give the appearance of old-fashioned tongue-and-groove aesthetic.

Though only time will tell what projects Worman Resources will take on next, one thing remains certain: When they want exposed trusses to add a stylish, non-traditional element to their buildings, they can count on RedBuilt to deliver.

Grand Hotel Parking Garage: Saving time, money and space

When Spokane-based design-build contractor DIVCON, Inc. was designing a 900-stall, 250,000 square foot parking garage for the Grand Hotel, they had a choice to make. Should they use a traditional hand-set framing method for the forms, as they had on garage projects in the past, or should they use prefabricated, concrete forming tables from RedBuilt?

They chose the forming tables, a decision that enabled them to shave three months off their construction schedule.

“When the owner told us we needed to finish the project much sooner than anticipated, we knew we had to find an alternative solution to hand-set shoring,” says Shane Miller, President of DIVCON. “We’d worked with RedBuilt before on commercial projects, and after researching the tables’ labor advantage, time savings and re-use potential, it just made sense.”

Construction began in April and the project was complete by early October. In the end, the project required only 21 pouring days versus the 28 the team had planned—an achievement that helped lower costs. “The tables kept everyone productive,” says Miller. “There was no lag in production and our crew was always three pours ahead. Thanks to the tables’ wide footprint and long spans, we eliminated a lot of shoring, too.”

Because of the site’s constricted size, RedBuilt manufactured the 8′ x 22′ tables in Stayton, Oregon, and delivered them just-in-time for installation. Throughout the process, RedBuilt worked closely with the DIVCON team to ensure they had what they needed. “After the first three tables we tweaked the specifications,” says DIVCON Project Manager Jeremy Kinney. “We changed the dunnage placement and wanted the edges more beveled. RedBuilt was there when we required assistance and refined and customized the tables to our specifications.”

“We also needed a high re-use level on the formface, which is why we chose Super-Matte™ MDO by Olympic® Panel Products,” explained Kinney. “It has higher re-use than any MDO panel on the market today. After finishing the project, we moved tables back to our yard that we won’t even have to resurface,” he says. “They performed very well. We’ll get at least 15 pours out of the tables.”

Kinney says forming tables kept the project site safer, too, because pieces weren’t likely to fall over the edge of the deck—a hazard that can occur with hand-set forming. “Fall protection even came pre-installed,” says Kinney. “When our guys were up on the deck, we had fewer safety concerns. In this business, the biggest risk is falling from height, but using the RedBuilt tables helped us minimize risk.”

Now that the parking garage is complete, guests at the Grand Hotel have ample space to park their vehicles. And though they may never know the benefits of using concrete forming tables to create a garage versus traditional hand-set forming, they certainly reap its benefits.

Desert Mountain Residence: Solving Site Building Height Issues

Back in 1998, a successful entrepreneur from the Midwest bought land to build his dream home in Desert Mountain—a golf community in sunny Scottsdale, Arizona. Sixteen years and a few obstacles later, his 11,000 square-foot home is now a reality.

In 2012, architects at Scottsdale-based H&S International began designing the home. After H&S put the project out to bid, the owners selected the team at the Carefree, Arizona-based Manship Builders to build their residence. Eventually, Manship selected RedBuilt™ to provide a variety of Red-L™ open-web trusses for the home.

In the residence’s main living area, the Manship crew created a large vaulted ceiling with Red-L™ barrel trusses. “The roof design called for an arch that required recessed lighting, 12 inches of insulation and room for other mechanical lines,” Steve Hall, project manager at H&S, said. “RedBuilt’s Red-L barrel truss was the only product we could find that filled that requirement.”

Although the roof came together smoothly during the framing stage, the shop drawing phase was a different matter. Part way in, the team discovered that the roof, as planned, would exceed neighborhood height restrictions. And in Desert Mountain, a community with highly coveted million-dollar vistas, obstructing a neighbor’s view is not an option. By identifying the problem at this stage, and without altering the integrity of the design, the RedBuilt™ team changed the radius of the barrel truss and redesigned the bearing detail to keep the roof at an acceptable height.

The RedBuilt™ team also helped train Manship’s framing crew prior to installing the trusses. Because they had never used RedBuilt open-web trusses, RedBuilt Technical Representative Steve Smith provided a training session using a sample truss. He showed the team how to properly install products and provided a variety of helpful tips. He also met with the framing crew when the trusses were delivered onsite to review job-specific details.

“Once we had the trusses, the crew completed framing and rough carpentry within 70 days—an impressive amount of time for a custom home of this size,” Mark Laidlaw, general contractor at Manship, said.

In all, the Manship crew installed 3,400 lineal feet of barrel and 3,540 lineal feet of tapered and parallel Red-L™ series trusses. Barrel trusses were used in the living rooms, foyer, main entry, master bedroom, guest area, dining room and one of the garages. The team framed the rest of the home with tapered Red-L™ trusses.

Now that the residence is complete, the owner can enjoy his new home without worrying about obstructing his neighbor’s view. And now they—and their amazing views—can all live happily ever after.

The 951: Creating an All-Wood, Mixed-Use, Mid-Rise Structure

When Glenn Levie of the Encino, California-based Levie Development and Architectural Group decided to build in Boise, Idaho, he didn’t follow in the footsteps of developers who were creating separate commercial and residential buildings on the outskirts of town. He built a mixed-use structure in downtown Boise with everything under one roof.

Planning for Levie’s four-story building, called The 951 (the structure’s address), finished in the fall of 2013 and site work started soon after. The building will be ready for tenants this December.

Overall, The 951 is made up of 74,500 square feet of mixed-use space. Around 4,100 square feet of that is designated for retail use on the first level with the rest dedicated to the 68 apartments on the upper floors. Seven of those apartments will be two-story units, combining a street-level workspace with private stairs leading to the living quarters above.

Early on, RedBuilt representatives met with contractor/estimator Roy Jackson from the Eagle, Idaho-based Steed Construction, and engineer Craig Brasher from the Boise-based AHJ Engineers to develop an engineered wood structural solution unique to the building’s requirements.

Levie says preplanning helped save the team time, money and significantly improved the overall process. They had to make special considerations for the all-wood structure. When buildings reach four or more stories, lateral forces from wind and seismic events create heightened design challenges for connecting the structure to the foundation. High-strength 2.0E RedLam™ LVL provided an answer and large hold-down anchors were embedded into the foundation and bolted to the RedLam LVL. RedBuilt engineered wood provides strength and reliability in critical connection locations such as these because its wood fiber is so consistent.

Additionally, since Red-I™ joists, RedLam™ rim board, and RedLam™ beams come off the press with a low moisture content (compared to solid sawn lumber), the use of RedBuilt engineered wood products decreased the amount of expected wood shrinkage for The 951.

The 951’s main level has a different use than the upper floors, requiring walls to be jogged and open space provided in the interior. Loads need to be concentrated into beams and transferred to columns and walls that do not align with the walls above.

“RedBuilt helped us provide the ceiling room needed for the large beams, re-route the ducting due to tight joist spacing in certain areas, and add large columns in the floor space,” Brasher said. “They had the products we needed to frame intelligently, keep costs down and move the project along at a good pace.”

Another unique development RedBuilt proposed was to redesign the original second, third and fourth-level floor systems into a more stout system at 24″ on-center spacing between joists (instead of the typical 16″ on-center). By switching to a joist series with a greater flange width, the team was able to achieve the required fire rating and eliminate the need for two layers of gypsum board.

“RedBuilt suggested we change to a higher series joist that had the required width and greater capacity,” Brasher said. “This provided a solution for the fire rating and reduced the number of pieces to be placed in framing.”

According to Levie, around 70,000 square feet of The 951 is made up of RedBuilt products:

  • Redlam™ 2.0E LVL
    • Columns on the first and second floor
    • Tall wall studs in the center entry
    • Beams and headers on all floors and roof window openings
    • Stringers on all stairs
  • 16" Red-I90™ I-joist second, third and fourth floor framing system
  • 14" Red-I90™ I-joist roof framing system
  • Glulam beams on first floor retail areas provided by RedBuilt as a third-party product

“Throughout the entire process, RedBuilt has been hands-on and helped us deal with unforeseen issues before they became problematic,” Brasher said. “We knew if we had questions in the field our sales rep would be there to help. RedBuilt not only has great quality products, but also the customer service to back it up.”

Tuxedo Grill at Kansas City Zoo

In October 2013, the Kansas City Zoo opened a new penguin exhibit. Shortly before the exhibit opened, the Zoo also decided to renovate the nearby restaurant—the park's main eating facility. The project went out to bid, and the environmentally friendly design of the Kansas City-based McCownGordon Construction was eventually selected.

McCownGordon began designing the 7,300 square-foot café, renamed the Tuxedo Grill, in the summer of 2013, and construction started that fall. Its design incorporated many sustainable building practices and included natural elements such as bamboo and exposed wood.

Steven Crosley, senior project engineer at McCownGordon, said they wanted a roof with an exposed look, so they chose 40-inch deep RedBuilt™ Red-H™ open-web trusses. "The trusses fit perfectly with the building's natural theme," he said. "And RedBuilt even matched the panels in each bay to keep the visual appearance consistent."

Aesthetics, however, weren't the only thing the RedBuilt team helped Crosley and McCownGordon accomplish. Wayne Hess, structural engineer at the Kansas City-based Leigh & O'Kane, the engineering company involved with the project, said the ingenuity of RedBuilt's team also helped prevent cost overruns.

Hess said the team designing the café had to make multiple changes after much of the design had been completed, including alterations to floor plans, materials and mechanical equipment. "Some of these adjustments caused changes to the roof load," he said. "But RedBuilt helped us keep the original trusses by manipulating the spacing so they had adequate capacity for the reconfigured loads. And since we didn’t have to replace the trusses, we were able to stay within budget."

According to Hess, the trusses were also chosen based on their ability to route mechanical piping and ductwork. The depth of the truss offered wider spacing in many locations, allowing ductwork to pass without interrupting the structure of the building, he said.

Two sections of the roof called for short trusses, which couldn't be produced in the Red-H series. RedBuilt solved this problem by using RedLam™ LVL for the shorter sections.

The café is now open for business, and Crosley anticipates the building will achieve LEED status in the near future.

Founded in 1909, the 200-acre Kansas City Zoo is home to more than 1,300 animals. It recently added two critically endangered Sumatran tigers to its collection. Fewer than 250 of these tigers are believed to exist in the wild.

Each year, the Zoo receives about 400,000 visitors. And soon, when they stop by the penguin exhibit, the choice of where to eat will be black and white, but won’t require tuxedo attire.

DesertSol Solar Decathalon Home

You’ve probably heard of an academic decathlon. How about a solar decathlon? Every year, the U.S. Department of Energy holds an international solar decathlon, inviting 20 teams from universities around the world to design and build solar-powered homes. The goal of the program is to educate the public about energy-saving residential designs.

This year RedBuilt™ is mentoring UNLV’s Team Las Vegas, helping the students build their home’s structural frame. For the decathlon, the team is building “DesertSol”, a 754-square-foot prototype home designed to maintain a comfortable interior climate solely through the use of water and solar energy.

Grad student Iani Batilov, DesertSol’s structural lead, says Team Las Vegas chose RedBuilt’s RedLam™ LVL for wall framing studs, beams and headers, and Red-I65™ I-joists for the roof because they wanted quality, sustainable materials with advantages in strength and dimensional accuracy.

“DesertSol is unique because of its highly irregular geometry and demanding energy-efficient design,” says Batilov. “We needed a solid, cost-effective solution that would contribute to the energy performance expected of the home. Conventional lumber and framing techniques would have resulted in wasted material and taken away valuable insulation space.”

Batilov also says there’s another reason the team needed RedBuilt’s strong LVL: DesertSol has to be transported from Las Vegas to Irvine, California, for the competition in October. “Our goal is to construct sturdy yet lightweight framing for DesertSol. The material we’re using has to be exceptionally rigid,” he says. “While on the road, the home will be subjected to all kinds of irregular forces.”

To date, RedBuilt™ representatives have provided Team Las Vegas with a full set of engineered shop drawings, counted all parts and pieces, and assisted with installation. “We provide a lifetime warranty for the products we manufacture for our customers,” says RedBuilt™ representative Gary Collinsworth. “And since the home is being built here in Las Vegas, traveling to California for competition, and returning to Las Vegas for permanent display, it needs a professional engineer’s stamp for both states—an unusual requirement for one of our projects.”

This year’s decathlon features nine returning teams and 11 new teams, from as far away as the Czech Republic and Austria. Ten point-driven contests—based on categories such as architecture, affordability, energy balance and hot water—will determine the winner.

Team Las Vegas is comprised of UNLV’s brightest architectural and engineering students, as well as faculty staff and other local professionals. Because DesertSol is student-driven, the participants are serving as general contractors, architects, framers and engineers.

UNLV student and project manager Alexia Hsin Chen is confident her team will do well this year. “We set out to create a structure that would promote harmony among the house, the people who live in it and the desert environment,” she says. “DesertSol is all about the responsible use of the sun and water. We are poised to score high.”

Some of the home’s highlights include retractable solar shade screens, a cooling tower, a steel chassis foundation and environmental controls, including a system that allows lights, appliances and the thermostat to be controlled by a smartphone or tablet.

Designed as a second home for desert explorers in search of an escape, vacation or retirement retreat, DesertSol will cost $320,000 to build. The project has an overall budget of $750,000, which includes transport and travel.

“The students are sizing all the materials,” says Collinsworth. “We’re just helping to check their numbers and make sure all of our products work for each specific application. RedLam™ LVL (Laminated Veneer Lumber) is one of our specialties—after all, RedBuilt™ pioneered its use back in the ‘70s.”

Chen says her team hopes to wrap up construction in Las Vegas at the beginning of July, and they plan to transport DesertSol to California in late September. “We’re ready to show the world that a solar home is a reality, and not just a dream,” she says.

After the competition, DesertSol will return to Las Vegas, finding a home at the Springs Preserve, a 180-acre attraction designed to educate visitors about life in the Mojave Desert. At the Preserve, the home will serve as an exhibit for sustainable desert living, and Chen hopes it will eventually receive net-zero certification.

Undoubtedly, the 2013 solar decathlon is teaching tomorrow’s leaders like Chen and Batilov how to build an ultra-efficient solar-powered home. Along the way, it’s also teaching them how to build the foundation for a promising career.

DesertSol in the news:

UNLV students compete to build energy-efficient home

UNLV Students Prepare For Solar Decathlon

UNLV student design projects seek to solve practical problems

Introducing Team Las Vegas

Duluth Depot Train Shed

As home to both rail engines and rail cars, the triple-bay Duluth Depot Train Shed at the Lake Superior Railroad Museum is a triple bay depot with parallel gable roofs that replicates the historic rail stations of the early 1900s. Following the original construction, an addition was built adjacent to the depot roof, however it was built without taking into consideration factors such as drifting and sliding snow. And during winters in Minnesota, there’s no shortage of either.

To remedy this situation, Riihiluoma Construction and LHB Engineers & Architects doubled up on the roof trusses, adding sister open-web trusses to the original legacy trusses. In total, 108 new open-web trusses were added spanning 38’ with gable pitch top chords and a unique radial curved bottom chord. Additionally, the roof’s natural daylighting was improved by increasing the size and quantity of skylights, adding yet another twist to the project.

To add to the complexity of this project, the open-web trusses had to be built to precise tolerances, allowing them to be installed without removing the existing roof. Thanks to the lightweight nature of the open-web trusses, and the ingenuity of the builder and framers, the trusses were able to be handled and installed without the need for a large crane, saving both time and expenses.

First United Church

In October 2009, an early morning fire claimed the First United Church of Wetaskiwin in downtown Wetaskiwin, Alberta, Canada. The congregation’s building had disappeared, but its spirit and determination had not. The members knew they had to rebuild.

That’s when they contacted George Berry at Berry Architecture & Associates. Shortly thereafter, Berry’s engineer Nick Leshchyshyn started developing working drawings for the new structure.

Leshchyshyn’s drawings called for a 12,486-square-foot building on the same site as the former church. They also specified classrooms, a dining hall, commercial kitchen and conference room in the basement, as well as a sanctuary, kitchenette and administrative wing on the main level.

While reviewing the project’s drawings before they were sent out to bid, however, RedBuilt’s technical sales representative immediately noticed a potential issue: the design called for pitched trusses with a flat bottom. With a span of approximately 62 feet, the combination of the span and slope created a situation where pitched Red-M™ truss geometry limitations were exceeded. RedBuilt’s representative suggested replacing the pitched trusses with Red-M™ scissor trusses that maintained the specified roof pitch, and also opened up the sanctuary space. The unique truss profile allowed for an elevated ceiling, making it an awe-inspiring space, while still keeping the pitched roof – a critical component in the overall design.

Using Red-M™ open-web scissor trusses, however, presented KellerDenali, an Alberta-based construction company and Frank Pring, jobsite superintendent, with a logistical challenge. Because of the truss length, they had to be transported in two pieces and assembled on the ground at the job site before being hoisted into place with a crane. But once again,RedBuilt’s expertise and commitment to service came through.

“We knew there was a potential for logistical obstacles in assembling the trusses onsite,” says Gerard Reinke, KellerDenali’s jobsite coordinator. “But the RedBuilt™ team made sure everything fit the way it was supposed to. The trusses were installed quickly and without unnecessary complications.”

While the building is new, the congregation was able to hold onto pieces of the church’s past. Members salvaged timbers from the old building and transformed them into a cross, which serves as a reminder of what the church has been through.

Freedom Truck Center

Freedom Truck Center of Spokane, WA needed a workhorse of a building—a 45,000 square foot full-service trucking facility with maintenance bays, display showrooms, and administrative office areas.  They also needed it fast and at a cost-effective price—presenting challenges for everyone involved, from design through finished construction.

Initially considering a steel joist and deck system, but faced with escalating steel prices and a very aggressive construction schedule, the project design team of ALSC Architects, DCI Engineers and Lydig Construction turned to RedBuilt to design and deliver a high-performance engineered wood solution for the complete structural roof and floor system. Lydig Construction then enlisted Mandere Construction, Inc. as the framing contractor to install it.

“The project presented a unique set of challenges,” said John Mandere. “There was a critical construction path timeframe, coupled with an extraordinary amount of product to be installed very fast.”

The 48” on-center spacing of the RedBuilt Open-Web Trusses also made installation safety considerations a priority for Mandere and his construction personnel. To address this, the roof panels were assembled and sheathed on the ground and then craned into position. This not only mitigated site safety issues and concerns, but also helped deliver on the project’s tight timeline since the panels could be built simultaneously along with work proceeding on other parts of the building frame.

Over nearly two decades Mandere Construction has built a strong reputation in constructing unique and specialized projects including high-end residential homes, hotels, churches, commercial and multi-family / multi-use structures.

“Our success is highly dependent on the performance and reliability of our trade suppliers and partners,” Mandere said. “RedBuilt performs at the same level we do. They get things right the first time, which kept us on track to meet our deadlines.  We consider them a true business partner.”

RedBuilt™ Products Used

RedBuilt supplied the complete structural and frame package, including:
Pitched and parallel Red-S Open-Web Trusses at 48” OC
Red-I65 14” I-Joists for the second floor

Gilbert Park Professional Center

Building the first privately-financed LEED-certified building in the heart of the Rogue Valley presented a unique set of challenges, and required a very detailed set of processes to meet the LEED requirements. To help facilitate that process, Corey Vitus of Vitus Construction depended on RedBuilt™ to provide quality products and top-notch support.

At 34,000 square feet, the Gilbert Park Professional Center in Grants Pass, Oregon is a two-story Class-A medical office building that houses five tenant suites and shared conference room space.

“It was a dream job to work on” said Vitus. “We had plenty of room to work and good access everywhere. It was just one of those fun jobs to work on.” And given the challenges involved with LEED certification, “dream job” is high praise indeed.

Vitus also spoke highly of his experience working with RedBuilt™. “They are very professional in everything they do. They simplify the process - all the way down to making sure that each component is correctly marked and labeled, and include great instructions. Also, since they take care of all of the processing, there was very little waste and we didn’t have to modify any parts.”

The Gilbert Park Professional Center included a range of RedBuilt™ products – from Red-L™ Open-Web trusses in the roof and Red-W™ Open-Web trusses in the floor to Red-I45™ joists and RedLam™ LVL throughout the building.

And to help make sure the entire process went as smoothly as possible, Vitus relied on his RedBuilt™ Technical Sales Rep. “He was absolutely wonderful,” he said. “He ensured that the entire RedBuilt team took care of us, and coordinated the total effort from the draftsman on up.”

Vitus, and others involved with the Gilbert Park project are looking forward to working with RedBuilt™, and using RedBuilt™ products again on projects in the future.

Havens Elementary School

The Havens Elementary School project in Piedmont, California consists of three new buildings in a tight residential area. Boyett Construction teamed up with their local RedBuilt rep for assistance in making this project a reality.

Central to the success was the level of trust and partnering approach quickly established between Boyett and RedBuilt™. And given the tight timelines and budget constraints, this partnering effort proved to be instrumental.

With design specifications that included the use of Red-I™ Joists and RedLam™ LVL, RedBuilt™ continued to work with Boyett to deliver on our commitments, including delivery coordination and jobsite service. And while some field challenges were inevitable, they were quickly resolved through a cooperative effort by Webcor, Boyett, RedBuilt™ and Arun Saha at ATI Architects and Engineers.

The Havens Elementary School project, which began in July, 2009, is scheduled to be completed in time for the upcoming school year, starting in early September.

Jamie Wolf Professional Building

Shell/Ackerman installed 13,700 sq. ft. of floor with a four-man crew in 7 hours using Red-L™ Open-Web Trusses. Shell/Ackerman have been the go-to framing subcontractor for Silvey Construction for nearly 30 years. Silvey’s core business consists of Medical and Dental buildings requiring quality floor systems with no floor bounce.

From Dave Schell of Schell/Ackerman: “We’ve been very busy, which is interesting in this environment. We always promote Open-Web products because of the speed of installation and ability to keep project costs down. For a project of this size, using conventional framing methods would have taken three times as long.”

“Our RedBuilt™ rep is top-shelf,” Schell went on to say. “He works with us from engineering all the way through completion. After we rolled on our first RedBuilt job, there was no other way to go in terms of span and speed.”

Las Vegas Cyclery

In 2008, bicycle enthusiast Jared Fisher dreamed of owning a bike shop that could power itself and generate almost no waste. At the end of 2012, his dream became a reality.

Last December, Fisher opened Las Vegas Cyclery, a two-story, 9,793 square-foot bicycle shop at The Gardens Summerlin South Village in Las Vegas. Located on one acre, Las Vegas Cyclery is housed in a net-zero, Platinum LEED certified building that runs at 103% energy capacity (produces 3% more power than it is expected to consume in the next year!).

In 2008, Fisher began meeting with Wade Takashima, the Henderson-based chief architect at TWC Construction and chief executive officer of Creative FIT, about developing a net-zero building. Eventually engineer Todd Goshorn of Henderson’s TG Engineering got involved, as well as Jose Martinez, Sr., president of Pepe Construction, the Las Vegas-based company that served as framer for the project. TWC selected RedBuilt™ to assist with the creation of Las Vegas Cyclery because of its ability to offer environmentally friendly trusses that could achieve the look they wanted.

For the ceiling, Fisher and Takashima asked for an exposed finish with a raw feel, and they liked the combination of wood and metal. The solution? Red-L™ and Red-W™ open-web trusses that met both the aesthetics and helped contribute to the building’s Platinum LEED certification. RedBuilt™ open web trusses are eco-friendly because they help minimize jobsite waste, and the wood products come from renewable sources and are free of urea formaldehydes. In addition, the steel components contain 23% post-consumer recycled content and 7.3% post-industrial recycled content.

“The decision to use the open-web trusses from RedBuilt was essential to the overall open structure design concept,” says Takashima. “The trusses worked perfectly and contributed a nice harmony of wood and steel with the other structural elements of metal decking and glulams. Plus, they helped us achieve LEED points for recycled content and regional materials.” Overall, the entire Las Vegas Cyclery project achieved 30% recycled content and 92% regional materials, he says.

So far, Las Vegas Cyclery has caught the attention of many newspapers and magazines, including Bicycle Retailer, which called the building “a functioning model of ultra-green retailing and energy efficiency.” According to the Las Vegas Review-Journal, Las Vegas Cyclery is “state-of-the-art” and a “shrine to energy efficiency.”

Every day, shoppers at Las Vegas Cyclery admire the store’s earth-friendly resources, which include 208 solar panels, a wind turbine, recycling stations, solar-tube lighting systems, a bike-wash station that collects and filters water for continued use, and waterless urinals in the men’s restroom.

“A lot of thought went into every part of this building,” says RedBuilt™ representative Gary Collinsworth. “All parties involved, from framer to engineer, hope the design and achievement of Las Vegas Cyclery will send a message to the community that everyone has a responsibility to take care of the environment.”

Jennifer Turchin of the Las Vegas-based Sellen Sustainability, who served as the building’s LEED consultant, says the shop is likely the first net-zero building in the Las Vegas Valley, and Fisher believes it’s the first net-zero bike store in the country.

Las Vegas has always been known for bright neon colors like red, pink and yellow. If Fisher has his way, it will soon be known for being green too.

Read about Las Vegas Cyclery in the news

Las Vegas Cyclery takes green retail to extreme - Bicycle Retailer

Las Vegas Cyclery's design, systems make it 'net-zero' site - Las Vegas Review-Journal

LEEDing the Way - Vegas Seven

Summerlin Bike Shop Sheds Light on Energy Efficiency - Prudential Americana Group Blog

Lighthouse Baptist Church Multi-Purpose Building

When you think of a typical basketball gymnasium, you probably imagine a court built on top of a ground-level slab on grade with nothing underneath. But for the Lighthouse Baptist Church multi-purpose building in La Verne, California, putting the gym floor at ground level wasn’t an option.

The solution: Build up.

And that’s just what they did. Working with architect Cliff Parris, Manning Engineering and Hunte Construction as the Framer, General Contractor Construction Counseling Ministry built the 22,000-square-foot Lighthouse Baptist Church Multi-Purpose Building with a basketball gymnasium and roll-out bleachers on the second floor.

Engineers designed the second story, which sits above multiple rooms, with Red-L™ and Red-W™ open-web floor trusses. They also added 90-foot Red-H™ open-web trusses at 48 inches O/C to the roof over the gymnasium.

Gary Center, Project Manager for Construction Counseling Ministry, likes that the open-web floor trusses let them run mechanicals through a complex building at a budget-friendly cost. “This 22,464-square-foot wood-framed, two-story, 45-foot-high building is unique,” he says. “The first floor consists of an apartment, offices, classrooms, eight restrooms, a sanctuary and sundry other rooms. The second floor has a regulation gymnasium for basketball and volleyball with a 25-foot ceiling. An HVAC with 20 zones and the extra floor load of spectators and bleachers required a design that would allow all the mechanical trades room to service the multiple uses.”

Along with being functional, the open-web trusses add an aesthetic element to the building. The engineers left the trusses exposed to view, creating an attractive, clean-looking roof structure. And to keep the overall construction simple, they built the entire roof in modules at the ground level, erecting them later by crane.

One of the project’s biggest design challenges was accommodating heavy loads on the second floor, particularly those from the roll-out bleachers. To overcome this obstacle, the RedBuilt Technical Sales Representative and Design Team replaced the floor trusses under each bleacher’s wheels with RedLam™ Beams, easily keeping the weight supported in any position.

In the end, Mr. Center was impressed with RedBuilt’s customer service. “I appreciate working with a company that has positive attitude toward customer service throughout all aspects of the organization,” he says. “Everyone that I dealt with from sales, engineering, manufacturing, shipping and onsite technical help was very knowledgeable, timely and courteous, and helped this project move forward without any delays or overruns. I look forward to my next project with RedBuilt in Newport Beach.”

Riverstone International School

With over 300 students from 16 countries, Boise’s Riverstone International School’s mission is to provide a quality independent education to students in the Treasure Valley. As enrollment has grown, so has their need for adequate classroom and facility space.

Recently, construction was completed on the Lower School’s new building, a 25,000 square foot facility serving students through grade 10. The new building’s design incorporated the use of RedBuilt’s Red-I Joists and glulam beams to create the unique look of the exposed roof.

The school’s architect, erstad ARCHITECTS, designed the school to have a clean, elegant appearance. With RedBuilt’s products they were able to achieve that design while retaining the warm look and feel that wood provides, as opposed to the cold feel that typically accompanies steel. And with the spans and open look the design called for, RedBuilt’s products proved to be an economical solution. The precision in engineering and manufacturing also made the framing virtually problem-free.

On top of the excellence in design, manufacturing and engineering, the school’s roof also met Idaho Power’s “cool roof principles” for energy efficiency. But the ultimate praise comes from those who are most affected by the new building. Said a parent of one of the school’s students: “It’s fantastic. It’s big and open and has a sense of freedom. It’s warm without being too ornate.”

Skyway Professional Centre

Often, when you think of the construction of multi-story medical office buildings, you think of steel as one of the primary materials. And when steel is involved, of course, it adds another layer of complexity to the project, requiring welders and other specialty trades throughout various stages of construction.

For the construction of the four-story Skyway Professional Centre in Red Deer, Alberta Canada, however, that additional complexity was avoided by using RedBuilt’s Red-I Joists throughout each level of the building. Working with Burgess Bredo Architect and Cognidyn Engineering, Timcon Construction developed a schedule and process whereby floor sections were assembled at ground level, including all hangers, and then flown into place by crane.

The result? A job that proceeded smoothly, without any of the delays that can accompany a multi-story project, that followed the schedule set by Timcon, and met all National Building Code of Canada requirements.

Warnock Phase 2 Housing

Warnock Phase 2 is an 85,000 sq. ft. mixed-use building, adjacent to Phase 1 townhome units for the Philadelphia Housing Authority (PHA). The building includes apartments, PHA offices, retail space and a senior center. It also features a Green Roof and rooftop deck, all in the heart of Philadelphia.

The building’s design used all five series of RedBuilt Open-Web trusses – 185 different truss types in all – in a variety of conditions.

We worked very closely with the engineer to find a solution for this building as neither steel bar joists nor wood plated trusses could perform. "During the design phase, with all of the changes and everything that came up, RedBuilt accommodated us with all the needs we had," said Phil Ferenz of Glenview Construction.

The framer and general contractor coordinated all details with the trades to make sure everything fit perfectly, and the whole framing package was installed in only 3 months. "From the start we knew that the tolerances were minimal on this job – 3/8ths of an inch within 38 feet. I was truly amazed when the parts and pieces came out that they were that accurate in all cases. Everything fit right in where it should have," said Ferenz. "RedBuilt accommodated us with all the needs we had – design changes, field conditions – you guys were on the mark every minute of the way!"


The Yogurtland project in Southern California was one of the more unique projects we’ve been involved with lately, and provided a number of big challenges. The building’s design required the use of a barrel truss profile, and included a number of skewed and sloped bearing surfaces.

This project was initially designed to use steel, but RedBuilt’s Tomas Carlos worked with the customer and project’s engineer to provide a more cost-effective and time-efficient solution using RedBuilt’s Red-W™ open-web trusses. At 74 feet long with a 7 foot camber, these were some of the longest trusses of this type produced at the Chino facility.

With the barrel profile and curves in every truss, the work of our veteran truss designer Dave Vanderzanden was outstanding, and couldn’t have happened without the efforts of everyone from scheduling to engineering and the team at our Chino manufacturing plant.

U.Village Parking Garage

For shoppers at U.Village, Seattle’s trendy outdoor mall near the entrance to the University of Washington, finding a parking spot can be next to impossible. Chris Moes, senior project manager at the Maple Valley-based McClone Construction, hopes that will change with the mall’s new five-story, 350,000-square-foot parking garage that is currently under construction.

Moes and McClone Construction helped form all of the garage’s horizontal concrete decks and beams. Because the job site was small and time was limited, McClone enlisted RedBuilt™ to create 180 fully prefabricated formwork tables up to 8’ x 23’ in size to form the underside of seven-inch-thick concrete decks.

“The project schedule and site logistics were a challenge from the start,” says Steve Murray, field operations manager at McClone Construction. “There was not time in the schedule or room on site for us to fabricate the deck tables needed for the parking structure. We needed tables that could be delivered and ready to use immediately, and RedBuilt provided that.”

To create the formwork tables, the RedBuilt™ team used cambered RedForm™ I-joists, a product manufactured and designed specifically for use in forming applications (temporarily supporting a concrete slab until it has enough strength to support itself and all imposed loads). RedBuilt™ also provided McClone with a dedicated team of technical and field support specialists with expertise in forming applications throughout the design and installation process.

According to Moes, using prefabricated table forms with cambered RedForm™ I-joists gave the McClone team the flexibility they needed to carry concrete slabs with bay widths of 26 feet without the need for any intermediate shoring or support.

“Working with RedBuilt™ to build the deck panels at their plant was instrumental in the success of this project,” he says. “We were able to truck them to the site for use on scheduled pours right when we needed them.”

Featuring 550 parking stalls, the U.Village garage will offer free parking to mall patrons. Construction began in January, and is scheduled to be completed in October 2013. Once open and more parking spaces are available, shoppers will likely be wearing a new accessory—a nice big smile.

Taylor Middle School Cafeteria

By the end of 2013, students at Taylor Middle School in Millbrae, California, will be able to enjoy a balanced meal in the comfort of a new 15,694-square-foot cafeteria.

Because the students’ old cafeteria had become too small and was showing its age, Millbrae School District (MSD) enlisted the help of architect Richard Lawrence from IBI Group Architecture Planning to create a cafeteria with a central kitchen that could serve all schools in the district and function as a venue for graduations, board meetings, community meetings and even basketball and volleyball games.

IBI retained the services of Michael Parolini, an engineer at the San Luis Obispo based Smith Structural Group, to design the structure. Parolini asked the RedBuilt™ team to assist with the project’s roof system.

Initially, Parolini started with a four-foot on-center scissor truss system that spanned the width of the cafeteria. Lawrence and IBI reviewed the initial concept and conveyed that they wanted more of an open feel since the roof system was going to be exposed. To achieve this look, the team came up with a final design that consisted of double trusses at eight-foot on-center. RedBuilt™ engineers worked closely with Parolini on designs, revising calculations and truss panel layouts to meet seismic and other loading requirements from California DSA (Division of the State Architect) and the school district.

Prior to installation, RedBuilt™ engineers worked with Blach Construction and its in-house design team to build 3D AutoCAD® models to get an accurate layout and slope, as well as bolt locations for the hold downs. The double 75-foot Red-H™ scissor trusses were then shipped in two pieces, and the Santa Clara-based Blach Construction assembled them on-site.

“Installing the trusses was challenging because of the eight-foot on-center system and because they needed to be connected to CMU block walls while meeting DSA requirements,” says RedBuilt™ sales rep Mike Hayley. According to Parolini, connecting the trusses to the block walls was a key part of the project. “Since the cafeteria is in a high seismic risk area, we had to take special consideration in connecting the roof framing system to the wall,” he says. “The attachment is essentially what holds the building together so all structural systems can remain fully functioning before, during and after a seismic event.”

Aside from the trusses, RedBuilt also supplied Red-I™ I-joists and RedLam™ LVL in the cafeteria’s kitchen, bathrooms and entry.

Built in 1939, Taylor Middle School is number 10 on the Millbrae Historical Society’s Millbrae History Walk. Its students are known for their academic achievements.

IBI Group Architecture Planning began the cafeteria project in December 2012 and plans to complete the building in December 2013. During construction, students have been eating across campus in a space converted into a temporary lunch kitchen.

Although no one knows for sure what the future holds for Taylor Middle School’s 1,000 students, we do know one thing: by the end of the year, they’ll be eating lunch in style.