Yesodei Hatorah High School, Naugatuck, CT
Unique Torah Community Selects Precast Concrete
Yeshivas Ohr HaChaim, a Waterbury, CT based Jewish community is building an all-boys private Jewish high school and other support facilities on a 56-acre parcel in Naugatuck, CT. The plans include two dormitories, a gymnasium, kosher market and 86 housing units that will be a combination of townhouses and single-family homes.
Developed by Yeshivas Ohr HaChaim, the campus is a first-of-its-kind community in Naugatuck and will include a Mesivta High School and Kollel building and apartments for kollel (married students) and their families. The Jewish school or seminary (Yeshiva or Mesivta) where unmarried students intensively study Torah is part of the Institute for Advanced Talmudic Studies and the Touro College System based in New York City.
Their vision is to create a community centered around Torah values. The Mesivta will serve the nearby Waterbury community including yeshiva and professional families who are looking for affordable housing in a spiritual setting. The beautiful location in Naugatuck is proximate to Waterbury and considered the right environment conducive to create a self-contained academic community.
Total Precast Structure
Peter L. Amara, AIA, NCARB, Principal, Amara Associates, LLC recalled that their firm had been brought on board for preliminary design sketches to get the school project through zoning board approvals and the permit process. Ultimately Amara Associates prepared the design and construction drawings and worked with Robert Jacobs, the owners representative, to reach their aesthetic goals. “Now that the school is finished we are designing the other buildings as part of the overall master plan,” says Amara.
The project was broken into several phases, starting with the construction of the school and the dorms, according to Amara. Architectural insulated load bearing precast concrete panels enclose the single story school that was designed for a future second floor expansion.
“One of the main reasons for the selection of precast concrete was the strength and durability,” recalls Amara. “Speed of construction was another key factor,” he adds. “There were other less expensive solutions that could be considered, but you would not get the same quality and longevity. It was a balancing act and I think we made the right choice,” says Amara.
In addition to the architectural precast wall panels, the project utilized other structural precast components such as stairs, landings, slabs, interior shear walls, exterior shear walls, column covers, columns, beams, hollow core plank floor and roof deck. Different program requirements utilized precast panels - -not just in classrooms. Most of the structure was precast, except for the synagogue which utilized a steel frame with metal stud back up.
To provide adequate clear, column-free space at the main entrance, a DELTABEAM® was designed. The DELTABEAM® allows for a flush-beam solution, which is ideal for a condition where the ceiling height is low. The precast floor system was also selected for the purposes of a future second floor. The school has plans to add an upper level, and the hollowcore roof is designed to handle the structural loads and serve as floor system.
The finish was an exposed aggregate (several levels of sandblast), thin brick, raised sections on the precast enclose the classrooms. The recessed Hebrew letters cast into the precast concrete wall panels are the finishing touch on this distinctive learning environment.
Precast flexibility gave Coreslab the wherewithal to adapt quickly to changes as they developed during the shop drawing phase. They pushed the precast envelope to include finishes on the inside of the panels as well as the outside. The design-assist process allowed the owners rep to understand changes to scope and related costs in real time. This eliminated scope creep and reduced cost with the collaboration.
In addition to the aesthetics and finish considerations early on, the design team examined whether the panels would be load-bearing, which type of connections were best suited and how to transfer the loads from precast to precast and precast to steel in certain areas.
Some of the interior face of the panels have recesses for bulletin boards. The insulated wall panels also provide a resilient learning environment with limited maintenance required.
Winter Time
In a mere two weeks the precast concrete pieces were installed despite the unfavorable winter conditions. During February of 2018, the low winter temperatures forced the contractor to use propane heating for the grouting phase. The accelerated construction schedule allowed the school to open for spring term in February 2019.Rob Del Vento, Jr., General Manager, Coreslab Structures (CONN), said that Coreslab expanded their typical scope of services with this project. Coreslab purchased and installed the steel as well as the precast installation portion of this project to provide greater control and service to their customer, some coordination and economies by providing both services.
Amara explains that the owner liked the speed inherent in precast concrete construction. “Precast offered a huge benefit, mainly to the construction schedule, especially the precast plank floor system.” The precast stairs were also quickly delivered to the site and dropped in place for immediate access.
In addition to Hebrew lettering, three colors, textures and finishes can be seen on the precast façade. Thin brick tiles were inset that were off set with smooth finish as well as exposed aggregate.
Architectural finishes selected were generated by a tour of Coreslab’s precast plant and that sparked some ideas for the project. There were a few round of samples to select the color tone that would best complement the brick.
There were no energy goals or LEED requirements other than to meet the Connecticut State energy code.
Amara said that Coreslab was very collaborative and receptive and willing to work outside the box. They provided excellent detailing and were receptive to the team effort. Cornice details and reveals add to the architectural aesthetic. Full columns were used to cover the joints between the horizontal panels. The precast around the windows emulates a trim effect where the thin brick is held back.
The architectural panels are exposed on the inside to save money on furring out the walls and ultimately limit the maintenance required. In the lobby, some precast panels support the precast hollowcore slabs. Exposed panels in the lobby back up to the synagogue which were furred out on the unfinished side.
Lifetime Learning
The façade of the Yeshiva includes Hebrew lettering cast into the precast concrete panels. Roughly translated the prayer for both teacher and student asks for success in their educational endeavor. Grant wisdom in our hearts to enable us to understand and to enlighten, to listen, to learn and to teach, to safeguard and to perform, and to fulfill all of the teachings of your Torah, with love and with kindness.
The design options took advantage of the natural beauty of concrete as well as incorporating the brick accent to complement the lettering.
Peter Amara reflects on lessons learned from this project. “There are always small things that I would do differently on the next job, but with that said, the project was a success. It definitely helps to think and design like a precaster. After this project, and other similar projects, I really have a good handle on the design and delivery process especially the detailing. I have a better understanding of how to maximize the capabilities of precast concrete and stay within budget,” says Amara.
This project was such a success the owner has selected the same design team, including Coreslab Structures for a new precast concrete Torah based elementary school in New Rochelle, NY.
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