KAY'S CREEK ELEMENTARY
Project Confirmation Number: 1983
Entry Category Commercial:
Institutional: Schools, Churches, and Transportation Facilities
2260 Island Drive
Kaysville, UT 84037
Brief description of the project:
Kay’s Creek Elementary’s theme is Bodies in Motion: The Mechanical World. It is a net-zero facility and one of the greenest, most energy-efficient public schools in the state. It accommodates any learning modality. At 81,000 square feet, the building’s exterior is roughly 94% masonry CMU following three distinct pattern courses.
Size of Building:
81,000 Sq Ft
Amount of Masonry Used (include all types and number of units):
Over 9,000 12-inch blocks
Over 48,000 8-inch blocks
Within these sizes were: honed blocks, split face blocks, and colored block.
Some portions of the building had honed block on one side and split face on the other side.
853 yards of grout
241 yards of mortar (2 colors of mortar plus natural mortar)
Some sections used one color of mortar on one side and a different color on the other side.
Project completion date: May 2016
Explain the project and its unique use of masonry materials and techniques:
The specific pattern of the building’s masonry made production difficult (the mason had to carefully plan for the cuts made in advance of placement). The pattern on the first floor of the building is different from that of the second which is the reverse of the first. The masons thoroughly planned and marked out the placement of blocks to be certain the patterns were faithfully executed (it involved three courses of patterns). Communication was paramount.
The wings of the building are askew from one another which made it challenging to assure that the roofs and embed were properly brought together. The mason implemented careful processes to make sure that the angles were lined up correctly. The masons had to deal with a 65-degree angle in two locations because of the skewed wings. They don’t make that dimension of block so they had to run a 30-foot vertical joint that would stay plumb and true by the main entrances to the building. They were building the school in 8-inch increments and so they had to be very careful and precise to keep that joint nice looking and plumb.
Roughly 94% of the building’s exterior is masonry CMU. There are some metal panel accents.
The schedule was a challenge. The masons were tasked to go fast enough to have the roof on the building by winter so that work could continue inside. They were successful.
The gym/auditorium space was challenging. There was a lintel from the hallway to the auditorium which incorporated two steel columns. The masons had to lay masonry all around the lentil to carefully achieve flow. The masons had to drive a forklift into the auditorium to continue working on the masonry, necessitating that the lentil be shored up until the work was finished.
All of the walls in the kitchen and mechanical area were used as a roof beam, a joint deck laid on top of them. All roofs have to slope to allow proper drainage and such, so the masons had to make sure that all of these angles came together just right. They closely collaborated with the iron workers and other project team members.
The main corridor of the building opens to the wings. The ceiling of this main corridor has varying ceiling heights (it is not flat). It has various angles and directions. It was challenging to plan and execute the masonry to match up with the ceiling heights. One of the reasons this is so important is that, to save the client money, masonry that goes above the ceiling height (and is not visible) is done with generic, natural block. The masons put in the necessary time to plan for the ceiling height to get the right look while saving some money for the client.
All cut off CMU and unused mortar or grout was recycled on this project.
HARV & HIGAM MASONRY
DAVIS SCHOOL DISTRICT
HUGHES GENERAL CONTRACTORS
SPEC MIX® a QUIKRETE COMPANY
Click on photos below to enlarge.
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