Eight-Story Structural & Envelope Rehabilitation

Preconstruction and Construction – Structural and Exterior Envelope Rehabilitation

Multi-Story Mixed-Use Facility

Eight-story occupied building in the Rocky Mountains

Location

Avon, Colorado

Summary

DCPS delivered a structural and exterior envelope rehabilitation, addressing severe corrosion and deterioration of the building’s structural steel column system. The scope included replacement and repair of critical load-bearing columns, beam repairs, fireproofing installation, and full exterior façade restoration. To support these repairs, DCPS installed full-height scaffolding and implemented a phased construction plan that allowed the building to remain occupied throughout the project. Work was performed during winter conditions with temperatures as low as 10-15°F, requiring tenting and heating of entire façade areas to maintain proper installation conditions. The completed rehabilitation eliminated the risk of catastrophic deck failure while restoring long-term structural integrity and exterior envelope performance.

Challenge

The building’s structural steel column system had experienced extensive corrosion and deterioration over time, likely beginning shortly after the original construction. Several columns were significantly compromised, creating the potential for structural deck system failure if repairs were not completed. The project was further complicated by winter construction conditions including snow, rain, and temperatures dropping as low as 10–15°F, which could affect welding, coatings, and waterproofing installation.

Solution

DCPS executed a comprehensive structural rehabilitation strategy supported by intrusive testing, engineered repair specifications, and controlled environmental conditions. Entire building facades were tented and heated to maintain proper substrate temperatures during structural repairs and waterproofing installation. Through close coordination with structural engineers, architects, and city inspectors, DCPS successfully reinforced and restored critical structural components while maintaining safe occupancy and continuous building operations.

The DCPS team began by performing intrusive investigation to identify all areas of structural deterioration within the building’s steel column system. Findings were reviewed with the project structural engineer, who developed repair specifications and reinforcement requirements for each affected location.

To safely access the structure, DCPS installed full-height scaffolding across the eight-story building and developed a detailed sequencing plan for structural and envelope work. Wall assemblies were opened to expose the deteriorated steel columns, and severely rusted sections were cut out and replaced or reinforced with new structural steel. Repairs included replacement of five full-height HSS columns, repair of ten additional columns, and associated beam repairs.

Following structural repairs, all columns received three-hour fireproofing protection to meet code requirements and long-term performance standards. Exterior envelope work then proceeded with installation of WRB waterproofing systems, Sika waterproofing products, EIFS and Hardie board cladding systems, flashing, caulking, railings, and architectural exterior finishes. Traffic coating systems were installed on elevated deck areas to provide durable waterproof protection.

Because construction occurred during extreme winter conditions, DCPS tented and heated entire façade sections to maintain consistent working temperatures for welding, coatings, and waterproofing installation. Throughout the project, the team maintained close coordination with the structural engineer, architect, and city inspectors to verify repair methods, conduct required reinspections, and ensure full compliance with engineering and municipal requirements.