As well as one of life’s “essentials,” water is a crucial element in a variety of industrial processes, not least construction.

To the casual observer, the only visible evidence of construction site water use might be a worker hosing down a truck full of construction waste to prevent the escape of dust.

But lots of water is used in many aspects of construction and in a variety of ways.

Amid a climate change crisis and the increasing threat – and instance – of drought, the sector is looking at ways to improve water efficiency in construction projects, as well as doing more to source what it does use responsibly while striving to minimize waste and leaks.

How much water is used in construction?

According to the Construction Products Association, water is used throughout the construction lifecycle, from extracting raw materials to construction product manufacturing, throughout the building phase, and obviously once buildings have been completed and are occupied.

And when a building has reached the end of its useful life and is set to be demolished, water is used in that process too, not least to reduce the spread of dust and other debris into the air.

The CPA goes on to say that manufacturers of construction products rely on water across a broad spectrum of uses. Water, it says, “can serve as a lubricant, a cleaning agent, a sealant, a heat transfer medium, a solvent, an air pollution control medium, plus an array of other uses depending on the material and products being produced.”

Crucially, water is used in the manufacture of mortar and cement concrete, materials that have their own issues when it comes to energy efficiency and their environmental impact.

According to the journal Nature Sustainability, in 2012 concrete production was responsible for 9% of global industrial water withdrawals and 1.7% of total global water withdrawal.

The UK Centre for Moisture in Buildings reckons that up to 8,000 liters (2,113 gallons) of water may be included in mixtures and materials as construction of an average-sized new-build home proceeds, although this varies depending on the design.

The importance of water management during construction activity

Water is clearly a crucial component of construction activity. Consequently, its sourcing, storage, use and eventual disposal need to be managed effectively.

With mounting pressure on existing water supplies amid threats of droughts and other climate change-related events, having a construction water management plan in place is a must.

There is plenty of information available to the construction sector covering how to use – and conserve – water during project delivery.

In the UK, the Construction Leadership Council has drawn up water management guidance that asserts the need “to improve the efficiency of water use on construction sites through better planning and management … and to encourage consideration of environmental risks associated with construction activities.”

The CLC said its ultimate aim was to eliminate the demand and use of potable water in construction. “It is unlikely that water demand can be eliminated, but efforts can be made to reduce and use alternative sources, as well as reuse water for construction activities,” it added.

Once a project’s water needs have been identified, alternative sources should be planned for, with a metered potable supply available as backup.

The CLC calls for a water use hierarchy to be put in place, addressing – in descending order – the elimination of unnecessary water use; consideration of alternatives to potable water, such as rain and “grey” water; reduced use; and the reuse and recycling of water.

Effective water management is a group effort

The Water Conservancy organization encourages water conservation at every stage of a construction project, from design to planning and the construction process itself.

It also highlights the importance of involving the people tasked with delivering a scheme in the water use goals.

It is important, it says, to establish water conservation as a key objective of the project and ensure that everyone involved is aware of their responsibilities.

The Water Conservancy adds that induction training should be provided for new employees and contractors “so that they are also aware of their responsibilities and the benefits of the program,” while the project’s water management plan needs to be kept on-site to “ensure that all employees are aware of and have access to it.”

Water management needed to be discussed at regular meetings, the Water Conservancy says, with ongoing achievements monitored.

And in a nod toward the benefits of highlighting good practice, it adds: “Promote your successes with press releases to local media and industry associations.”

What are the rules and regulations around water consumption?

There are several areas of regulation covering water and the built environment, although these are focused on the degree to which water is used – and saved – once a development has been completed.

The mayor of London’s office spells out how agencies in London and adjoining regional and local planning authorities will work to “protect and conserve water supplies and resources in order to secure London’s needs in a sustainable manner.”

It stipulates that development should minimize the use of mains water by incorporating water-saving measures and equipment and by designing residential development so that mains water consumption would meet a target of 105 liters (28 gallons) or less per head per day.

There will also be support for sustainable water supply infrastructure in new developments as part of water companies’ water resource management plans.

How to reduce water consumption in construction: Now and in the future

While construction is improving water usage, designers of the homes and other buildings society needs will be creating them with water efficiencies in mind.

Planning authorities want limits of 125 liters (33 gallons) of water per person per day on new housing developments as part of the Building Regulations Part G and can demand a lower limit of 110 liters (29 gallons) as part of a planning condition.

The water footprint of a new home or office can be reduced considerably by thoughtful design.

Showers can replace baths, or baths can be designed to be more water efficient. Dual flush toilets are becoming the norm, while rainwater collection, via a water butt system, can replace tap water for most outside uses. Meanwhile, appropriate landscaping can protect homes from flooding – another consequence of climate change – and prevent wasteful water run-off.

With the world on the brink of a full-blown climate crisis, water efficiency in construction must be addressed. The sector is no doubt fully aware that it makes good environmental – and business – sense to tackle the water issue sooner rather than later.

At one time, nightfall plunged our ancestors into darkness and let them marvel at celestial objects in an inky sky. But in recent times, our ability to alter natural light levels has advanced to the point that stars, planets and galaxies are fading from view. Of the 2,500 stars that should be visible, the typical American suburbanite can see only a few hundred.

Instead of starlight, the night is filled with streetlights, spotlights, stadium lights, neon signs, billboards and parking lot towers—all contributing to light pollution, defined by National Geographic as the excessive or inappropriate use of outdoor light. Light pollution damages human health, alters wildlife behavior and wastes energy and money as light blazes when and where it’s not needed. The result is glare that blinds drivers, light trespass that disturbs sleep, eerie orange skyglow over metro areas and confusing and garish groupings reminiscent of Times Square.

Until light is policed in the same way as air, water and land pollution, it falls to architects, engineers and designers to select lighting systems that perform their function while still preserving the night sky—with the help of manufacturers whose fixtures meet the specs for responsible lighting and governments that support policies to protect darkness.

“I think people are understanding the urgency of lighting design, because it’s become more and more difficult to see a clear night sky from anywhere,” said James Brigagliano, lighting program manager at DarkSky International.

The harmful effects of too much light

Light where it doesn’t belong disrupts the night and day rhythm encoded in the DNA of all animals and plants. That impacts behaviors from feeding and sleep to reproducing and evading predators.

Human circadian rhythms are attuned to outdoor light during the day and darkness at night. Breaking that cycle with artificial light increases the risk for obesity, depression, sleep disorders, diabetes and other diseases, according to research reported in Environmental Health Perspectives.

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For wildlife, prey use darkness as cover and predators use light to hunt, so illumination dramatically alters the environment and the odds. For instance, newborn sea turtles need to turn toward the ocean and safety after hatching on the beach, but often they’re confounded by light on shore. Birds that migrate or hunt at night are lured by brightly lit cities and veer from their flight patterns. And after dark, the insects that birds depend on are drawn to burning bulbs and their deadly heat.

Worse still, lights are often pointless, adding economic waste to ecosystem harm. DarkSky International estimates that at least 30% of all outdoor lighting in the United States serves no purpose and is emitted by lights that don’t have shields to prevent spillage. Wasting light costs $33 billion each year and uses about 120 terawatt-hours of energy—enough to meet New York City’s electricity needs for two years. Quality outdoor lighting could cut energy use by 60% to 70%, saving billions of dollars and reducing carbon emissions. But that depends on lighting responsibly.

Five principles for responsible outdoor lighting

DarkSky and the Illuminating Engineering Society jointly published the Five Principles for Responsible Outdoor Lighting to prevent and reduce light pollution. Designing new projects or retrofits using the principles can create beautiful, functional, healthy lighting that minimizes harmful effects and saves energy and money.

1. Useful: If it’s not serving a function, you shouldn’t have it.

Identify the purpose of lighting and its impact on everything in the vicinity, including wildlife and habitats.

• Targeted: Aim light so it falls only where it’s needed.

Direct and shield light beams so they point down and don’t spill outside the area being lit.

• Low level: Light should be no brighter than necessary.

Use only the light required and make sure nearby surfaces don’t reflect light and create excess.

• Controlled: Use light only when it’s needed.

Install motion detectors, dimmers and timers to allow only the minimum light needed available at any time.

• Warm-colored: Use warmer-color lights where possible.

Cut back on shorter wavelength light (blue-violet) to the least amount needed.

New standards, programs and policies to bring back the night

The DarkSky Approved program provides objective, third-party certification for lighting design,  products and installed projects that reduce light pollution. Designers can search products by manufacturer, use, retailer, light temperature and residential use. Project standards fulfill requirements for Leadership in Energy and Environmental Design (LEED) certification as well, but requirements continually evolve based on new information.

“We’re cutting down on what we allow for high-angle lighting—from 90 to 80 degrees,” Brigagliano said. “So now we’re allowing only 1% of the total light output of a fixture to be between 80 and 180 degrees. There’s no benefit to light between 80 to 90 degrees and the new cutoff will help reduce uplight and sky glow.”

DarkSky Approved programs now include pedestrian lighting as well as sea turtles, sports venues and lodging. The new program addresses glare from light fixtures used in areas like campuses where people need lower-level lighting for safety at night.

“We also have wildlife-tuned luminaries, with subcategories like sea turtles,” Brigagliano said. “That’s needed because different species have different sensitivities to wavelengths. However, if we control brightness and shield the light source, we’ve taken care of much of the issue and the color of light is less important.”

In addition, DarkSky recently released an updated and simplified model policy that was written to make it easy for states and municipalities to adopt. “Just a little bit of improvement is better than none,” Brigagliano noted.

Every place a dark sky place

The International Dark Sky Places program certifies areas worldwide that preserve and protect darkness through responsible lighting policies and public education. Not all are remote parks and sanctuaries—a neighborhood or city can earn recognition as a Dark Sky Community or Urban Night Sky Place if residents are committed to a healthful and beautiful night.

“Anywhere where there’s a DarkSky-approved place, there’s been a fair amount of dark sky conceptual lighting design,” Brigagliano said. That work may soon be required as part of state or local regulations. At least 19 states and a number of municipalities have laws in place to reduce light pollution.

To be ready, architects, engineers and designers must recognize that light can be a pollutant—and balance providing light with protecting the dark.

Hero image courtesy Mark Eichenberger

Renovations, retrofits and adaptive reuse projects are complex, and real-time coordination is critical as hidden structural problems or unexpected code compliance issues can crop up with no warning. But that collaboration and coordination hasn’t always been easy. Not that long ago, stakeholders were relying on countless physical drafts and outdated sketches to weigh the pros and cons of potential designs and solutions.

Today, technology is increasingly playing a leading role in these deliberations, allowing teams to work more efficiently. With it, architects, engineers, contractors, building owners and occupants can take advantage of a seamless exchange of technical expertise and innovative ideas that can drive a project forward.

Together, they can work in-person or virtually to collaborate on comprehensive risk assessments, mitigation strategies or quality assurance measures, for example. Document management and version control ensures everybody is looking at the same information.

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Here’s how technology can support adaptive reuse, retrofit and resilient design projects.

BIM

Building information modeling (BIM) captures the current conditions of existing buildings, allowing stakeholders to visualize and simulate various future scenarios for planning and design purposes. With it, users can assess different structures, systems and components to refine and improve on designs.

Energy Modeling

Energy modeling simulates a building’s potential energy use. It lets stakeholders assess the lifecycle cost of various materials, designs and plans so they can consider the long-term financial implications of each design to make informed decisions.

Overall Environmental Analysis

A comprehensive environmental analysis of a building and its future design uncovers a range of data—from calculating potential carbon emissions and energy use to examining its indoor comfort and air quality and helping to reuse and conserve building materials.

Indoor Environmental Quality Analysis

Indoor environmental quality analysis evaluates buildings and designs for air quality, thermal comfort and daylighting. The tools help stakeholders enhance a building’s indoor comfort.

Smart Building and IoT Integration Platforms

Smart building technology, typically integrated with Internet of Things (IoT) platforms, allows for real-time monitoring of building performance, energy consumption and occupant behavior. Incorporating smart HVAC and lighting controls, for example, into renovations or adaptive reuse projects allows for the remote monitoring and management of energy use to ensure it’s always optimized.

Green Rating Systems

The architecture, engineering and construction (AEC) industry doesn’t need to start from scratch as it moves forward on retrofit, adaptive reuse and resilient design projects. Globally, green building rating systems and performance certifications set performance metrics and requirements to ensure projects meet globally accepted practices.

Leadership in Energy and Environmental Design (LEED): The worldwide certification encourages adaptive reuse projects that rely on using existing building resources or demonstrate a reduction in materials. LEED for Operations and Maintenance encourages retrofitting projects that improve energy performance and incorporate energy-efficient systems.

WELL Building Standard: The global performance-based system, which can be used for both new and existing buildings, measures how buildings impact occupant health, considering seven factors—air, water, nourishment, light, fitness, comfort and mind.

BREEAM: The global sustainability assessment calculates how well buildings meet sustainability goals and will perform in the future.

Energy Star Certification: The US Environmental Protection Agency program encourages the use of energy-saving strategies.

Green Star Certification: The Australia-based rating system sets standards for buildings that aim to reduce the impact on climate change and restore and protect biodiversity and ecosystems.

Future forward

As the construction industry continues to evolve, the integration of advanced technologies has become essential in addressing the unique challenges of adaptive reuse and retrofitting projects. By leveraging tools like BIM, energy modeling and smart building technologies, stakeholders can optimize project outcomes, ensuring that both current and future needs are met with precision and sustainability in mind.

The seamless collaboration enabled by these technologies not only improves efficiency but also enhances decision-making, allowing for more informed choices that benefit both the environment and building occupants.

Looking ahead, the role of technology in the AEC industry will only become more prominent, as the demand for resilient, sustainable and adaptive design solutions grows. By adopting these innovative tools and adhering to global green building standards, the industry can lead the way in creating buildings that are not only functional and efficient but also contribute positively to the environment and the communities they serve.

As a result, technology is not just a tool for today but a cornerstone for the future of construction.

Spurred on by a desire to keep fit and healthy, or commute to and from work, or simply to get around their local area, the number of people regularly using a bicycle has risen sharply in recent years.

The World Economic Forum (WEF) estimates that around the world some 2 billion people ride bicycles, a figure which it expects to rise to 5 billion by 2050, as we transition away from fossil-fueled vehicles and onto more sustainable forms of transport.

As we take to bikes more, governments and local authorities will need to design, plan and invest in the infrastructure to cater to the increased numbers of those riding bikes. This will enable cyclists to travel more safely and attract more people to use two wheels to get around.

Europe’s Cycling Bonanza

A recently published report has revealed that more people now cycle in central Paris than drive, 11% vs. 4%, while in Amsterdam—where the 835,000-strong population owns around 881,000 bikes and 63% of  people ride a bike every day—such is the proliferation of two-wheeled riders that as a pedestrian you’re more likely to be dinged at by a cyclist’s bell than blasted with a car horn.

The picture is similar elsewhere in Europe. According to the European Union, 70% of adults in Norway own a bicycle, as do nearly the same percentage of households in Switzerland. The WEF says Copenhagen is the most cycle-friendly city in the world, adding that when asked, residents of the Danish capital said they choose to ride their bikes rather than travel in a car or on public transport “because it’s the fastest way of getting around in the city.” 

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Across the English Channel, figures from Transport for London (TfL), the organization that operates and manages public transport networks in the UK capital, showed the number of daily cycle journeys increased in 2023 to an estimated 1.26 million trips per day, up 6.3% from 2022, and 20% higher than 2019.

The onset of COVID-19 boosted rider numbers; once the pandemic began to abate, many people—still worried about catching the virus—cycled to avoid crowded trains and buses. The development of electric bicycles has also given cycling a boost; in 2017, UK sales were around 55,000. This figure is now north of 155,000.

Meanwhile, the global value of all bicycle sales by 2029 is expected to be a whopping $70 billion, up from $63 billion this year.

Investing In Cycling Infrastructure

This is all hugely encouraging for those looking to promote the benefits of cycling. Yet work needs to be done to improve the on-the-road environment for those taking to two wheels.

Authorities have sought to react to the growing trend by investing in cycling infrastructure, in particular the creation of dedicated cycle lanes.

The UK government says it has invested more than £100 million in cycling and walking paths and e-bike loan programs, while in London, TfL said the Cycleway network, which includes those routes that are mostly but not continuously segregated or protected from vehicles, has grown from 56 miles in 2016 to 223 miles in 2024.

However, the amount being invested in the UK is dwarfed by that being spent in Europe.

The European Cycling Federation (ECF) notes that around €3.21 billion is set to be invested in cycling projects across Europe as part of the 2021-2027 EU structural funding program, a 30% increase on the previous 2014-2020 financial period. This equates to building about 12,000 km of cycling infrastructure. 

The ECF says that, in absolute terms, Poland will be the biggest beneficiary of the current funding program, with €780 million in financing, followed by the Czech Republic (€409 million), Italy (€376 million) and Hungary (€300 million), with these four countries accounting for 60% of total planned investments.

The largest investors measured in euros per capita are Lithuania and Estonia, both investing €46.6, followed by the Czech Republic (€38.8), Slovenia (€35.4) and Hungary (€30.9).

Cycling’s ‘Benefit to Cost’ Message

The cycling website cyclinguk.org makes several cases for investing in cycling infrastructure. First, it highlights that improving routes for cyclists boosts business, particularly among retailers on high-traffic streets and cycling routes, while cycle lanes also move more people in less space, reducing congestion.

Investment pays off, the site adds, with the average benefit cost ratio for walking and cycling projects both in the UK and further afield an impressive 13:1. That means for every pound spent on walking and cycling infrastructure, £13 or its equivalent is returned to the economy.

Cycling.org makes a “Field of Dreams” point too: build a dedicated cycle path and people will ride on it, as evidenced by the increase in cycle journeys in Seville in Spain—a country not noted for the popularity of urban cycling—after some money was pumped into creating new lanes.

It’s not just governments and local authorities that see an upside in considering the needs of cyclists. A growing number of workplaces now make a big deal of offering secure bike storage and showering facilities for employees to attract staff, while many firms help their workers buy a bicycle for their commute.

And new housing developments often make great play of the cycle parking facilities for residents, encouraging healthy lifestyles.

Designing and Planning Cycling Networks

Building cycle lanes first needs careful design and planning, and governments often issue advice to local authorities to steer them through the process.

The UK government’s guidance on planning and delivering cycling lanes, for example, spells out a series of “do’s and don’ts” that aim to improve outcomes for all concerned, including giving consideration to a potential route’s directness, its safety—actual and perceived—and how it interconnects with public spaces.

Inevitably, some car drivers object to having their road space being taken away and allocated to cyclists. But as people become more aware of the issues, cycling will become more accepted. Greater investment in cycle lanes and more advanced methodologies to accommodate cycling through better transport network design and planning feel inevitable.

Copenhagenize, a design consultancy that works with local authorities who want to plan and design cycling infrastructure, has helped a number of European cities, including Lisbon in Portugal and Tours in France.

It also recognizes the importance of establishing safe and user-friendly cycling networks beyond cities. As it says in its latest report: “In rural settings, individuals often need to favor using their bicycles for short trips and seamlessly connecting to other modes of transportation, specifically trains.

“In these contexts, embracing the bicycle not only enhances local mobility, but becomes a pivotal catalyst for holistic rural development.”

Improving conditions for riding bicycles in large cities and towns and beyond is a work in progress, but it is heading in the right direction. Indeed, it has to, since the genie is already out of the bottle. Cycling is no longer a niche activity but is becoming the urban norm, creating the conditions for more sustainable, climate-friendly and healthier travel.

Considered from any point of view, it’s fair to say we’ll all be the better for it.

Our world isn’t static, and our buildings can’t be either. Aging commercial and residential buildings waste energy, and new regulations increasingly mandate sustainability. Office buildings and malls sit vacant as more people work and shop from home, leaving these outdated assets poised for redevelopment. Moreover, devastating climate change-triggered natural disasters are becoming more frequent, and older buildings can’t withstand them.

These emerging and shifting needs and regulations are forcing property owners to take another look at their portfolios. That’s triggering a boom in projects that involve updating, retrofitting and adapting existing buildings. The architecture, engineering and construction (AEC) industry must be ready.

As anybody in the AEC industry knows, working with existing buildings presents plenty of obstacles. Unknown and underlying conditions can easily make an already complicated project even more challenging. But the move toward retrofitting and renovating presents plenty of opportunities for the industry, too. Consider this: About 80% of the world’s existing buildings will still stand in 2050, according to the World Economic Forum, and most will need some form of updating.

And now there is a helping hand. Just as the market for retrofits and adaptive reuse projects grows, so does the number of new technologies, including artificial intelligence (AI) and smart building software, which can streamline the work.

Not just a renovation

There’s nothing new about renovating and updating existing structures. Yet for generations, that work had mostly focused on structural or cosmetic enhancements—repairing a foundation, updating a floor plan or adding new coats of paint.

Today, amid changing climate, lifestyles and needs, this work is taking on a new urgency. The focus on refreshing and modernizing buildings encompasses a range of improvements.

Retrofit: Upgrading or modifying buildings, infrastructure and systems to meet current standards, address safety concerns and adapt to new advancements, including smart building technology.

Adaptive Reuse: Updating an existing building for a new use, often making major changes to the interior design and floor plan and allowing for the preservation of historic buildings and facades. Supports the reuse of materials and other green building approaches.

Resilient Design: Improving existing buildings to withstand the impacts of climate change, including increasingly extreme weather and more serious natural disasters. Ensures durable designs so buildings can continue to operate regardless of disruptions.

Needed change

The construction industry is at a pivotal point where the convergence of sustainability, technology and necessity demands a rethinking of traditional approaches. The push for adaptive reuse and retrofitting is not just about keeping pace with regulations but also about innovating for a better, more resilient future. This requires a multifaceted approach, integrating cutting-edge technologies like AI to predict and manage building performance and employing smart materials that enhance energy efficiency and durability.

Adaptive reuse projects are particularly exciting because they breathe new life into buildings that might otherwise be demolished. This not only preserves cultural heritage and architectural history but also significantly reduces the environmental impact associated with new construction. By repurposing materials and minimizing waste, adaptive reuse is a key strategy in the sustainable development playbook.

Additionally, resilient design is becoming indispensable in the face of climate change. By incorporating features that enhance a building’s ability to withstand natural disasters, we protect both the structure and its occupants. This can include everything from flood-resistant landscaping and reinforced structures to advanced HVAC systems that maintain air quality and temperature during extreme weather events.

The future of reuse

The shift toward retrofitting and adaptive reuse in the construction industry is more than a trend. It’s a necessary evolution driven by environmental, economic and social imperatives. The AEC industry must embrace these changes, leveraging new technologies and methodologies to create buildings that are not only functional and aesthetically pleasing but also sustainable and resilient.

The way we construct buildings in the United States hasn’t changed much in decades. But with the confluence of high materials prices, a skilled labor shortage, high mortgage rates and sustainability challenges, the construction industry has a need for change.

In short, there’s “an importance of trying to figure out new ways of doing things,” said Joe Benvenuto, chief operating officer for contractor LIFTbuild. The Southfield, Michigan-based company is finding success with an unconventional construction process: building from the top down, with a patented method that LIFTbuild refers to as “vertical manufacturing.”

Elevated idea

To be sure, top-down construction—where the top floor is built first and the process works its way down—isn’t totally new. Architect David Termohlen is credited with having invented the concept and further developing it in the 1970s with Charles H. Thornton, founder of Thornton Tomasetti structural engineering firm. A few buildings such as the Russian Diplomatic Compound in Riverdale, New York City, were built in the early 1970s. But then the idea—and the patent—languished, with some exceptions. 

In 2017, Detroit-based Barton Malow, a now-100-year-old construction company, made an investment in the top-down approach to construction, “which fueled the effort to innovate the concept of building a building starting at the top and working downward,” Benvenuto said.

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The company established LIFTbuild to meet its goal of doubling construction efficiency, and it spent about three years in research and development to improve the concept, the way the building is designed and constructed, the way the floor plates are connected and the way they’re lifted.

“In some cases, we sent the engineering methods through destructive testing to validate the process. What LIFTbuild is trying to do elevates the process to create a safer and less expensive way to build commercial buildings,” Benvenuto said. “These R&D efforts have resulted in more than 15 US patents, which protect LIFTbuild’s unique technological and delivery means and methods.”

Benvenuto added, “by 2020, LIFTbuild had significantly improved system safety with innovative means, methods and technologies centered on the superstructure, façade, assembly pad and lifting. Improved safety, increased efficiency and higher quality all lead to a better and more sustainable product for our end user.” 

The Exchange

Built on a small, tight, triangular site surrounded by streets, businesses and the elevated light rail system known as People Mover, the 16-story high-rise called the Exchange in Detroit is LIFTbuild’s first proof of concept. It comprises 153 residential rental units, 12 condominiums, ground-level office space and approximately 6,000 square feet of commercial space. 

The structural steel and concrete building took extensive planning, with much of the engineering done in a 3D model and a virtual environment. LIFTbuild then created a kind of manufacturing environment on the site. “Picture more of an assembly line in which a vehicle gets created. It’s very rapid. All the critical parts and pieces come into the process at just the right time,” Benvenuto said. 

The build works this way:  

Builders start on site by completing the foundation and underground work consistent with a conventional building. They then begin erecting concrete and steel “spines.” The spines are structural elements and could include stairwells, bathrooms, kitchens—anything, really, depending on the design, according to Benvenuto.

Next, they begin placing the concrete assembly pad, what LIFTbuild refers to as the factory floor. The assembly pad is located exactly where the building footprint is. A building’s design and geometry determine the number of spines needed. The Exchange has two, each of which encase elevators, stairs, storage and mechanical rooms.

Strand jacks, linear winches that pull heavy loads from above, are staged at the top of the spines. The floor plates are then built around the spines, about three feet off the ground with metal decking and concrete. The jacks lift the floor plates just above the builders’ heads to install the underdeck mechanicals—no need for scaffolding or ladders.

The façade and rough mechanical, electrical and plumbing go in before the floor plate is lifted. After the floor is locked into place, interior fit out begins, which includes interior walls and ceilings. Once the façade and fire protection are installed, the floor plate is lifted by the strand jack into place. Each floor in the Exchange weighs about 1 million pounds, and during placement rose about 30 feet an hour. The highest lift on the Exchange was about 200 feet.

“Placement is a cantilevered approach where we structurally connect that floor plate to the spine,” Benvenuto said. “From there the floor plate is able to provide structural stability out all the way to the exterior of the building without columns.” Every floor plate is individually supported. 

Lift and learn

The foremost reason to use this method is safety, Benvenuto said. According to the Bureau of Labor Statistics, in 2022 the construction industry accounted for 1,092 deaths by falling, slipping or tripping—47.4% of all workplace fatal falls, slips and trips. “We eliminate the hazards when we install the façade at ground level. Fall protection is naturally built into it,” Benvenuto said.

Benvenuto cites increased productivity as the next major benefit, pointing to the difficulty of finding available, qualified tradespeople, rising construction costs and material pricing. “Projects have a hard time meeting financial feasibility at times,” he said. With LIFTbuild, because assemblies are done on site, often using prefabricated products and with little need for large cranes, there are fewer people needed for a build. 

The method also saves time. Although builders could customize individual floors, each floor is basically a repeat of the one above. There’s more of a manufacturing process—which also can instill better quality, said Mark Tamaro, managing director of Thornton Tomasetti, who consulted on the Exchange.  

Tamaro also points out that these projects can be more sustainable. Because the floor system uses steel frames, it requires less material than concrete construction. “There’s a significantly lower amount of embodied carbon than in a typical concrete product,” he said. Additionally, Tamaro said that as they learn more, there may be ways to incorporate mass timber or other materials. 

Ultimately, LIFTbuild can be less expensive when compared to conventional building. Benvenuto said that using LIFTbuild, the company aims to provide savings of 10% to 20% on cost and 20% to 30% in schedule savings. 

Nothing is without its challenges, however. There’s a certain level of education—for municipalities, lenders, insurance companies, builders and tradespeople—that must happen. Benvenuto said the company went through some “pretty intensive education sessions to make sure they truly understand what’s happening and address any concerns or what they would perceive as a risk.”

Tradespeople and others working onsite had safety training and “education around optimizing their time on site to make sure they were the most productive,” Benvenuto said. “But realistically, the work conditions are better and easier than you would see on a conventional project,” he added.  

The education piece helped with permit applications and inspections. “Some of the preliminary inspections can happen at grade level, so it’s advantageous for them,” Benvenuto said. 

LIFTbuild also collaborated closely with MIOSHA to adhere to all safety standards. The strand jack system is safe, able to take four to five times the amount of capacity needed to lift the floor plates. 

Not just a novelty

Top-down construction can work beyond commercial building. There’s need for more housing, and the LIFTbuild method is “well-suited for residential construction,” Tamaro said. The method could be a game changer for the industry.

“This is something that can truly transform the way we build buildings,” Benvenuto said. “About 10 years ago, Barton Malow set the goal of doubling our efficiency by our 100^th anniversary [in 2024]. The investment into LIFTbuild is a significant effort to accomplish that.” 

While the Exchange is LIFTbuild’s first completed building, Benvenuto said they have a handful of opportunities coming. “With the Exchange, we’ve been able to validate the technology. Now our focus is to commercialize LIFTbuild on a broader scale throughout North America.” 

Top-down in action: A different take

In 2014, Thornton Tomasetti used the “traditional” top-down build method to build the Marriott Marquis in Washington, D.C., said Tamaro, who was the project’s engineer of record. “We constructed the building both upward from the ground level and downward simultaneously.” 

Builders drill into the site and install shafts, called piers or plunge columns, Tamaro said. In the case of the Marriott these were dug down about 130 feet to get below the lowest basement level. The piers stop at the floor level of the first floor. The build continues upward in the traditional way with concrete columns. 

At the same time workers are building up, others are excavating below, around the piers. “If you do it right, you can top out the building before you get to the bottom of the basement,” Tamaro said.

Why do it this way? “In the case of the Marriott job, there were two fundamental reasons,” Tamaro said. “One is speed of construction.” In a conventional build you’d dig all the way to the bottom and then come back out. With this top-down method, you effectively start in the middle and work down and up at the same time. There’s no wait time. 

The other reason to choose this method is that this particular site was constrained with both a high water table and the need to go extremely deep as there were multiple basement levels. “This method of construction allowed us to build deeper and avoid having to address the groundwater,” Tamaro said. “Doing things this way made an otherwise very challenging project feasible.”