Kaplan Construction selected for Castle Island Brewing build-out : NEREJ

South Boston, MA Kaplan Construction, a WBE general contractor and construction management company that provides comprehensive construction programs throughout Boston, has been hired by Castle Island Brewing Company to run a 9,500 s / f at 10 Old Colony Ave. to house a craft brewery scheduled to open this summer.

Castle Island Brewing is the tenth largest brewery in Massachusetts in a ranking of total beer production by 2020, according to the Boston Business Journal. Located in an existing industrial building, the South Boston location will have a 4000 s / f main trial room that can accommodate 220 people, retail space and a private 1900 s / f event space that can accommodate up to 140 people. A quarter of Castle Island’s new space will be reserved for the brewing operations, including a brewhouse and seven 10-barrel tanks. A large focal wall will be made of wood and metal and feature the Castle Island Brewing Company logo.

“It is a pleasure to work with Kaplan again,” said Adam Romanow, founder and president of Castle Island Brewing Co. “They helped us build our first brewery and they were the natural choice when we decided to open a second brewery instead. Whatever comes up during construction, their staff will find a way to make it work. “

The building is a turn-of-the-century high-rise production space of 15 to 18 ft. ceiling heights, industrial beams and exposed concrete. Kaplan will cut out part of the existing exterior wall and install a new overhead door to create a seamless indoor / outdoor experience and maximize natural light. In addition to removing a series of interior overhead doors, Kaplan will demolish existing walls at the front of the building to make room for taproom seating and new bathrooms. Two existing glass garage doors remain to provide access to an outdoor patio for the brewery’s patrons.

At the start of construction, Kaplan discovered several unexpected pre-existing conditions in the century-old building, despite multiple exploratory efforts by the design team and the landlord. While removing concrete to accommodate the underground plumbing, the slab was discovered to be three times as thick as the original exploration work indicated.

As such, the construction team had to work with the structural engineer to determine the best approach to address the cutting and backfilling of the structural slab. Numerous underground obstacles, such as abandoned concrete structures, construction debris from previous projects and layers of old concrete slabs, were also found when the team excavated for plumbing to maintain the bar and brewery. As demolition progressed, it was also revealed that the bathroom’s original plumbing had deteriorated significantly and needed to be completely replaced.

National Development, along with AEW Capital Management on behalf of one of its funds, acquired in 2019 the property bounded by Old Colony Ave., West Seventh St. and D St. from the former owners of the Cole Hersee Co. improvements to the buildings of the former industrial buildings in order to repurpose them into retail-ready. The Cole Hersee redevelopment will accommodate another eight to ten catering operators on a new ground floor.

In 2015 Kaplan converted an existing warehouse at 31 Astor Ave. in Norwood, Massachusetts, for Castle Island’s first brewery. In 2017, Kaplan was hired again to expand their production space and build a taproom at their flagship location.

The members of the project team for this project include:

Client: Castle Island Brewing Company;

Developer: National Development;

Construction manager: Kaplan Construction;

Architect: Joe the architect;

MEP / FP Engineer: BLW Engineers; and

Structural Engineer: Souza True & Partners.

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