Jeremiah Program and Excelsia Injury Care Tenant Fit-Out
CAM Construction provided design/build CM services to help the Jeremiah Program it open its 10th regional office one the second floor of the Gateway at Station North office building. The nearly 7,000 sqft fit-out included a Board Room/Training Area, Administrative & Executive Offices, Huddle Rooms, a Family Coach Suite, a Break Area, and a Children’s Play Area. The mix of private offices, meeting rooms, and open collaboration areas, in conjunction with brightly colored walls and a generous glassline, turned this long-vacant shell space into a warm and inviting destination for the staff and beneficiaries of Jeremiah Program. CAM worked closely with Jeremiah Program to assist them with architectural layouts and designs, which not only resulted in cost savings but also provided a final product that closely aligned with what Jeremiah Program wanted and needed for the space. CAM also helped Jeremiah achieve their goals of maximizing natural light and views over the Jones Falls, providing a safe destination for mentorship and consulting, and creating flexibility for future expansion of their programs over their lease.
CAM also provided design/build CM services for Excelsia Injury Care to open a branch office on the first floor of the Gateway at Station North office building. The scope of the renovations included new drywall partitions, drywall wrapped openings into a new long “PT” room, new drop ceiling and LED lay-in fixtures for exam rooms and the chiropractor’s office, window frosting for privacy in all existing glass windows, HVAC modifications, and lead-painted walls and ceilings for the X-Ray rooms. The renovation area was approximately 9,500SF and included a lunchroom, a reception area/waiting room, four private offices with full glass exposure, four private exam rooms, six private physical therapy rooms, an 800SF open area for group physical therapy, which included a rubber floor, and the renovations expose 14-ft high ceilings in the public and therapy areas.
St. Joseph Parish
The St. Joseph Parish project involved two additions and a 12,000-square foot renovation of the historic St. Joseph Parish sanctuary in Cockeysville, Maryland. This project, which won the ABC Excellence in Construction Project of the Year for Greater Baltimore chapter, included additions facilitated a new radiused seating scheme that provided parishioners with better visibility of the sanctuary. To meet this objective, our team had to shore up the original structure and integrate new steel framing into matching stone veneer additions, with copper gutters, downspouts, and slate roof, all while navigating immovable obstructions (foundation rock, etc.) that were pervasive beneath the church.
In addition to exterior wall modifications and various ADA site improvements, CAM’s work included the construction of a new altar with a stone arch hand-picked from the local quarry, new radiant piping, ductwork, underground plumbing, ornamental tile flooring, a coffered ceiling system with a dome and back-lit stain glass oculus, and a radiused cornice with cove lighting around the perimeter of the sanctuary. The original stained-glass windows were protected, and four windows had to be removed and reinstalled in the new openings created by the additions. The building is now equipped with a new sprinkler system, architectural lighting, hand-crafted millwork, and a 2,200-pipe Peragallo organ that was custom-built within this space and engineered to optimize the acoustical performance of the sanctuary. Additionally, MEP upgrades were made throughout the facility to extend the life and enhance the efficiency of existing equipment.
The construction of the dome required our tradesmen to curve approximately 80 steel studs to frame the shape of the dome ceiling structure. Five layers of drywall and thousands of screws were required to achieve not only the aesthetic design intent, but also the acoustic performance goals for the dome.
To integrate environmentally conscious features to the project, our team replaced all lighting with new LED fixtures replete with automation features and daylighting sensors. Additionally, we upgraded the controls for the mechanical system, which will lead to a dramatic decrease in energy usage and optimization of the existing HVAC units.
This project required numerous skilled trades to complete the myriad challenging tasks presented. Most notably, the majority of new framing and drywall work had to be conducted from a scaffolding platform to remove the old wood ceiling without damaging the original historic wood roof framing above. This challenge was compounded by the need to conceal the new mechanical distribution throughout before finishing the installation of the coffered ceiling system. To allow for the construction of the dome, extensive modifications had to be made to the roof truss construction as well as the relocation of MEP systems whose routing had to traverse the future dome.
Several unforeseen circumstances resulted in a temporary 2-month delay within the 11-month project timeline. In the early stages of work, the rock that was discovered within the historic portion of the church required CAM to reduce the size of the planned utility room, relocate the Fire Alarm Control Panel, and backfill the obstructed half of the basement. Asbestos was also discovered within the waterproofing of the historic church and required extensive abatement that delayed critical close-in of the new exterior walls. A key design feature was to remove and replace all of the existing sloping slabs with a new flat slab; however, the existing hot water heat piping was so close to the surface that it had to be entirely removed and replaced. Various replacement piping alternatives were presented and priced, and finally approved, sourced, and installed.
Daily correspondence between CAM and the owner facilitated a safe working environment that prevented disruptions to the operations of the adjacent, occupied, K-8th school facility. To this effort, our project management team coordinated deliveries so that they would not overlap with drop-off and pick-up times for the students. Furthermore, our superintendent and project manager worked closely with utility companies so that electricity and water services were never disrupted during the school’s hours of operation.
On several occasions, CAM saw opportunities to save the owner cost by value engineering different alternatives to line items that had to be purchased. By suggesting an alternative regulation to the heating system and enlisting a different lighting supplier who could custom-fabricate a pendant fixture that was comparable to the much more expensive fixture specified, CAM was able to generate over $100,000 in savings for the owner—a substantial percentage of those line items.
This project has a significant communal impact, which CAM embraced throughout its various phases. When the church was first constructed in 1852, stones from the local Beaver Dam Quarry were used to create the building, and many of the Irish immigrant quarry workers were members of the parish. For this project, our crew created a stone arch that mirrors the original entrance and surrounds the crucifix, above the new tabernacle, to extend the sense of being welcomed just as the front door symbolizes; this was done by sourcing stone from the very same quarry from which the church was originally built. This feature not only serves as the most prominent visual focal point behind the priest during mass but also as a reminder that the parish is a place built by the community and for the community.
Chick Webb Recreation Center
CAM Construction was hired by the Baltimore Department of Recreation and Parks to complete extensive renovations and an addition to the historic Chick Webb Memorial Recreation Center in East Baltimore. The Rec Center, which was built in 1947, serves as a community hub for East Baltimore, and was threatened with demolition in 2017 before receiving its historic designation. When complete, the ~43,000 sqft Chick Webb Recreation Center will feature a new pool, gym, basketball court, walking track, office space, locker rooms, a teen lounge/game room, kiln room, and a recording studio and vocal booth, in honor of Chick Webb’s musical legacy.
Baltimore City District Courthouse
CAM Construction was hired by Maryland’s Department of General Services (“DGS”) to convert a 1960’s-era office building into the Baltimore City District Courthouse, a transformative $71 million redevelopment project for the Maryland Judiciary. This 170,000-square-foot facility exhibits a complete modernization of a functionally obsolete and largely vacant municipal building, providing the city with a state-of-the-art civic complex featuring eight modern courtrooms, four of which are dual-purpose and can hold both civil and criminal trials, advanced detention facilities, secure sallyport operations, and a two-story, partially underground parking garage.
The project scope involved comprehensive demolition and reconstruction of the existing building while maintaining the original structural steel framework—essentially creating a new building within the original structure. This effort is emphasized by the $9,000,000 steel package for a project which was a renovation. Existing steel columns had to be reinforced for additional loads on the roof for the new rooftop steel and equipment that is also surrounded by a new screen wall supported with new structural steel. Five-story holes had to be cut through the building to allow for the construction of new elevator shafts, stair towers, mechanical shafts, all requiring new structural framing and reinforcement.
The original steel column grid was built “out-of-plumb”, which made it difficult to install the sensitive metal panel system, as the grid had a 500 pounds-per-square-foot tolerance while the equipment intended to install the steel was 5,000 pounds-per-square-foot. Furthermore, the original office building was constructed a mere 8-inches above the water table, so the existing steel columns were largely corroded and required extensive repairs.
The interior construction encompassed five floors of public-facing judicial spaces along with private staff workspaces, beginning with new courtroom construction featuring custom millwork, custom judge’s benches, and jury boxes designed specifically for court proceedings. Secure detention areas were constructed with specialized security features including detention elevators equipped with protective cages for prisoner transport. A secure sallyport was built with roll-up doors and vehicle processing areas to facilitate safe prisoner transfer.
The new building provides distinct circulation patterns for the general public as well as the judges (and their staff), with separate elevator banks and monumental staircases featuring terrazzo treads/landings and a glass/steel railing. Notable public areas include restrooms with modern faucets that dispense soap and water and also dry hands, along with ceramic tile finishes and common areas that were installed throughout the building to serve both visitors and staff. The design improved the customer service areas, which include cashier stations and transaction counters with custom granite tops and ballistic-grade glass. Aside from the courtrooms and detention areas, other private areas included a law library that was constructed to support legal research, IT rooms and security command centers, and administrative offices and support spaces to support the courthouse staff. Shell spaces were also prepared for future tenant improvements, as needed.
Challenges for the site included managing lane closures throughout the duration of the project and completing all façade demolition and re-construction with less than 20’ of working space. Even with the lane closure, there was an extremely tight limit of disturbance around the east and south perimeter of the building, and the west side of the building along the alleyway required extensive coordination with the neighboring properties to maintain access, continuity of trash removal services, etc. One of the most critical aspects of the job, which required intensive oversight due to the limitations of the LOD, was the utilization of a 175-ton crane that was deployed on Calvert Street (with permission via street closure permit). The crane operated nearly 200 feet of boom and jib to deliver and set the DOAS units and Air-Cooled Condensing units to the rooftop. These units were then concealed on all sides by a complex architectural roof screen from I-83 and surrounding buildings. The substantial mechanical loads added to the roof level required load transfer down to new footers and ground improvements beneath the garage level, and the low clear heights required strategic planning to utilize the typical equipment required to install deep foundations.
The tight sight constraints also impacted the installation skin of the building, which aesthetically juxtaposes yet compliments the historic Mt. Vernon neighborhood that borders the building on the western elevation. The installation process included the interfacing of six distinct veneer materials including : ground face block, ceramic panel (stone-look), wood-look aluminum panels, traditional composite panels, rain screen, and curtainwall glass, much of which had to be upgraded to ballistic-rated to ensure the safety of personnel in the building within an urban environment surrounded by tall buildings. Coordinating the installation of distinct systems to avoid conflicts, executing the architect’s specified patterns, and ensuring the building would be water-tight and thermally sound were especially remarkable feats, given that all work had to be completed via boom-lifts within a narrow alleyway along the LOD fence line.
The main entrance plaza was completely reconstructed to create a dignified and secure approach to the courthouse. This prominent public space features security bollards to protect against vehicular threats, flagpoles displaying national and state flags, and decorative paving. New exterior stairs and accessible ramps ensure universal access to the courthouse while meeting all ADA requirements. Sidewalk reconstruction was performed along Calvert, Centre, and Franklin Streets and required coordination with the city’s DOT to maintain pedestrian access throughout construction, and chemical injections were completed along the entire alley-side façade to waterproof the levels that were built into the hill on the Franklin Street elevation to below grade. The subterranean loading dock and service area were improved to facilitate efficient building operations and deliveries. A dedicated dumpster enclosure was constructed with security bollards to secure waste management operations while maintaining the aesthetic quality of the site.
Notably, this project is the first DGS facility eligible for LEED certification. A two-fold green roof system was installed and creates a cooling environment for the roof while mitigating stormwater runoff. The high-performance building envelope reduces heating and cooling loads through improved insulation and air sealing. LED lighting was integrated throughout the facility with occupancy sensors and daylight harvesting strategies to minimize electrical consumption while providing excellent illumination for judicial functions.
Maryland Food Bank – Foodworks Addition
CAM completed 21,000 sqft of interior expansions and additions at the Food Bank’s 100k sqft headquarters facility in Halethorpe, MD, which remained fully functional over the course of construction, to avoid any interruption in service to those in need. This project improves Food Bank’s distribution capacity, provides educational opportunities to certify new chefs and kitchen managers from low income communities, and greatly enhances the administrative office environment needed so their nearly 200 hardworking staff members can better carry out their mission. Our scope of the work included a substantial Kitchen Expansion and Renovation, building a new Loading and Receiving Queue, Dry Storage Area, state-of-the-art Conference Rooms, Private Offices, and Collaboration Areas, a new Break Room & Training Area, and a New Celebrated Entry to the sorting warehouse for volunteers and employees. This project was extremely challenging given the need to establish a temporary kitchen, insert completely sound-proof mezzanine structures within an occupied facility, interface additions with a pre-engineered building, and keep the Food Bank completely operational over the course of construction, given the mission-critical work that they carry out on a daily basis.
The Lofts at Stehli Silk Mill
Originally built in 1897, the 11-acre Mill complex comprises six (6) distinct buildings that employed 2,100 female textile workers at its peak, and it is now listed on the National Register of Historic Places. Most of the structures are three stories tall, with the main structure (bordering Martha Ave.) spanning over 900 linear feet, making it the longest building east of the Mississippi when it was constructed. The exterior elevation is characterized by a strong series of brick piers that correlate with the close beam and column spacing (7’0”OC), which produces a 300 lbs/sqft floor load capacity. Tall (9’0”) windows accentuate the façade and are woven between the piers to provide maximum ambient light, as was customary with factories of
that era.
CAM is in the process of converting this mill into 165 loft-style apartments, consisting primarily of one-bedroom units with a mix of two-bedroom units and studios, with occupancy scheduled for January 2025. Additionally, a resident clubhouse/common area is planned for the old women’s cafeteria, which is a single-story structure with a clerestory and exposed steel truss roof framing system. Ancillary structures related to the former boiler plant will be utilized to provide amenities such as a fitness center and brew pub open to the public, as well as leasable space for some smaller retail/office users. The interiors will have a combination of restored materials (ie: wood flooring) and brush blasted exposed brick walls and beams, as well as all new partitioning throughout. All new electrical service, and HVAC systems will be implemented, along with necessary low voltage systems. We take a minimalist approach to our design to allow as much of the original building features to show through. There are 1,400+ windows of all shapes, sizes & styles that CAM is replacing according to NPS guidelines.
Clifton T. Perkins Hospital Center
In 1993, CAM was awarded a contract to construct a 50,000 sq. ft. addition and complete renovations to 35,000 sq. ft. of this fully occupied hospital for the inmates with mental health disorders. The gymnasium was completely renovated as were the two main east/west corridors and the boiler room, where all of the major equipment was replaced without interruption to the existing services. The project included all of the “standard” security systems as well as a card access and remote personal duress system. Special meeting rooms with operable partitions, an exercise room, library, chapel, nurses stations, and day rooms were constructed. Three major skylight assemblies exceeding 300 l.f. provide natural lighting to the common spline area which was constructed with special knock-out panels to allow for future additions. An enclosed recreation area with pre-cast furnishings and shaded pavilions, plantings and security fencing provide exterior amenities. The wood gymnasium flooring and equipment, carpeting, seamless vinyl flooring, wood plank ceilings, ornamental lighting, glass rails, oak trimmed ceramic tile flooring and special finishes belie the fact that this facility houses individuals incarcerated for emotional and mental disabilities. Much sitework was completed outside the facility’s security fencing remote from the field superintendent working concurrently inside the fully occupied building. A fast track change order to modify and secure the ductwork was issued to CAM, and work was completed without interruption to the project schedule.
SARC
Chesapeake Employers Insurance Co. – HQ
The Chesapeake Employers’ Insurance Headquarters renovation project fundamentally began as a major fire and water damage restoration effort, and quickly transitioned into an opportunity to retrofit two entire floors of their facility to meet the demands of the modern office culture. After a brief RFQ process, Chesapeake decided to engage CAM as a repeat client of theirs over the past 15 years. The heart of this project involved the construction of a new central break area, which functions more as a community gathering space with a variety of different seating options, food service offerings, and basic culinary equipment to assist employees who bring their own lunch. The genesis behind this space was to provide a welcoming common area amenity that employees could either utilize individually, with one another, or even with external facing clients. The architect’s goal was to make this a visually distinctive space that will impress upon every visitor and staff member who walks off the elevator into level one of the office building.
The linchpin of their concept called for replacing an old drop ceiling with multiple acoustical clouds, and leaving the rest of the structural slab exposed above. Executing this look required an extensive amount of clean-up within the former plenum, to demo extraneous low voltage wiring, bundle up active IT/data wiring within black corrugated piping, and consolidate electrical conduit runs into specific areas. CAM then sprayed the entire above ceiling area black to help any remaining MEP systems disappear from view, which helps maintain the occupant’s focus on the space in front of them.
Other elements of this job included the construction of an all-new fitness center with connected ADA restrooms/locker rooms, a massive new training room with a folding partition, a variety of small conference rooms designed for brainstorming sessions and zoom calls, and completely new finishes and systems furniture layout within the open areas on either side of the core of levels one and two. On level one, the project also involved shifting many of the building’s main support functions into more interior portions of the floorplate without natural light, etc; as a result, CAM helped create a new mail distribution room, IT support areas, copy/print rooms, and storage rooms.
Some of the most challenging facets of this project pertained to the limited working hours, given the continuously occupied nature of this facility during construction. Certain trades preferred to work off-hours to avoid disruptions to Chesapeake’s employees, and CAM facilitated the accommodation by being physically present on the jobsite for numerous evenings, weekends, and early morning meetings. CAM’s PM also wore the hat of superintendent, spending half of his day working out of the on-site office of Chesapeake’s facility manager, which facilitated immediate communication with the owner, yielded swift answers to questions, and helped approve design tweaks when beneficial to the overall project intent or schedule. CAM ensured that noise would be kept to a minimum during normal business hours, and that life safety systems were sustained over the course of the job. One tricky subtlety of the project involved preserving a large section of the existing ceiling grid on one of the floors, which forced trades to employ thoughtful integration strategies at the connection points and exercise caution for all relocation work above. Lastly, CAM was able to save the owner tens of thousands of dollars by salvaging and re-installing nearly all of the prior doors, frames, and hardware that had been removed and stored on-site during the demolition phase.
