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Voyager Hall and Epicenter Masonry
Verona, Wisconsin

Owner: Epic Systems Corp.
Selection: Negotiated
Architect: Cuningham Group Architecture
Timeline:

Voyager Hall (Training Center)
May 2005 to May 2007
Epicenter (Auditorium)
March 2006 to August 2007

Size: Voyager Hall - 425,083 sq.ft
Epicenter - 195,888 sq. ft.
Contract Format: GMP
Self-Performed: 30%

Project Description:

Voyager Hall and the Epicenter utilize four main types of masonry and stone. First, Minnesota quarry creek natural strata finish stone (750 tons) makes up the main type of stone used on the exterior. Much of the building’s exterior walls are puzzled together using this coarse cut stone as “skin.” The quarry creek stone is also used on the interior as column covers and on the main fireplace facing. Second, glacier buff sawn finish stone (413 tons) was used in three main locations: it is located at the border of various exterior openings (for example, windows), the complete exterior stone cap on the stairways and two terrace decks, and the facing of eight interior fireplaces. It is also used on a large exterior wall face for an aesthetically smooth looking finish. Third, precast (29 tons) was used on the various sills and panels throughout the building. The precast is used on the exterior underneath the curtain wall and on the interior’s eight fireplaces and two registration areas. The precast panels are all wheat panels, where the artwork resembles tall blades of wheat blowing in the wind. Molds were created using actual wheat stems aesthetically positioned in the mold so that each poured piece would look exactly as it was designed. Fourth and finally, standard masonry block (67,000 units) was used on a mechanical chase wall that stands throughout the entire lower level. It was also used for elevator shafts, many interior auditorium walls, and as a structural support for the interior and exterior curtain wall systems.

There were many challenges that the masonry crew overcame during the course of the project. The biggest challenge was the weight of the stone. Each hefty piece varied in weight from 50 to 300 pounds and had to be raised upwards 40 feet in some places, making each ‘set’ a difficult task. In addition, keeping a three-inch joint for the Minnesota-quarried creek stone was no easy task for masons used to working with finer tolerances. This large joint was used because of its aesthetic value: it looked most fitting in the context of the rural surroundings dotted with red barns clad in field-stone. A further complication for masons – the serpentine radius of the building, which is so appealing to the eye – created many facet points and demanding intersections that only an experienced mason could perform. This masonry work was one of the major portions of work Cullen self-performed and its results speak for themselves. Finally, there were instances where stone needed to be set over 40 feet from ground level. To solve this problem, a Hydro-Mobile scaffolding system was brought in allowing the masons to easily work at any desired elevation. Even though Voyager hall and the Epicenter were very large scale and complex projects, the masons working for Cullen from the International Union of Bricklayers and Allied Craftworkers, Locals 7 and 13 did an outstanding job. Their great work ethic and unbroken dedication were crucial to the success of the project being completed on time and under budget.

 


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