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Prefabrication


Often referred to as the "oldest idea in architecture" prefabrication has a long history in the AEC industry.

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Prefabrication


Often referred to as the "oldest idea in architecture" prefabrication has a long history in the AEC industry.

A Long Lineage

Island understands this history, and looks to take the benefits of prefabrication, including the ability to control cost, labor, quality and design flexibility, and marry it with an in-depth understanding of the facade industry.  The facade is literally the face of the building, providing aesthetic appeal, identity, and ultimately the first line of interface against the exterior environment.  It is  a complicated science.  Given its importance, and the large percentage of the construction cost allocated to constructing it (typically 20% of a total construction budget goes toward facade erection), it would seem that there would be a high standard of quality for design, execution, and delivery of the facade.  However, like much of the AEC industry it has become fragmented, and heavily relies on very specialized trades fabricating, erecting, and installing on site, in trade specific bubbles.  This requires vast amounts of coordination by architects and contractors, but at the end of the day, it is very hard to understand who is ultimately responsible for work, especially when something goes wrong.

Notable examples of prefabrication in architecture and construction.


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Modular


Our core competency lies in the design, fabrication and installation of unitized, large format panelized facades.

Modular


Our core competency lies in the design, fabrication and installation of unitized, large format panelized facades.

Modular Construction

We have leveraged state of the art curtain wall technology to develop a perimeter interface system that does not rely on wet seals, but instead benefits from a two-part air and vapor gasketing system that is fully pressurized.


Our fabrication operations are performed within seven clear span, large volume structures formerly occupied by the United States Navy and Grumman Aircraft Engineering Corporation. The property is situated on a combined 30 acres of land, where both fabricated and raw materials are stored. The fabrication facilities themselves total over 300,000 sq. ft. of indoor, climate controlled space which enables Island to operate year round in any weather.


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Single Source


Every project is an opportunity to innovate and expand the breadth and depth of prefabrication as it pertains to delivery, cost, performance and design.

Single Source


Every project is an opportunity to innovate and expand the breadth and depth of prefabrication as it pertains to delivery, cost, performance and design.

Single Source Building Enclosure

Island conducts exhaustive research and development in a reactionary manner, utilizing project demands and constraints to push the boundaries of our technology.  This devotion to innovation is a direct benefit to our clients, evolving our systems to become increasingly more adaptable, high-performance. and cost effective.  Our goal is to leverage our in-house knowledge base and experience to develop single source building envelop solutions, in order to capture every envelope interface and condition.  From opaque rainscreen, to curtain wall, to sun shades and balconies, the key to controlling the performance of the exterior wall is the ability to control all the transitions and connections.

Fabrication

One of the keys of single source facade delivery, is the ability to fabricate and source as much of the building envelope in-house to help control cost and accelerate lead times.  Island has the capacity to roll its own steel stud and CNC fabricate many of the components comprising the building envelope.

Assembly

All of Island's facade systems are assembled by foremen led crews under 300,000 square feet of climate controlled, optimally lit space to ensure the best in quality and precision construction.

Installation

Facades are delivered to site on a as needed basis and installed by Island led union installers.  We are able to mobilize utilizing our own mobile cranes to capitalize on the speed and efficiency a panelized process can afford the overall project schedule.


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Performance


We deliver project-tailored envelope solutions that enable developers, contractors and architects to realize complex projects.

Performance


We deliver project-tailored envelope solutions that enable developers, contractors and architects to realize complex projects.

Engineered for High Performance

Island prides itself on providing facade systems that meet or exceed today's stringent building energy codes.  The key to this is Island’s proprietary panelized approach to building envelopes.  We utilize a robust, yet flexible framing structure coupled with a dynamic hanging system to accommodate project specific variations in building performance, construction requirements, and design demand.  All of Island's facade panel solutions comprise of:

Steel Frame

A fully engineered steel frame that can integrate hot and cold rolled shapes, as well as aluminum framing members if needed. The frame is the "backbone" of the system and it is the engineering of this precision fabricated frame that allows Island Exterior Fabricators to build a "megapanel" frame.

Continuous Insulation

Continuous Insulation occurs fully outboard of the air vapor barrier to greatly enhance energy performance requirements.  This allows for more control over dew point management within your wall section.

Integrated Glazing

Integrated project specific glazing (provided either by third party manufacturer or developed in-house), allowing the fenestration to be "factory installed and sealed" in a controlled environmen

Dry Set Gasket Interface

Fully dry set gasket type interfaces, eliminating the need for maintenance of heavy wet seals at panel to panel interfaces, and more importantly providing a watertight enclosure as each individual floor is enclosed. The gasket system is a "double piston" mated stack assembly with a pressure equalized gutter for moisture evacuation.


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System Flexibility


We work with architects and builders in developing a customized approach to building enclosure and have performed work with all material systems, including but not limited to: terracotta, stone, glass, metal panel, brick and cementitious.

System Flexibility


We work with architects and builders in developing a customized approach to building enclosure and have performed work with all material systems, including but not limited to: terracotta, stone, glass, metal panel, brick and cementitious.

A Flexible Backbone

We strive to incorporate design flexibility into the world of prefabrication, by developing a robust system that is unique to Island Exterior Fabricators.  All insulation, weatherproofing, framing, and cladding substructure is incorporated into the panel and fabricated in a climate and quality controlled environment.  In addition, Island also integrates windows and glazed openings into our panels and will work to accommodate all interfaces into our system for single source responsibility and efficiency of construction, in addition to improved thermal and vapor infiltration performance.

Example of an Island panel build assembly.


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Design


Every project is an opportunity to innovate and expand the breadth and depth of prefabrication as it pertains to delivery, cost, performance and design.

Design


Every project is an opportunity to innovate and expand the breadth and depth of prefabrication as it pertains to delivery, cost, performance and design.

Integration and Transparency

The keys to Island’s methods are integration and transparency.  We work very early on to understand goals, requirements, constraints, and ambitions for all of the projects we collaborate on, and reflect that in the work we perform.  We stress early collaboration to help define aesthetics. performance requirements, budgets, schedules, and constructability studies for architects and contractors and work diligently with all parties to maintain the requirements throughout the process, from early schematic design all the way through to panel fabrication and erection.  Early involvement in project delivery allows the owner, the architect, and the general contractor to have greater say in the molding of the project, while costs are still somewhat fluid.

Island brings years of experience in building enclosures to our design assist process.