Thursday / September 12, 2019 / 12:00 PM - 1:30 PM

US Air Force Academy Cadet Chapel Re-Cladding: Architect-Built Enclosure Mock-Up Case Study

Gensler, 11 East Madison Street, Suite 300, Chicago

When an architect designs a custom cladding, it is not uncommon to require a mock-up to verify enclosure performance, before construction commences.  Such a mock-up will typically be constructed by the specialty enclosure subcontractor, once that contractor has been selected through bidding or by negotiations.  But what if the enclosure is so far “off the shelf” that even a sophisticated enclosure contractor will have difficulty understanding how to bid the intricate design?  And, what if the Owner is worried that this will result in “risk-adverse” bidding - with built-in fudge factors in the bid pricing.  

In the case study that will be presented, these concerns led to a relatively unique proposal by the design team - build a full-scale mock-up of the proposed enclosure DURING the design phase.  This way, the design can be built and tested to demonstrate that it works - BEFORE it is issued for bid.   Allowing the bidders to visit and observe first-hand the mock-up will give bidders more confidence in their pricing.  It also can help avoid a successful bidder from concluding that the design “looks good on paper,” but it can’t really be built that way - which can trigger a round of uncomfortable VE proposals.

Bruce Kaskel of WJE will review this process as it was applied in the re-cladding design of the US Air Force Academy Cadet Chapel in Colorado Springs, CO.  The case study will review how shop drawings, extrusion die drawings, and panel fabrication drawings were all prepared under our auspices as necessary to build two full-scale representations of the proposed re-cladding design.  The process included hiring an extruder to push custom aluminum shapes; a fabricator to build the custom panels; and tradesmen to erect it at a certified test lab.  The test protocol which was developed during the design process was then implemented on these mock-ups.  The “lessons learned” from this testing (yes it leaked the first time around) where resolved and added to the final construction documents, now being bid by contractors.

Speaker: Bruce Kaskel is an architect and structural engineer with Wiss, Janney, Elstner Associates, Inc. He has over 35 years’ experience with cladding and glazing, both investigative and repair designs. He served as the Project Manager on the WJE team participating in the re-cladding design of the US Air Force Academy Cadet Chapel. The re-cladding design is completed. Currently, the Government is bidding the project with anticipated start of construction in early 2020.


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Sponsored By

Building Enclosure Council-Chicago

Learning Units

1.5 LU/HSW

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Non Member Price