As a centerpiece at the heart of Los Angeles' Century City/Beverly Hills region, the 42-story, 147-unit luxury condominium tower known as "The Century" is being designed to be an elliptical epicenter of upscale living on the Avenue of the Stars.

Designed by world-renowned Robert A.M. Stern Architects LLP of New York, every imaginable detail has been nuanced to achieve the epitome of elegance including approximately 256 fluted concrete finished columns created with customized FRP (fiber-reinforced polymer) fluted round column forms (FRCF) produced by Molded Fiber Glass Construction Products (MFG-CP) of Independence, Kan.

The 884,468 gross-square-foot Century Project began construction in June 2007 and is to be completed in December. The tower is supported by an interior moment frame system with a 7,109 CY concrete mat foundation with an exterior skin combining sculptured precast concrete and stone cladding. Upon its opening, residents will experience 13-foot fluted concrete finished columns accentuating the decorative élan of the floor-to-ceiling window balconies on the upper-level exterior of 26 of buildings' 42 floors (eight per floor). The final effect will create a visual evolution of West Coast upscale living with unparalleled panoramic views stretching from downtown, to across the Santa Monica Mountains and Pacific Ocean.

Architectural Firm of Record HKS Inc. of Dallas enlisted the project's concrete contractor Webcor Concrete of San Mateo, Calif., to secure a source for the design's unique fluted column forms. After considering steel and plastic concepts, Webcor contracted MFG-CP (mfgcp.com), which specializes in a range of custom and standard fiberglass-reinforced thermo-set composite column forms, to custom-build 15 FRP/FRCFs; in addition to a multitude of standard FRP/RCFs throughout the tower.

The goal was to create a unique fluted design to provide flexible stability for the 13-foot scale during concrete pour, and deliver a lavishly smooth finish.
According to MFG-CP Engineering Manager Eric Brace, "We utilized the four-piece design vs. the two-piece so it could be stripped in pieces during production to ensure a smoother finish and capture the meticulous luxury of the Stern/HKS design specifications."

Upon design approval, MFG-CP produced the FRCF's using a chopped strand matt, sandwich construction of 24-ounce Woven Roving — made in quarter sections to alleviate difficulties in stripping away from the mold/peal and ensuing concrete pour/peal process. The production leveraged a spray up/open mold process (with mold-release pre-treatment) which involved simultaneous deposition of the chopped strand matt laid in place on the cavity mold with the catalyst resin poured-over for an even-flow material.

Although created in quarter sections, the FRCF's were delivered as 15 full-forms with four seams and 9/16-inch lip-holes to accommodate ½-inch Coil Bolts during assembly. The FRCF's composite properties also made them corrosion resistant and reusable for future projects.

Upon assembly of the FRCF, standard rebar and base specifications; approximately 3 yards of self-consolidated concrete mix were required for each column pour in a standard monolithic pour sequence. According to Webcor's Senior Superintendent Ryan Isbell, "Construction to-date is meeting the aggressive six-day-cycle (one-floor every six days) as the fluted forms are an easy pour; taking approximately 2-4 minutes per column." Isbell also said that the result is a unique exposed concrete flute-effect with a smooth architectural finish.
HSK Inc. Architect Patrick Treadway said the tower's fluted concrete columns were more cost-efficient than the originally conceived pre-cast or stone options and provided a practical alternative for time, design and efficiency.

MFG-CP manufactures a range of one-piece round column forms (RCFs), dome and pan forms for one-way and two-way joist slab floors and customer forms for cast-in-place concrete construction applications. Made of fiberglass-reinforced thermo-set composites, MFG concrete forms can significantly reduce finishing costs and are fully reusable.

Comprised of 12 key entities in eight states, Molded Fiber Glass Companies has been a pioneering force in optimizing resins and fiber reinforced polymer (FRP) materials and continues to build strength through focused diversity in providing superior composite material solutions worldwide.

Joe Kusiak is with MFG-CP, and can be reached by calling 800-225-5634 or e-mailing . CM