Total Precast
Residence Inn by Marriott
Overview
The Residence Inn by Marriott is a modern flat iron-style structure located in downtown Grand Rapids, Michigan. Designed to maximize a compact urban lot, the building brings back architectural elements from the original structure that once stood on the site in the late 1800s. Fabcon’s use of precast elements allowed for the efficient vertical construction of a geometrically complex building while maintaining historic character and design intent.
2022 PCI Best Hotel/Motel
2022 PCI Best BIM Project
Project Details:
General Contractor
Wolverine Building Group
Architect
Yamasaki Architecture
Engineer of Record
PTAC Engineering
Owner
The Hinman Company
Innovation Brings Historic Charm and Modern Efficiency to a Unique Flat Iron Design in Downtown Grand Rapids, MI
Fabcon’s role in the construction of the Residence Inn focused on creating a fully integrated precast solution that could meet the demands of a non-traditional structure on a highly constrained urban site. The use of hybrid framing and precision-engineered precast components allowed the team to solve multiple structural, spatial, and aesthetic challenges—while speeding up construction and reducing long-term costs for the building owner.
Problem
The project’s triangular footprint and unique curvature presented significant structural and architectural challenges. A precast load-bearing wall system combined with hybrid steel framing was selected to eliminate vertical supports in occupied space—preserving valuable square footage and maximizing flexibility.
Designing the precast shear core required close coordination with corridor and vertical transportation constraints, resulting in highly reinforced walls with multiple large openings. The constantly evolving layout, driven by ongoing BIM coordination, required the engineering team to revise structural analysis several times using advanced 3D modeling tools.
The curved precast panels, critical to the building’s exterior aesthetic, required custom steel forms capable of holding three distinct radiuses within PCI’s strict tolerance requirements. Additionally, all precast panels were pre-glazed to avoid on-site window installation delays and expedite enclosure.
Solution
Fabcon fabricated complex curved precast panels using steel forms custom-built to achieve tight radiuses and PCI-compliant tolerances. The pre-glazed panels allowed for a faster enclosure of the structure, helping the project stay on schedule despite the geometric and logistical complexities.
The hybrid structural system used —a first of its kind in Michigan—combined composite steel beams and columns with cast-in-place infill, precast hollow-core slabs, and load-bearing precast walls. This innovative solution created a thinner floor profile, eliminated the need for fireproofing, and provided the strength and flexibility of traditional cast-in-place systems, while offering speed and quality control advantages inherent to precast construction.
Results
By leveraging a hybrid framing approach and custom precast fabrication, Fabcon helped the project team meet design goals and schedule constraints on a complex urban infill site. The durable, low-maintenance materials not only enhanced the building’s long-term performance, but also ensured that its historic-inspired appearance could be delivered with modern efficiency.
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