Star Lane Winery

Santa Barbara Contractors Association 2010 Award for Outstanding Craftsmanship by a Subcontractor

Framing the Star Lane Winery complex is one of the most challenging and rewarding projects of the many we have done with Melchiori Construction. At about 80,000 square feet, the large scale curvaceous design, and exposure of the framing components as architectural elements make this a job that showcases our trade proudly.

To meet schedule requirements framing started even while the foundations and CMU walls were still being constructed, making a very congested, potentially dangerous, and hectic jobsite. We had to precisely locate numerous beam and rafter hardware connections in elevated and curved concrete/masonry walls, well before the complete outlines of the building were defined.

At many of the masonry walls custom fabricated hardware connectors for the GLB rafters had to be installed and grouted in place at precise locations, in multiple layers on radian layouts, well in advance of rafter installation. We used computer modeling software to place every one of these embeds, without error, and also provided critical layout information for other trades with our 3d modeling program.

For the site-built heavy beam trusses we made a temporary truss table in our main staging area, located onsite, but far from the building. We also pre-fabbed the numerous dormer roof assemblies in that yard, and "flew" them into place with a crane.

Besides all of that direct construction activity we were frequently working around and over millions of dollars worth of wine making equipment that was being installed even as we framed roof structures over it.

The timely procurement of special order Glu-Lam beams, custom milled 3x12 planking, SIPS panels, custom hardware and other unique materials all added to the challenge. A fabrication yard and truss tables were set up to pre-fabricate as many components as possible, such as the dormer roofs, well in advance, to accelerate the job schedule.

Four of our most experienced and energetic foremen carefully planned and supervised this job, but our most senior foreman, Louis Rose in particular carried the day.