Construction Today - January 2017 - 31
efficiently form and pour the cast-in-place
concrete. "It starts in the office," he says. "We
develop the means and methods, with field
input, explain it to them and they build it."
Villa Construction's reputation precedes
it such that most of its work is generated by
word of mouth. "There are certain architects
that know us and might tell the general
contractor or owner about our expertise in
architectural cast in place concrete work,"
DiNunzio says. "In other cases there are
different leads from structural engineering
firms and or consultants."
Molded for Life
In spring 2004, Villa Construction was
contracted to construct cast-in-place
concrete tanks at the Westport Waste Water
Treatment Plant. The company spent a yearand-a-half constructing 12 tanks with an
average of 30 to 40 employees on site. Some
of the tanks were as large as 100 feet in
diameter. The project was about $10 million
and completed in 2005.
"Most of the challenges were the curvature of the walls with the integration of the
vertical architectural rustification strips,"
DiNunzio remembers. "This architectural
feature became difficult and complicated
due to the nature of wall form work curvature and interior reinforcement."
The skills of Villa Construction's carpenters helped the architect's design become
reality. "It's sort of like the mold for a cake,
you can make any kind of shaped cake, but
to make the mold for the cake is the part
that these skilled carpenters can visualize
and put together," DiNunzio explains. "It is
a reverse image of what the product should
over, becoming the outline for the skylights
that have a garden roof above. The end of
the wave housed seating for the spectators."
The Wellness Center received the Concrete
Industry Board's Award of Merit with Special
Recognition. "[The Wellness Center is] a
cast-in-place concrete project well integrated
into the surrounding landscape," the board
said. "Fine use of sandblasting concrete
surfaces to expose coarse aggregate. Fifty
percent proportional use of slag substitution
contributed to LEED Silver rating. Versatility
of concrete is very evident in this project."
The biggest challenge Villa Construction
faced during construction was creating the
tight curves at the seating area where the
wave starts. "The pressure of the concrete
onto this curved section of the wall was
tremendous," DiNunzio says. "It becomes
difficult to make up form work to create the
tight curves, but in order to achieve this, we
used a quarter-inch bath liner backed with
form work to create the shape of the curve."
Villa Construction used ground and polished concrete with a 50 percent proportion
of blast furnace slag and portland cement
for the floors of the lobby, concourse and
the main public circulation spaces. A
second contractor broadcasted crushed,
multi-colored recycled glass chips into the
concrete and "created this beautiful floor,"
Villa used 10-foot by 10-foot panels on
7 Bryant Park to permit a panoramic
view of the Manhattan park.
The wave-shaped pool area in the New
Wellness Center at the College of New
Rochelle, N.Y., is shaped like a wave,
which was molded out of concrete by Villa
Construction. "As the wave starts on one
side, it begins to fold over like a wave, thus
creating a hollow tunnel above the pool,"
DiNunzio describes. "What the architect did
was smart. He made the base of the wave
the seats for the swimmers while the roof
seven-foot upturn beams curve and fold
JANUARY 2017 CONSTRUCTION-TODAY.COM