Dextall Completed Projects

DEXTALL COMPLETED PROJECTS

THE 116TH PROJECT:

Completed in 2022

Introduction

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116th Street Project: A in Kew Gardens, Queens, NY. 9-story, 55-unit apartment building Size: featuring Dextall’s pioneering 12,656 square feet, DWall 2000 system.

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A testament to prefabricated construction's potential, offering enhanced efficiency and sustainability.

In collaboration with JLS Group Construction LLC and architect-of-record Chris Hwa Tan, of Tan Architects, PC , the project is noteworthy for its utilization of Dextall’s DWall 2000 product, marking a leap forward for both Dextall and the field of prefabrication at large.

Project Goals

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Steven Li of JLS Group Construction LLC, the project developer, emphasized the importance of innovation in meeting project goals:

“Before we select anything, we’re looking at costs and time, and any kind of innovation that can bring those numbers down.

Li’s partnership with Dextall was driven by the potential to significantly impact the construction process’s efficiency and environmental footprint. The design, facilitated by Tan Architects,PC,  was aimed at creating a building that seamlessly fits into the historical context of its neighborhood while embodying modern sustainability and efficiency standards.

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Ensuring the new development was in harmony with the neighborhood's historic fabric, using alternating swatches of aluminum cladding to complement the area’s aesthetic.

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Integration with the Historic Streetscape Cost Reduction

Slashing exterior construction costs by more than half, demonstrating substantial savings for the developer.

Significantly reducing the construction timeline and labor resources compared to traditional methods, thereby accelerating occupancy and reducing carrying costs.

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Environmental Responsibility Efficiency in Construction Innovation in Design and Fabrication

Showcasing Dextall’s DWall 2000 panels' versatility and efficiency from design through assembly, proving the system’s value in urban settings.

Minimizing material waste and carbon consumption through prefabricated panels, aiming for a zero-waste construction site.

These goals highlight the project’s broader ambitions: to illustrate the practical and environmental advantages of prefabricated construction in urban environments while maintaining aesthetic integrity and financial viability.

Design Phase

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Architectural Vision Challenges Overcome

Challenges

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A challenge was the sites unique wedge shape and ensuring that the panels met at the perfect angles. Dextall incorporated a lot of poured-in-place balcony slabs, which interrupts the unitized wall panel façade. Dextall provided lightweight panels which were hand installed between slabs, instead of being hoisted via crane. Loose windows were then installed into the panels on site. To achieve the tricky transitions at the balconies, 3D details and instructions were provided to the installers.

A building that fits the historic context and sets new sustainability standards.

Custom solutions for balconies and perfect panel angles despite the site’s wedge shape.

Fabrication and Materials

DWall 2000: Specifications and Benefits

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D-Wall 2000 Aluminum Cladding

High performance, exceptional R-value, and sustainability with near-zero waste.

Chosen for durability, aesthetics, and maintenance savings.

Aurimas Sabulis, Dextall's founder, highlighted the system’s all-in-one solution:

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"Our panels arrive on site ready to install, which drastically cuts down on waste and inefficiency."

The choice of aluminum cladding not only aligned with the aesthetic goals but also contributed to the building's durability and maintenance savings.

The fabrication process, characterized by close to zero material waste and a focus on sustainability, underscores Dextall’s commitment to reducing the environmental impact of construction.

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Efficiency and Innovation on Site

This efficiency allowed for the apartments to be ready for occupancy three months ahead of schedule, resulting in considerable savings on carrying costs for the developer. The utilization of Dextall’s system reduced the jobsite labor from the 47 workers typically required for a conventionally built exterior to just six, effectively minimizing the project's carbon footprint and eliminating traditional construction waste.

Spyder crane installation of 1,500 square feet of panels per day.

Construction sped up by 15%, labor reduced from 47 to 6 workers.

Sustainability and Energy Efficiency

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Enhanced Building Façade

DWall 2000 panels ensure optimal insulation and lower energy consumption.

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Embodied Carbon Footprint Material Waste

Reduced by 47% compared to traditional methods.

Reduced from an average of 30% to close to zero.

Tenant Comfort and Building Performance

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Long-term Benefits

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The Dextall system’s impact extends beyond construction, promising longterm benefits for residents in terms of energy savings and maintenance costs. The durable, high-performance exterior contributes to optimal insulation, leading to lower energy consumption and enhanced tenant comfort. This translates to enhanced comfort levels, reduced energy bills, and a lower environmental impact over the building's lifespan.

Optimal insulation leads to lower energy bills and enhanced tenant comfort.

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Collaboration for success between and

TAN ARCHITECTS

Steven Li’s decision to adopt Dextall’s prefabricated system was driven by the desire to innovate in terms of cost, time, and performance. Steven Li notes the significance of this partnership: "We’re already looking at several more projects together on the horizon," indicating a strong endorsement of Dextall’s technology and its potential for future developments. This partnership has set the stage for future projects, with plans already underway to incorporate Dextall’s panels in additional developments in Queens.

JLS Group Construction LLC, Tan Architects, Dextall.

Project Outcomes and Impact

A Model For Future Construction

The completion of the 116th Street project has set new benchmarks for the construction industry, achieving:

Construction Timeline reduced by 15%

90% reduction in waste

Labor ExteriorEfficiency: assembly labor reduced from 47 to 6 workers

Cost Savings: 52% reduction in exterior construction costs, saving nearly $1 million

47% reduction in carbon footprint

The 116th Street project has not only achieved its goals of reducing construction timelines and costs but has also provided a model for prefabricatedintegratingtechnology into urban environments. This success has solidified the client's decision to continue partnering with Dextall for future projects, indicating a shift towards more sustainable, efficient construction practices in the industry.

Reduced from an average of 30% to close to zero.

Conclusion and Future Implications 010

Pioneering Sustainable Urban Development

a significant achievement in the field of prefabricated construction

The completion of the 116th Street project marks , offering a glimpse into the future of sustainable urban development. Dextall’s innovative approach to design, fabrication, and installation has proven that it is

possible to deliver highquality, energy-efficient housing at a reduced cost and with a lower environmental impact.

As Dextall continues to collaborate on new projects in Queens and beyond, the 116th Street building will remain a landmark achievement,

demonstrating the tangible benefits of prefabrication technology in transforming the built environment.

THE METROPOLITAN PROJECT:

Completed in 2023

Introduction

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A New Construction in Queens, New York, featuring 8-story mixed-use marvel38 residences, community spaces, and retail.

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14,211 square feet

Area: of groundbreaking design using system.

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Location: 132-77 Metropolitan Avenue, Jamaica, Queens, NY.

Dextall’s DWall 1750

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A model for future urban development, blending affordable housing with sustainability

This project is not just a construction endeavor but a model for future developments seeking to integrate mixed-use spaces in urban settings.

Project Goals 002

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003 Efficiency Sustainability Innovation

43% reduction in embodied carbon with Dextall’s prefab walls.

80% faster installation, optimizing construction schedules and costs.

Technological advancements in construction for improved safety and labor efficiency.

The Metropolitan project was conceived with ambitious objectives that align closely with Dextall’s commitment to transforming the construction industry through sustainability, efficiency, and innovation.

Sustainability

The project's life cycle assessment underscores this, revealing a

43% reduction in embodied carbon compared to conventional construction methods.

The choice of materials, such as aluminum, further supports the sustainability objective by combining durability with environmental responsibility.

43% reduction in emboided carbon

001 Efficiency

The project sought to redefine efficiency in construction through the use of Dextall’s digital system and prefabricated unitized exterior walls. These innovations allowed for an

80% faster installation time compared to traditional on-site construction processes

, significantly improving construction schedules. The streamlined design and construction process facilitated by Dextall's technology also offered end-to-end project cost analysis from the earliest design stages, optimizing both time and financial resources.

80% faster installation time compared to traditional on-site construction processes

These goals highlight the project’s broader ambitions: to illustrate the practical and environmental advantages of prefabricated construction in urban environments while maintaining aesthetic integrity and financial viability.

Innovation

At the heart of the Metropolitan project is a drive for innovation, reflected in the integration of Dextall’s precision-manufactured structural wall panels that require no wet-sealing and eliminate the need for scaffolding. This not only accelerates the construction process but also enhances safety and reduces labor needs. The project stands as a testament to how technological advancements can overcome skilled labor shortages by lowering barriers to entry and raising the capability level of the construction workforce.

Aligned with Dextall’s vision, the Metropolitan project serves as a pioneering example of how to decarbonize the construction sector while addressing the urgent need for mixed-use developments that are both affordable and sustainable. It demonstrates a holistic approach to building that considers environmental impact, operational efficiency, and the wellbeing of residents and the community, setting a new benchmark for future projects in the industry.

Design Phase 003

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Architectural vision for sustainability and efficiency, supported by Dextall Studio

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Collaboration with Angelo Ng & Anthony ArchitectsNgStudio, P.C. Challenges Overcome

Facade design to meet energy codes and integration of mechanical systems.

Collaboration for Sustainability and Efficiency

Dextall worked closely with architects: Angelo Ng & Anthony Ng Architects Studio, P.C. from the early stages to ensure that the building's design incorporated sustainable practices and efficient use of materials. This partnership enabled the integration of high R-value prefabricated walls, high-performance triple pane windows, and other energy-efficient features right from the design phase.

Challenges such as accommodating the mechanical system within the prefabricated panels were addressed through engineering solutions that allowed for thru-wall vents and exterior louvers, demonstrating the flexibility and adaptability of Dextall’s approach.

Solutions to Design Challenges

One significant challenge was designing a facade that could meet stringent energy codes while also fitting the aesthetic character of the neighborhood. Through Dextall Studio, the team was able to iterate designs quickly, selecting materials and systems that aligned with both performance goals and visual identity.

Another challenge involved optimizing the design for the limited access site. Dextall’s prefabricated systems were chosen for their ability to be installed from the interior, minimizing disruption in the high-traffic area.

This project has three elevations of unitized panels and one elevation of EIFS. Dextall was tasked to develop a detail that can easily transition from prefab panels to EIFS construction. To achieve this goal, Dextall incorporated their proprietary gasketed system onto the site-built EIFS wall which easily connected to the prefab panels, maintaining the air/ water line of the building’s façade.

Fabrication and Materials

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DWall 1750 System

With R-value of R 29.64, emphasizing aluminum’s durability and recyclability.

The benefits of these materials included not only superior insulation and energy efficiency but also minimal maintenance requirements and adaptability to various design aesthetics.

Prefabricated Exterior Wall Products Fabrication Process

Precision manufacturing reduces waste to 3-5%, enhancing efficiency.

Dextall’s fabrication process emphasizes efficiency and waste reduction, with materials precision-manufactured in a controlled factory environment. The use of dry perimeter gaskets for the panels eliminates the need for wet- sealing on-site, further streamlining the installation process.

Construction Process

Reduction in On-Site Labor and Cost Savings

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Dramatic reduction in on-site labor

With a six-member crew and approximately 4 days of panel installation per floor.

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Completing exterior installation 80% faster

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Innovative use of cranes

"Plug-and-play" panel installation eliminated the need for scaffolding- further reducing costs and improving safety on-site.

accelerated the timeline substantial cost savings in terms of labor and insurance premiums.

This reduction in labor not only but also resulted in The project also showcased the effectiveness of Dextall’s industrialized design, engineering, fabrication, and installation process in improving the quality of the finished product, reducing embodied carbon impacts, and minimizing unused materials costs.

Sustainability and Energy Efficiency

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Prefabricated walls and highperformance windows

Leading to significant energy efficiency improvements.

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Life cycle assessment shows a 43% reduction in embodied carbon Sustainable material selection

Prioritizing responsibilityenvironmental and performance.

Sustainability from Design to Disposal

Sustainable Material Selection

The project prioritizes materials that offer durability and environmental benefits. Aluminum was chosen for their low maintenance requirements and longevity, in addition to their recyclability, supporting the circular economy.

Recycling-Ready at End of Life

At the conclusion of its lifecycle, the Metropolitan building's materials are designed to be easily recyclable, ensuring that the environmental impact is minimized even beyond its operational phase.

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By incorporating Dextall’s innovative building solutions, the Metropolitan project not only complies with current energy codes but significantly exceeds them. The project’s design and materials selection are geared towards surpassing the standard requirements for energy efficiency, setting a new standard for the industry.

Tenant Comfort and Building Performance

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Superior insulationthermal and air quality advancedthroughventilation systems

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Enhanced natural lighting contributes to a healthier, more comfortable living environment

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The Metropolitan project places a strong emphasis on tenant comfort and building performance, integrating features that enhance the living environment while ensuring energy efficiency. Key aspects include:

Thermal Insulation

The use of Dextall's prefabricated exterior walls with high R-values significantly improves the building's thermal insulation. This not only reduces energy consumption but also ensures a stable indoor temperature, contributing to a more comfortable living environment year-round.

Air Quality

The design incorporates advanced ventilation systems that work in conjunction with the prefabricated walls to enhance indoor air quality. By ensuring proper ventilation and minimizing air infiltration, the building promotes a healthier indoor environment for its occupants.

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Natural Lighting

High-performance windows and strategically placed balcony doors maximize the use of natural light, reducing the need for artificial lighting during the day and offering tenants a connection to the outdoor environment.

Feedback from occupants and post-occupancy data, while not explicitly provided, would likely reflect positively on these features, highlighting improvements in comfort levels, satisfaction with the indoor environment, and potentially lower energy costs for residents.

The successful completion of the Metropolitan project was the result of collaborative efforts among key stakeholders:

43% reduction in embodied carbon

Enhanced environmentliving for tenants, setting a precedent for future developments

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Streamlined construction process due prefabricatedto panels

Conclusion and Future Implications 010

The projectMetropolitanshowcases the potential transformativefor urban development

Sets a blueprint for future projects with a focus on sustainability, efficiency, and tenant comfort

Dextall’s innovations signal a shift towards more sustainable and efficient construction practices

Dextall’s innovations could significantly influence industry trends

Looking ahead, , driving the adoption of prefabricated building systems, digital design integration, and sustainability-focused construction practices. As the industry continues to grapple with challenges like labor shortages, environmental impact, and the need for affordable housing, the lessons learned from the Metropolitan project provide valuable insights and solutions.

The project's success underscores the potential for transformative change in the construction industry, paving the way for a future where sustainable, efficient, and comfortable urban living is the norm.

to Design. build. think. A New Norm