Originally built in 1918 for immigrant Kohler Company employees, The American Club reemerged in 1981 as a full-service hotel located in Kohler, Wisconsin. The American Club contains an underground parking garage that is a 120,000 square foot precast concrete framed structure built in 1981. The structure consists of a single level of precast concrete double tees supported by a concrete foundation wall along the perimeter and precast inverted tee beams and columns at the interior. The precast structure supports vehicle traffic and parking, as well as a landscaped plaza.

ZS was retained to prepare rehabilitation and structural improvement construction documents for the parking structure. To minimize the impact of construction on the hotel operations, the construction schedule was limited to between the New Year’s celebration and the beginning of the 2018 golf season. ZS was onsite to facilitate every phase of construction from demolition and concrete repair to waterproofing installation and the reconstruction of final detail features including a covered stairwell and American Club Signage support structures.

ZS’ scope for the project included:

• A thorough survey of the structural conditions, including a hands-on examination of all structural components
• Waterproofing investigation and design
• Laser scanning and BIM conversion
• New topping slab with hydronic snow melt system
• Below grade ventilation upgrades
• ADA improvements throughout the parking structure
• Concrete surface repairs and stair replacement
• Detailed use maps for staff to accommodate delivery trucks and motorcoaches on the supported drive lanes
• Waterproofing upgrades to underground tunnels connecting adjacent properties
• Drive snow melt system
• Construction administration services during each phase of construction