Dextall New Construction - Completed Projects 01

DEXTALL NeW Construction COMPLETED PROJECTS

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Table Of Content

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03 The 116th Project 13 The Metropolitan

Project 29 The 30th Street

Project

THE 116TH

PROJECT: Revolutionizing Urban Construction Efficiency Completed in 2022

Sustainability Innnovation

001

Introduction 116th Street Project: A 9-story,

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55-unit apartment building in

Kew Gardens, Queens, NY.

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Size: 12,656 square feet, featuring Dextall’s pioneering DWall 2000 system.

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

002

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.

001 Integration with the Historic Streetscape

002 Efficiency in Construction

003 Environmental Responsibility

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.

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

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

004

Cost Reduction

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

005 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.

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

003

001 Architectural Vision

002 Challenges Overcome

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.

Challenges 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.

Fabrication and Materials

004

DWall 2000: Specifications and Benefits

001

002

D-Wall 2000

Aluminum Cladding

High performance, exceptional R-value, and sustainability with

Chosen for durability, aesthetics,

near-zero waste.

and maintenance savings.

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

"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.

Construction Process 001 Efficiency Achieved

002 Timeline and Labor Reduction

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

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

005

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.

Sustainability and Energy Efficiency

006

001 Enhanced Building Façade

002 Embodied Carbon Footprint

003 Material Waste

DWall 2000 panels ensure optimal insulation and lower energy consumption.

Reduced by 47% compared to traditional methods.

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

Tenant Comfort and Building Performance

007

001 Long-term Benefits Optimal insulation leads to lower energy bills and enhanced tenant comfort.

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.

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Roles and Contributions

TAN ARCHITECTS Collaboration for success between JLS Group Construction LLC, Tan Architects, and Dextall.

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.

Project Outcomes and Impact

009

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 Efficiency:

Exterior 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 integrating prefabricated technology 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

The completion of the 116th Street project marks a significant achievement in the field of prefabricated construction, 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: A NEW ERA

OF URBAN

LIVING Innovation Completed in 2023

Sustainability

Efficiency

Introduction

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001

A New Construction 8-story mixed-use marvel in Queens, New York, featuring 38 residences, community spaces, and retail.

Area: 14,211 square feet of groundbreaking design using Dextall’s DWall 1750 system.

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Location: 132-77 Metropolitan Avenue, Jamaica,

Queens, NY.

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.

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Project Goals 001 Sustainability

002 Efficiency

003 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

Efficiency The project sought to redefine efficiency in construction through the use of Dextall’s digital 001 and prefabricated unitized exterior walls. system 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 001 Architectural vision for sustainability and efficiency, supported

by Dextall Studio

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

003 003 Collaboration with Angelo Ng & Anthony Ng Architects Studio, P.C.

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

004

Prefabricated Exterior Wall Products 001 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.

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 wetsealing on-site, further streamlining the installation process.

Construction Process

005

Reduction in On-Site Labor and Cost Savings 001 Dramatic reduction in on-site labor With a six-member crew and approximately 4 days of panel installation per floor.

002 Completing exterior installation 80% faster

003 Innovative use of cranes "Plug-and-play" panel installation eliminated the need for scaffoldingfurther reducing costs and improving safety on-site.

This reduction in labor not only accelerated the timeline but also resulted in substantial cost savings in terms of labor and insurance premiums.

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 001 Prefabricated walls and highperformance windows

002 Life cycle assessment shows a 43% reduction in embodied carbon

Leading to significant energy efficiency improvements.

006 002 Sustainable material selection

Prioritizing environmental responsibility 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.

Compliance with Energy Codes

By incorporating Dextall’s innovative building solutions, the Metropolitan 001 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 001 Superior thermal insulation and air quality through advanced ventilation systems

007

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

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.

001

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.

008

Roles and Contributions

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

Project Outcomes and Impact 43% reduction in embodied carbon

Enhanced living environment for tenants, setting a precedent for future developments

009

Streamlined construction process due to prefabricated panels

010

Conclusion and Future Implications 001 The Metropolitan project showcases the potential for transformative urban development

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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

Looking ahead, Dextall’s innovations could significantly influence industry trends, 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.

THE 30TH STREET

PROJECT: TRANSFORMING

URBAN

LIVING Cutting-edge Completed in 2024

Sustanable High- Performance

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Introduction

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The 30th Street project is an

11-story residential

building

Area: 37,313 square feet designed as a multifamily

residential building

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Location: 9 - 26 30th Street,

Long Island City,

NY

A testament to Dextall’s capabilities in delivering cost-competitive, highperformance buildings

Project Goals

002

OBJECTIVES: The primary objectives of the 30th Street project were to:

001 Sustainability

002 Efficiency

003 Innovation

Achieve high sustainability standards.

Enhance construction efficiency.

Implement innovative building practices.

Design Phase

003

Collaboration between Dextall, architects, and the design team ensured that sustainable and efficient building practices were incorporated from the outset.

One challenge faced during the design phase was ensuring all components

met high sustainability standards while maintaining cost-efficiency. This was

overcome through the meticulous selection of materials and the use of advanced design software.

“Thanks to efficient practices and close collaboration with

a highly professional external team, we managed to wrap up shop drawings for the project in a remarkably timely manner approximately 4 months from kick-off to final shop drawings.

The client's team of top-level architects streamlined the process, making everything smooth and efficient.”

Dextall Project Manager

Fabrication

and Materials

004

Prefabricated Products and Specifications. The project utilized Dextall’s

7-inch insulated panel system, featuring:

001 R-VALUE

003

Met and exceeded code requirements, ensuring superior thermal performance.

Factory-installed cladding and windows, reducing on-site waste and improving energy efficiency.

SUSTAINABILITY

ASPECTS

002 MATERIALS

Powder-coated painted aluminum composite material.

Fabrication Process Dextall’s fabrication process includes precision cutting using CNC and laser machines, optimizing material orders, and pre-assembling components.

This approach minimizes waste and enhances efficiency. The materials were selected for their performance characteristics and sustainability, such as steel, aluminum, gaskets, sheathing boards, stone wool, tapes, fixing materials, and windows.

Quality Control Air and Water Tightness: A significant advantage of Dextall's factoryassembled products is the rigorous quality control procedures that ensure the highest levels of air and water tightness. This controlled environment allows for meticulous inspection at every stage, reducing the likelihood of defects and ensuring that the panels perform exceptionally well once installed on-site. This level of precision is difficult to achieve in traditional onsite construction, further highlighting the benefits of prefabrication.

Energy Savings The high R-value of the 7-inch insulated panels is a key factor in energy savings. The panels not only meet but exceed code requirements, providing superior thermal insulation compared to traditional construction methods.

This leads to significant reductions in heating and cooling energy requirements, translating to lower utility bills for residents and a reduced carbon footprint.

Construction Process

005

001 On-Site Labor Reduction and Cost Savings

By prefabricating

components off-site,

the project saw enhanced safety and more effective workforce deployment. This approach reduced the need for on-site labor, leading to faster project completion

and significant cost savings.

002 Innovative Techniques

Advanced construction techniques and sustainable building practices, were employed. These methods improved durability, reduced waste, and minimised the environmental impact.

Sustainability and Energy Efficiency

006

Sustainability Features: The 30th Street project incorporated several 001 sustainability features:

001 Energy Efficiency Measures

002 Sustainable Materials

003 Carbon Footprint

Superior thermal insulation provided by the 7-inch insulated panels.

Use of recycled and recyclable materials

in the panel construction.

Reduced through efficient material use and waste management practices.

007

Impact Metrics ENERGY SAVINGS:

The building’s energy efficiency measures contribute to lower utility

costs for residents. Specific calculations show that the enhanced

R-value of Dextall panels leads to approximately

30-40% reduction in energy consumption for heating

and cooling compared to traditional methods.

REDUCTION IN EMISSIONS: Preliminary calculations based on Dextall's Life Cycle Assessment (LCA) results demonstrate a significant reduction in emissions:

The use of Dextall panels over traditional construction methods in the 30th Street project has led to a substantial decrease in CO2 emissions, underlining the environmental benefits of Dextall’s prefabricated solutions.

Dextall Panels: Global warming potential of

80.46 kg CO2 eq/m²

On-Site Built Construction: Global warming potential of

143.11 kg CO2 eq/m²

Tenant Comfort and

Building Performance

008

The project prioritized tenant comfort through features such as: 01 Thermal Insulation

Enhanced thermal performance of the insulated panels ensures a consistent indoor temperature, improving overall comfort.

02 AIR QUALITY

Use of materials and construction practices that promote healthy indoor air quality by reducing volatile organic compounds (VOCs) and other pollutants.

03 NATURAL LIGHTNING

Well-designed windows and terraces to maximize natural light, creating a bright and inviting living space.

Roles and Contributions

009

Developer/General Contractor: JLS Group Construction (Flushing, NY) As both the developer and general contractor, JLS Group Construction was responsible for overseeing the entire project, from inception to completion.

They ensured the proper integration of Dextall's prefabricated components and managed the on-site construction activities, focusing on delivering a highquality, cost-effective building within the scheduled timeline.

Architect: MY Architect (Flushing, NY) MY Architect provided the architectural vision for the 30th Street project. They collaborated closely with Dextall and the design team to incorporate modern aesthetics, durability, and energy efficiency into the building’s design. Their expertise was crucial in ensuring that the building met high sustainability standards while maintaining aesthetic and functional goals.

“Dextall’s prefabricated panels have transformed our approach to construction, enabling us to deliver high-quality buildings faster and more sustainably.”

Project Manager

010

Project Outcomes and Impact 1

Success in Meeting Goals The 30th Street project successfully met its goals of sustainability, efficiency, and tenant comfort. The integration of Dextall’s technologies and practices resulted in a highperformance building delivered ahead of schedule and

within budget.

2 COMMUNITY AND INDUSTRY IMPACT The project has positively impacted the local community by providing a modern, efficient residential building. It serves as a model for future sustainable construction projects and demonstrates the viability

of prefabrication

in urban settings.

Future Implications

011

The 30th Street project exemplifies Dextall’s commitment to pioneering sustainable and efficient construction practices. As the industry evolves,

the lessons learned and technologies developed through this project will

play a crucial role in shaping the future of building construction.

The team's competence with Dextall’s scope of work and the solutions provided, combined with the proactive collaboration with professional client-side architects, contributed significantly to the project's success. By leveraging Dextall's advanced prefabricated solutions, the project achieved impressive energy savings and emission reductions, setting a new benchmark for sustainable urban living. The emphasis on quality control, particularly in ensuring the highest levels of air and water tightness, further solidifies Dextall's role as a leader in innovative construction practices.

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