Commercial Industry Archives - Warfelcc

Building From Reality: Managing Risk and Quality in Complex Renovations

Transforming the former St. Joseph’s Hospital into West End Place Apartments required the project team to work through more than a century of renovations, structural changes, and concealed conditions.

Washington Place Equities’ vision was to give the historic Lancaster building a new purpose while preserving the character that made it familiar to the surrounding community. For many members of the project team, the connection to St. Joseph’s Hospital was personal — some were born there, while others had family members who received care within its walls. Preserving and repurposing a building with such deep community significance added another layer of meaning to the work.

Bringing that vision to life meant integrating modern apartments and building systems into a structure that did not always match the available drawings.

As demolition progressed, each area revealed new information. Floor conditions varied throughout the building, structural elements affected system installation, and portions of the façade reflected different eras of construction and repair.

The project’s success did not depend on avoiding every unexpected condition. It depended on how the owner, architect, project team, trade partners, and specialized support teams responded as a team. The project reinforced several important lessons about managing risk and maintaining quality throughout complex renovations.

The project reinforced several important lessons about managing risk and maintaining quality throughout complex renovations.

Lesson 1: Identify Risks Early

Renovating a historic structure begins with accepting that the drawings may not tell the full story.

At West End Place, demolition revealed structural inconsistencies, modified façades, uneven floor conditions, and other concealed conditions that could not be fully understood until portions of the building were exposed. While historical documents and investigations provided an important starting point, the building’s century-long evolution meant some conditions only became apparent as work progressed.

Each discovery had the potential to affect multiple aspects of construction, from MEP routing and ceiling heights to finish elevations and trade coordination. As new information emerged, the project team collaborated closely with Washington Place Equities, the architect, trade partners, and field teams to evaluate conditions, refine solutions, and adjust the approach as needed.

Before construction began, Warfel’s preconstruction team worked to identify areas of uncertainty by reviewing historical information, studying potential scope gaps, and developing risk logs. Early discussions with Washington Place Equities also helped establish allowances for work that could not be fully defined before demolition.

While preconstruction could not eliminate every unknown, it provided the owner and project team with a framework for responding as new conditions emerged. By acknowledging uncertainty upfront, the team was better prepared to make informed decisions throughout construction.

Lesson 2: Use Technology to Improve Decision Making

Following demolition, the team completed Matterport scans — a reality-capture technology that creates an interactive, 3D digital record of existing conditions. These scans documented exposed areas of the building and established a foundation for Virtual Design and Construction (VDC) coordination.

The scans provided a shared visual reference for the project team, owner, and design partners, allowing stakeholders to review conditions remotely and make decisions using the same information. As construction progressed, 360-degree photography continued documenting concealed systems before walls and ceilings were closed.

The VDC process ultimately became more extensive than originally anticipated. As actual conditions differed from the initial models, Warfel’s VDC team rebuilt portions of the coordination model using the Matterport scans as the foundation for coordination and layout planning. This allowed the team to refine layouts, coordinate building systems around structural constraints, and reduce rework in the field.

Technology did not replace problem-solving; it provided the accurate information needed to make better decisions.

Lesson 3: Embed Quality Throughout Construction

Technology provided valuable information, but experienced people remained critical to evaluating conditions and developing solutions.

Warfel’s Continuous Improvement and Quality team worked alongside project managers, field leaders, trade partners, and design professionals throughout construction. Their involvement included constructability reviews, material research, façade detailing, MEP inspections, and field validation.

This support proved especially valuable where new construction connected to the historic structure. Façade tie-ins, floor leveling, mechanical coordination, and system installations all required ongoing evaluation and collaboration to ensure quality expectations were met.

Rather than serving as a final checkpoint, quality was integrated throughout the project lifecycle.

Lesson 4: Build from Reality

One of the most important lessons from West End Place is that renovation projects must be built from reality, not assumptions.

The design documents established the project’s direction, but the existing building ultimately determined how the work could be executed. Through early risk planning, reality capture, VDC coordination, field reviews, and quality oversight, the team continually compared assumptions against actual conditions and adjusted accordingly.

Complex renovations will always involve uncertainty. Better outcomes come from teams that communicate openly, challenge assumptions, and respond to new information together.

While every renovation project is different, the principles remain the same: identify risks early, verify existing conditions, integrate quality throughout construction, and collaborate to solve problems as they arise. Those practices help transform uncertainty into opportunity and ultimately lead to better outcomes for owners, project teams, and the communities they serve.

 

Grace Evangelical Lutheran Church Celebrates Wall Signing

A Meaningful Moment During the Grace Evangelical Lutheran Church Renovation in Winchester, VA

On Wednesday, May 6, members of Grace Evangelical Lutheran Church gathered at their historic church renovation project in Winchester, Virginia, to leave their mark on a space that has served generations of worshippers and will continue to support the community for years to come.

As part of the ongoing renovation of the church’s communal spaces and offices, representatives from the congregation council, church staff, and the renovation task group participated in a special wall-signing ceremony. The event included a prayer and blessing for the renovation project, guided tours of construction progress, and an opportunity for attendees to write messages directly on the walls before the next phase of construction begins.

For a congregation with roots dating back to 1753, the event represented more than a construction milestone. Every signature, prayer, and handwritten message became part of the church’s ongoing story — preserved within the walls of a historic space shaped by faith, community, and connection for more than 270 years.

Preserving the History and Legacy of Grace Evangelical Lutheran Church

The wall-signing ceremony followed another meaningful project milestone, completed earlier this year. In March, Warfel Construction partnered with Grace Evangelical Lutheran Church to place a time capsule within the building renovation.

The time capsule contains messages, prayers, and reflections from current members of the congregation, preserving a snapshot of today’s church community for future generations.

Together, the wall signing and time capsule installation highlight the deeper purpose behind the renovation project. Beyond updating and improving the church facility, the project honors the people, traditions, and shared experiences that have shaped Grace Evangelical Lutheran Church throughout its long history in Winchester, Virginia.

A Personal Connection to the Church Renovation Project

For Warfel Construction Project Manager David Betz, the church renovation project also carries personal meaning.

David attended Grace Evangelical Lutheran Church with his family as a child. Eighteen years later, he returned with his wife and nine-month-old daughter for an Ash Wednesday service, reconnecting with a church community that continues to make people feel welcome.

Today, David is proud to help lead the renovation project, contributing to the preservation and future of a church that has impacted so many lives across generations.

 

Warfel Begins Construction on Catalyst Warehouse

Warfel Construction Company is pleased to partner with Catalyst Commercial Development on their new warehouse project, located on 2.78 acres in Bristol, PA. This 62,550 square foot steel and precast concrete panel warehouse began as a shell space and has now progressed into a manufactured food distribution facility housing 24,000 square feet of freezer space, 33,000 square feet of dry storage space, and 8 loading docks to serve the warehouse.

The storage spaces are also paired with a two-story office fit-out and additional office, dispatch, and bathroom spaces within the warehouse. The office fit out consists of single offices, open office workstations, meeting rooms, a kitchen, and a small gym. The project is scheduled to be completed in October 2022.

Warfel Begins Construction on Sierra Warehouse

Warfel Construction Company is pleased to partner with Sierra Office Park, LLC on their warehouse project in Ewing, NJ. This is Warfel’s first base-building warehouse project and will be the future location of the State of New Jersey Department of Treasury, DPMC. In addition to traditional warehouse space, this 195,000 square foot structure will consist of an office area with a vault, armory, mechanical workshop, laboratory, evidence rooms, equipment storage, and other common spaces.

Warfel is partnering with Bernardon, Michael A. Beach & Associates, McHugh Engineering Associates, and Maser Consulting P.A. for this project.

The project will reach substantial completion in March 2022.

UGI Utilities Celebrates Opening of New 93,000 sf Headquarters Building

On Tuesday, April 9, UGI Utilities celebrated the grand opening of its 93,000-square-foot headquarters building in Denver, PA. The new building, which currently hosts 260 employees, can accommodate as many as 350.

“Construction of our new headquarters building marks a significant milestone in the history of UGI Utilities,” Robert F. Beard, UGI CEO and President, said. “We are pleased to locate our new headquarters building in Lancaster County, which is one of the fastest-growing areas in our service territory. The location and design of our new building will enhance and expand our employees’ efforts aimed at providing excellent service and the safe and reliable delivery of energy to our customers and to the many communities located within our service territory.”

Located on 32 acres at the intersection of Route 222 and the Pennsylvania Turnpike, UGI’s headquarters boasts a multitude of features to improve employee health and wellness, including nearly a mile of walking trails, an outdoor patio and firepit, electric vehicle stations, a full-service kitchen, and a yoga studio and fitness center.

Originally planned for a 15-month construction schedule, the UGI project was completed five weeks ahead of schedule, allowing senior staff to move in at the beginning of 2019.

Quick facts:

  • Partnership with Bernardon Architects
  • Seeking LEED Silver status
  • Includes combined Cooling, Heating and Power (CHP) system
  • Completed on time and under budget
  • No major lost time incidents/accidents

Warfel Receives National Excellence in Construction Award From Associated Builders and Contractors

Warfel Construction is pleased to announce that the Aerzen USA project in Coatesville, PA has earned a National Excellence in Construction® Pyramid Award from Associated Builders and Contractors. Vice President of Operations Conlan Swope and Project Executive Fred Lohss received the award March 27 during ABC’s 29th annual Excellence in Construction® Awards gala at ABC Convention 2019 in Long Beach, California.

https://www.warfelcc.com/author/amber-schnader/

The Aerzen USA Expansion project was comprised of a 22,000 square foot office and manufacturing addition. The office expansion included the construction of new private offices, work rooms, conference rooms, and a new kitchen and café area. Renovations were also completed in select areas of the existing office. The manufacturing and warehouse expansion included the erection of a 35’ high pre-engineered metal building with insulated roof and wall panels. In addition to the building construction, various site improvements including the construction of underground rain water tanks, a large landscape package, and a new pervious asphalt parking lot were completed.

Aerzen-National-Pyramid

Proven LEED strategies from the original building, such as geo-thermal heat pumps (8 wells) and earth tubes, were incorporated into the addition. New advances in enclosure technologies such as structural insulated panels (SIPS) and ZIP system sheathing, as well as an integrated water- and air-resistive barrier that delivers moisture and air protection in one system were also utilized.

“We are proud to honor Warfel Construction Company with a National Excellence in Construction® Pyramid Award,” said 2019 ABC National Chair Tony Rader, telecom vice president of National Roofing Partners, Coppell, Texas. “The Aerzen USA project shows not only the exceptional talent in our industry, but the overall commitment to building safely, on time and on budget. Warfel’s breadth of skills and craftmanship greatly benefits the merit shop construction industry.”

The Excellence in Construction awards program is the industry’s leading competition that honors both general and specialty contractors for innovative and high-quality merit shop construction projects. The award honors all construction team members, including the contractor, owner, architect and engineer. The winning projects, selected from entries submitted from across the nation, were judged on complexity, attractiveness, unique challenges, completion time, workmanship, innovation, safety and cost.

A panel of industry experts served as the competition’s judges. This year’s panel included representatives from the Building Owners and Managers Association International, the Smithsonian Facilities Construction Division, the Construction Management Association of America, Engineering News-Record, Design-Build Institute of America and various construction-related firms nationwide.

A full list of EIC winners is available on ABC’s website.