GRACIANO NL 10-04OOR Program
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A N I N F O R M A T I V E N E W S L E T T E R O N R E S T O R A T I O N A N D P R E S E R V A T I O N
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Fourth Quarter u 2004
Graciano Assumes Key Role In Bowery Bay Expansion
Most people don’t give much thought to wastewater treatment. As long as sewage and storm water systems continue to operate
as they should, there’s little reason for the general public to be con- cerned with them. At the other end of the pipelines, however, it’s a different story.
New York City’s Bowery Bay facility in Astoria, New York – just off the shore of Manhattan – is the nerve center of the New York City Department of Environmental Protection’s (DEP) wastewater treat- ment operations for Astoria. Constructed in the 1930s, the Bowery Bay facility processes millions of gallons of sewage each day, 365 days a year. With the residents in the New York Borough of Queens depending on the plant to provide dependable wastewater handling services, it’s critical that it be kept in good repair and in compliance with all applicable environmental regulations.
Over the years, from non-stop use and exposure to the elements, many of the masonry surfaces at the plant began to deteriorate and require restoration and repointing. In addition, to accommodate changing environmental regulatory demands, it was becoming nec- essary to rethink the plant’s processing and power supply systems. After carefully examining their options, the New York City DEP brought together a joint venture formed by three leading firms in the mechanical and civil engineering arenas to oversee a series of upgrades, as well as restoration of the existing facilities.
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North Elevation, stairs #5
Graciano Puts Final Touches On Cloisters
As the leaves on the trees in Manhattan’s Fort Tryon
Park begin to change from lush greens to an explosion of fall color, Graciano Corporation is wrap- ping up its restoration work on The Cloisters, the home of the Metropolitan Museum of Art’s medieval art and architecture collection. For the past year, the company has been replicating and replacing numerous Mission-style roof tiles, cleaning and repointing the building’s granite façades, and probing of the struc- ture’s stonework to identify hidden structural problems. Graciano has also been responsible for resetting sections of the building’s granite
roof surfaces, and has overseen the removal and reconstruction of a 50-year-old stone walkway in the build- ing’s Fuentidueña Chapel area. Work commenced the first week of September, 2003, and should wrap up by the end of 2004.
“This project has been a true showcase of our skills,” com- ments Glenn Foglio, President of Graciano Corporation. “The fact that it houses some of the finest art in the world has encouraged our team to deliver nothing short of an exceptional job.”
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Restoration Contractor: Graciano Corporation
Tower work completed, scaffold removal in progress.
Approximately $7.5 million of the total project budget is dedicated to new building construction, and $1.4 million is earmarked for restora- tion initiatives. New structures include housings for two electrical substations and a froth-control building. Additions to existing buildings include a new boiler house facility and a residual handling building. All structures will feature masonry construction.
“As the masonry contractor on the Bowery Bay job, our responsibilities will include general masonry restoration and repair, extensive recon- struction of parapets, resetting of coping materials, and replacement of several three-story high windows that were installed when the buildings were built nearly 70 years ago,” comments Larry Tielsch, Graciano’s site manager on the job. “The assignment will also include the installa- tion of pre-cast lintels – including complex circular lintels that will border several sets of round louvers – and replacement of damaged structural glazed facing tiles that line the interior of the buildings.”
The assignment, however, presents a number of unique challenges for the Graciano team. According to Larry, “The existing structures require a great deal of cleaning and repair. Particular attention also needs to be focused on matching bond patterns, as well as colors and
textures. In addition, we are responsible for all masonry work on the new buildings, and are charged with coordi- nating the appearance of the new materials with the existing structures.”
Bill Vollmer, project leader for Frontier-Kemper, was pleased with the selection of Graciano for the assignment. “Graciano has an excellent reputation in the areas of masonry repair and building. Their exceptional experience will undoubtedly be an asset on this project.”
The Bowery Bay assignment is one of many projects Graciano has undertaken in the New York metropolitan area over the past 20 years. “We have had the privilege of completing award winning work on many of New York’s most beloved structures,” commented Glenn Foglio, President of Graciano Corp. “This project is a critical one for the citizens of New York City — all of whom depend on reli- able wastewater services on a daily basis. We are pleased to partner with the firms comprising the joint venture and look forward to providing excellent results that are attractive, as well as highly functional.”
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Graciano Assumes Key Role In Bowery Bay Expansion
Continued from front cover.
Project: Bowery Bay Water Pollution Control Plant
Owner: New York City Department of Environmental Protection
General Frontier-Kemper Contractors: Constructors,
Design Engineers & Architects: Hazen and Sawyer
MASONRY & Restoration Contractor: Graciano Corporation
Anticipated Date of
Completion: Fall 2006
View of Electrical building – north elevation
“This project is a critical one for the citizens of New
York City — all of whom depend on reliable wastewater
services on a daily basis.”
— Glenn Foglio, President Graciano Corporation
Academy of Music (BAM) is nearing a November completion. The oldest performing arts center in continuous operation in America, the 93-year-old building’s façade features extraordinary decorative detail in brick, polychrome terra cotta, granite and marble.
Working together with Hardy, Holzmann and Pfieffer Associates, a leading planning, architectural and interior design firm, Building Conservation Associates (BCA), consultants for the conservation and restoration of historic buildings, cultural resources and works of art, and Robert Silman Associates, structural engineers, Graciano super- vised and executed all phases of a comprehensive plan to restore the façade of the structure back to its original glory. After 10 decades of exposure to the elements, the Opera House required extensive masonry and stone rehabilitation, terra cotta repair and replacement, cornice, parapet and balustrade replacement and repairs to the building’s flashing systems and supporting structures.
“It is a remarkable building with incredibly complex detail,” comments Graciano’s Vice President of Operations, Dino Rossi. “We have successfully restored it to its original glory and are just as amazed as everyone else at how beautiful it really is.”
The project began at the base of the building’s roofline with reconstruction of four parapets – the largest of which had been removed from the building in the 1950s due to severe brick and terra cotta damage. To replicate the look of the original structures, Graciano worked closely with BCA to ensure that these significant architectural elements were of the correct size and material composition. According to Ric Viera of BCA, “They realized the importance the missing and damaged parapets had to the original design, and truly understood how these features added height, color, shadows and general interest to the building.”
Once the parapet repairs were underway, attention was directed at the building’s cornice. Five feet wide and 15 feet high, this major architectural feature had suffered years of severe water infiltra- tion that resulted in a cracked terra cotta veneer and deeply corroded steel supports. To repair the cornice, façade sections around the structure were shored and braced, and the entire terra cotta sur- face, as well as a one-foot thick brick wall behind the cornice was removed to reveal the steelwork. Rusted structural supports were scrapped, repaired and painted, and glass-fiber reinforced concrete (GFRC) replicas of the original terra cotta sections, manufactured by David Kucera, Inc. were attached to a newly designed and installed structural steel framing system.
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Work On Brooklyn Academy of Music Comes To An Impressive End
Brooklyn Academy of Music
Construction Greyhawk North Manager: America
General Contractor: Graciano Corporation
LLP
View of St. Felix reconstructed balustrade, cornice, terra cotta bonds, lettering and window arch.
Close up of restored door surround, “Baby Header”
View of main elevation, reconstructed cornice, balustrade, terra cotta bonds, letters reinstalled and rebuilt window arches.
Built by the Rockefeller family in the 1930s, The Cloisters is located on four acres overlooking the Hudson River in northern Manhattan. The structure incorporates architectural elements from five medieval French cloisters, as well as stone and other building materials indigenous to the Manhattan area. The facility features extensive gardens and contains artifacts dating from the twelfth through the fifteenth centuries. Due to its landmark status, renovation of The Cloisters required strict adher- ence to preservation guidelines.
“This assignment was definitely a challenge,” remarks Dino Rossi, Graciano’s Vice President of Operations. “We quickly discovered after getting to the jobsite that a traditional scaffolding installation around the building’s central tower was not going to work. Due to the way these structures are built, many of the roofs couldn’t bear the weight of the scaffolding. To get around this problem – and to ultimately get the job done – we had to build a steel framework over the roof surfaces and then run the scaffolding up from there.”
“It was a real feat of engineering,” adds Tom Corbo, Graciano’s Vice President, General Manager. “We were particularly concerned about not damaging any of the stone or tile work on the façades, and we
couldn’t obstruct any of the traffic in or out of the museum. Once we got the framework in place and redirected the weight of the scaffolding away from the roof structures, we were in business.”
When the restoration was underway, crews from Graciano carefully removed existing mission roof tiles to reach the deteriorated substruc- tures beneath them. New concrete roof decks, state-of-the-art roof membranes, and precisely crafted terra cotta roof tiles from Boston Valley Terra Cotta, were then installed. Pointing operations and stone restoration initiatives followed, along with replacement of some of the building’s windows. Final site clean up is currently underway, and the job should be completely finished by the end of the 2004 construction season.
“The artistry on this job is simply outstanding,” comments Dino. “The match between the new and old materials is so close that you really can’t tell the difference if you didn’t know precisely where to look. We’ve received a number of compliments about how well this job turned out, but the real credit goes to the Graciano artisans and craftsmen who really made the restoration look seamless.”
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Graciano Puts Final Touches On Cloisters
Continued from front cover.
Installation of new roof at the tower. View of south side of Longon Chapel roof restoration. Overview of Cloisters roofing project in various stages of completion.
Craning of tower shoring members over Late Gothic Chapel. Connection of shoring member into Late Gothic Chapel.
A fter almost a year, Graciano Corporation’s work on the Brooklyn-Battery Tunnel is near-
ing completion. The longest continuous underwater vehicular tunnel in North America, the facility is ventilated by equipment housed in four buildings – two located in lower Manhattan, one near the Brooklyn portal, and one just off Governors Island. When operating at full capacity, these ventilation stations facilitate complete air change within the tunnel every one-and-a-half minutes. Built in 1950, this is the first major overhaul of the tunnel’s masonry and concrete structural components.
“We have been very successful in keeping the tunnel operating at full capacity while our rest- oration initiatives have been underway,” remarks Dino Rossi, Graciano’s Vice President of Operations, New York Division. “Thousands of cars and commuters depend on the tunnel for daily access and exit from Manhattan, and we had to complete our tasks without getting in the way. Fortunately, that is a skill we have perfected on numerous other jobs, and it was second nature for us on this assignment.”
Since October of 2003, Graciano has been carry- ing out a full-scale rehabilitation on the façade of the Governors Island building. Specifically, the company has been restoring the building’s granite and terra cotta features, removing an existing acrylic stucco cladding system, and waterproofing the facility’s brick subsurface to accommodate a new granite curtain-wall cladding system that is to be installed by another contractor. Graciano has also been responsible for repairs to the building’s granite seawall, as well as repairs to expansion joints contained in the monoliths that comprise the foundation of the man-made island. The proj- ect is in the final stages of completion and should be wrapped up within the next several weeks.
“Getting out to the site has been one of our pri- mary challenges,” comments Richard Fitzpatrick, the General Foreman on the project. “This job is literally in the middle of New York Harbor, and can only be reached by walking through the tunnel and climbing eight stories to reach the structures we are working on, or by taking a water taxi. Tools, equipment and materials have had to be carried on to the island, and all heavy equipment is transported to the site by barge. Since we perfected getting out there and getting back, the job has moved along like clockwork.”
One of the more difficult segments of this job was the repair of the monoliths. Over time, the material in the expansion joints had deteriorated and water had begun to infiltrate these enormous reinforced concrete structures. To repair the joints, the monoliths had to be excavated and the deteriorated material needed to be removed. After the joint surfaces were thoroughly cleaned, inspected and repaired, they were filled with a hydrophilic foam product that expanded to seal the joint and curtail the water infiltration.
“The monoliths had to be fixed,” says Dino. “Doing so was the only way to keep the island stable. Once they were complete, we directed our attention at cleaning and pointing the seawall. Once again, we needed to tailor our operations to our surroundings, as we had to schedule our activities to accommodate the rising and lowering of the tides.”
Tom Corbo, Graciano’s Vice President, General Manager of New York Division, sees the company’s work as a true value for New York City. “This is a maritime environment out here, and the elements can be tough on the structures. The work we’ve done on the monoliths, the walls and the ventilation building itself improves both the structural integrity and the overall appearance of the entire island. It will last for years to come.”
Glenn Foglio, President of Graciano Corporation, agrees with Tom. “The structures on Governors Island were built to stand the tests of time. Through the efforts of our craftsmen, we are ensuring that generations of New Yorkers will be able to benefit from the tunnels for decades to come.”
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Brooklyn-Battery Tunnel
Owner: Triborough Bridge and Tunnel Authority
General Contractor: Kiewit Constructors
Masonry Contractor: Graciano Corporation
“The work we’ve done on the
monoliths, the walls and the
ventilation building itself
It will last for years to come.”
— Tom Corbo, Vice President, General Manager, New York Division Graciano Corporation
Sometimes, life can take you on a few unexpected journeys to some unfortunate destinations. And oftentimes, the outcomes are not
pleasant and life can look bleak. The only choice is to reach for the future and strive for a new start.
And that’s exactly what Stanley Smallwood and Antoine Thomas, two valued employees at Graciano Corporation, have done.
Stanley, a union pointer, caulker, and cleaner employed by Graciano, found himself going down a road that eventually led to incarceration in a Pennsylvania State Correctional Facility. “My life wasn’t going the way I wanted it to,” he commented. “Once I ended up in prison, I decided that it was time to make some serious changes so I could get out and never find myself there again.”
Fortunately, Stanley was accepted into the Operation Outward Reach (OOR) program at SCI Somerset. Formed in 1972 at the State Regional Correctional Facility at Greensburg, the program provides community-based training programs for inmates of the state correctional system. Specifically, the programs provide trainees with carpentry and masonry skills, work skills and life skills.
In the OOR program, Stanley added ceramic tile installation, concrete finishing, drywall installation and finishing and roofing to his skill set. “Being in prison was mentally difficult,” observed Stanley. “However, I knew that learning these skills would make me more marketable when I got out. Fortunately, I was able to go back to Graciano after I was released, and have found myself in a much better place.”
According t o Glenn Foglio, President of Graciano Corp., both he and the company were pleased to have Stanley back. “I’ve known Stanley since we were in high school, and was saddened to see the direction his life took. To his credit, he worked hard while he was incarcerated, and
learned a whole new set of skills that helped make him a more valuable asset here at Graciano. When he was released from SCI Somerset, I interviewed Stanley and saw a dramatic improvement in his attitude and his work ethic, and felt comfortable offering him another chance with us. Everyone here at the company is proud of his recovery, and we’re pleased he’s back to a productive and happy life.”
Antoine Thomas, another Graciano employee, also completed the OOR course when he was an inmate at SCI Somerset. “Antoine was a friend of Stanley’s, and he spoke highly of him,” commented Glenn. When he had completed his commitment to the correctional system, I interviewed him and hired him as a groundsman. He has excelled in his position, and we look forward to helping him get into the apprentice program with the bricklayer’s union this fall.
Stanley and Antoine are currently working on-site on the restoration of Two Mellon Center in downtown Pittsburgh. “We’re proud to have Stanley and Antwoine in the Graciano family,” summed up Glenn. “Everyone can use a second chance at one time or another in their lives.”
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Bronx and Manhattan Grit Chambers
Project: Wards Island Water Pollution Control Plant, Bronx and Manhattan Grit Chambers
Owner: New York City Department of Environmental Protection
Engineers: Hazen and Sawyer
A fter nearly a year of ongoing work, Graciano Corporation
has passed the midway point on the rehabilitation of two buildings, one on the Bronx side and one on the Manhattan side of Wards Island. The wastewater treatment plants are the first stage sewage treatment facility for Manhattan and the Bronx. Designed by McKim, Mead and White in the 1930s, the Wards Island Wastewater Treatment Facilities have long been part of the New York City skyline. The interior was designed to house grit chambers – large holding tanks that allow solids and dense materials to settle out of incoming wastewater. The structure’s exte- rior features an ornate façade integrating stone carvings,
decorative brickwork, and cast aluminum metalwork that effec- tively hide the inner workings of the buildings.
“This project has been challeng- ing, in that the facility needs to continue operating at full capacity during the renovation proce- dures,” comments Dino Rossi, Graciano Corporation’s Vice President of Operations, New York Division. “We have planned our activities around the schedule of the plant to make sure that wastewater operations are not disrupted and that every necessary task associated with the renova- tions is completely addressed.”
Restoration of the Wards Island buildings has involved brick restoration, removal, restoration
Wards Island Wastewater Treatment Facilities Pass Midway Point
OOR Program Brings About New Beginnings
Stanley Smallwood
Antoine Thomas
College is the time when students gather skills that
ultimately form the basis of their careers. And while classroom work and discussion of theories are important components in the educational process, real-world experience is a critical factor that’s necessary for making an effective transition into the workforce.
For the past two years, Graciano Corp. has been offering a select group of student interns opportu- nities to become more familiar with the inner-workings of the restoration and construction business. During this time, two students – Nick Kuntz and Dan McIntyre, Jr. – have gathered the real-world skills that are rounding out their educational careers.
“Our internship program gives students great opportunities to work side-by-side with profes- sionals,” remarks Glenn Foglio,
President of Graciano Corp. “They learn the business from the inside out, and then apply their experiential and academic knowl- edge to specific assignments.”
During his tenure with the company, Nick worked with Graciano’s Safety Manager, Rick Jovan. “Under Rick’s guidance, Nick developed a tracking system that lets company management continually monitor compliance with safety requirements,” observes Glenn. “Thanks to Nick’s hard and thorough work, we no longer have to wait for reports to determine where we stand with our safety programs.”
Dan served two tours of duty with the Graciano internship program. He began by working directly with Glenn on develop- ing control systems that monitor the sales performance of staff members. He also developed a
computerized application that systemized the development of project post audits. During his second stay with the company, he was actively involved in supporting the activities of the sales estimators. According to Glenn, “Dan was instrumental in helping us set up the Customer Relationship Management System (CRM), and has picked up a number of important estimating skills. We are exceptionally pleased with his performance.”
The internship program is open to full and part-time college students. “Currently, we have Ben Penigar, one of our field mechanics, involved with the program,”
comments Glenn. “He has been taking engineering courses at night for several years, and approached us about entering the program and gaining some expe- rience in the areas he has been studying. We were pleased to provide him with the opportunity to develop his career interests.”
For more information on the Graciano Corp. internship program, contact Glenn Foglio at 412-963-8400.
and replacement of spandrel covers and other carved stone features, and removal, cataloging, repair and replacement of the structure’s ornamental aluminum trim elements. Within the build- ing itself, concrete grit troughs are being patched and upgraded with concrete overlays. Work at the site began in August, 2003, and is scheduled for completion during the summer of 2005.
According to Dino, the compa- ny’s efforts have been extremely successful in restoring the build- ings to their original appearance. “These structures were extremely attractive and well-built to begin with. There was real attention to detail and excellent materials were used. Over time, wear and
tear, combined with the effects of the elements, have taken their toll on the brick and stonework. And the corrosive nature of sewage has caused the troughs within the grit chambers to deteriorate. We are mobilizing the concrete repairs, and will now begin con- centrating on the façade restora- tions. We are also currently working with the New York DEP – the owner of the facility – on building a series of new masonry and terra cotta walls within the buildings. A year from now, the exteriors of these structures will look much the way they did when they were built, and the interiors will be significantly upgraded.”
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Interns Learn Real-World Skills At Graciano
“These structures were extremely attractive and well-built to
begin with… Over time, wear and tear, combined with the effects
of the elements, have taken their toll on the brick and stonework.
— Dino Rossi, Vice President of Operations, New York Division Graciano Corporation
Manhattan Grit Chamber
Work On Brooklyn Academy of Music Comes To An Impressive End
Continued from page 3.
The rotation of the torso is the center of the swing, as well as the primary source of power. The path of the rotation must be exacted
for a repeating swing. When the torso spins on the through-swing, it becomes the center of the swing’s radius. So when you address the ball, imagine the path of the unwinding torso at an exact distance from the ball at impact. This is paramount.
The torso and shoulders unwind so precisely that they can “nip” the ball off a hardwood floor. That is, without rotating downward into the floor “fat.” Or, without a rotation that rises too quickly, “thin.”
This exact torso through-path enable the arms to make minute adjustments as they come through after the torso’s lead.
The only way to achieve a repeating nip of the ball with your torso and lagging arms is to make sure that your weight is evenly balanced on the balls of both feet (50% and 50%). So try imagining that you are standing on a sheet of ice. This will keep you level and balanced at impact, so your torso – and then, your arms and hands – can exact flush impact.
GRACIANO CORPORATE OFFICE: 209 SIGMA DRIVE, PITTSBURGH PA 15238-2826 • 412-963-8400 • 800-523-5076 • FAX 412-963-6284
NEW YORK OFFICE: P.O. BOX 3454 CHURCH ST., NEW YORK, NY 10008-3454 • 973-857-0507 X290 • NEW JERSEY OFFICE: 500 BORRIE AVENUE, BRIELLE, NJ 08730 • 732-292-0100
Graciano – A Reputation For Quality Since 1916, Graciano Corporation has specialized in historic preservation and concrete and masonry restoration, beautifi- cation and structural repair. We’ve been entrusted to restore some of the nation’s most prestigious structures. We’ve earned the highest reputation in our field because we offer:
u Unsurpassed Expertise u Competitive Pricing u Dependability u Project Problem Solving u Management Responsiveness u No Project Delays u Beautiful Results u Project Documentation
Graciano services include: u Free Specification Design and
Review Services u (Local Law 10) Building Inspections u Free Surveys u Concrete Restoration u Terra-Cotta Replacement
and Repair u Stone and Brick Restoration u Tuck Pointing u Masonry Cleaning u Abrasive Cleaning u Waterproofing u Caulking u Urethane/Epoxy Injection u Deck Coatings u Shotcrete and Gunite u Water-Control Grouting u New Construction
On these types of structures: u Historic Buildings u National Monuments u Parking Structures u Reservoirs/Dams u Schools/Colleges u Churches u Condominiums u Commercial Buildings u Bridges u Decks and Plazas u Industrial Processing Plants u Stadiums u Correctional Facilities
Graciano Corporation operates throughout the United States and is bonded, licensed and insured in all states of operation. We are affiliated with the BOMA, IMI, AFL-CIO Building Trades International, ACA, UMWA, PMI, SWI. We maintain a comprehensive safety program in compli- ance with OSHA and MSHA standards and are licensed to apply numerous state- of-the-art finishes, grouts and sealants.
Graciano welcomes the opportunity to bid on your upcoming restoration/preserva- tion project. Call 800-523-5076 for more information, or visit our web site at www.graciano.com.
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Golf TipGolf Tip
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ã Rockefeller Center, an art deco marvel consisting of 19 commercial buildings, covers 11 acres in midtown Manhattan from 49th to 52nd Streets and Fifth to Seventh Avenues. It is named after the multi-millionaire, John D. Rockefeller, who leased the space from Columbia University in 1928.
ã Mt. Rushmore features the faces of four exalted American presidents: George Washington, Thomas Jefferson, Theodore Roosevelt, and Abraham Lincoln. One of the world’s greatest stone carvings, these 60-foot high faces, 500 feet up the mountain, were begun in 1927 and took 14 years – and a budget of $1 million – to complete.
Significant rehabilitation of the masonry, terra cotta, stone and metal trim features on the build- ing’s façades was also necessary. Graciano turned to Boston Valley Terra Cotta to create new bricks to match the building’s original rough-finished, hand-made mate- rials. They also relied on the company to reproduce damaged and missing terra cotta elements. Restoration of some highly detailed ornamentation, such as cherubs and musical instruments, required the skills of Graciano’s Gino Marchese, superintendent at the site, as well as other crafts- men. Once the new materials were received, they were inter- spersed with dismantled bricks
to create a complicated seven- course brick bond that replicated the building’s original appearance. While the brickwork was being installed, terra cotta and stone elements were reinserted into their original positions. At the end of the masonry unit reinstal- lation phase, all shoring materials were removed and the entire building was carefully repointed.
With the masonry rehabilitation complete, all of the building’s brickwork was carefully cleaned. According to Viera, “Several dif- ferent chemicals and dilution rates had to be used to compensate for extreme variances in conditions and soiling patterns. Graciano’s
team didn’t simply clean the brick to look new. They cleaned it to meet our specifications – which took into account the condition of the brick and surrounding materials. The result was brick that looked clean, but not brand new. The building now has a harmonious, warm appearance, and nothing looks over- or under-cleaned.”
“The building is a great example of Beau Arts architecture,” observes Dino. “Now that it has been restored, and all the detail has been replaced and reinstalled, it can really be used and enjoyed the way it was intended to be.”
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