Situated just off Elvis Presley Blvd. on the northern end of the Las Vegas Strip, the Fontainebleau emerges like a phoenix, soaring 67 stories into the skyline. After nearly 16 years since its initial announcement and navigating various starts and stops, the 70-year-old, iconic brand welcomed its first guests in December 2023, marking the much-anticipated western expansion of its renowned luxury counterpart in Miami Beach, Florida.

At the heart of the $3.7 billion spectacular resort and casino, KHS&S is displaying its finest artisanship and ingenuity. The general contractor, W.A. Richardson Builders, enlisted the expertise of KHS&S with a longstanding history on the project. The Fontainebleau saga is one of perseverance; the building stood unopened and 70 percent complete for over a decade. Finally, in August 2021, when KHS&S joined the project for the third time, it proved to be a winning hand, and the team was on a fast track to completion ever since.

From the awe-inspiring, cantilevered porte cochere to the sprawling, six-acre pool deck, KHS&S’s work is a masterpiece of engineering and spectacle.

KHS&S played a pivotal role in delivering very extraordinary results at various locations within the project, including:

• The pool deck (center bar, La Ronde, Oasis, Serenity, Gigi’s Grotto, pool gaming, La Cote, Greek restaurant, Aquamarine, day club and cabanas)
• The porte cochere
• The hospitality garden and water feature
• The events center
• The north podium’s interior
• The north lobby
• The south lobby’s registration
• The thematic rockwork at Gigi’s Grotto
• The exterior cheese wall feature
• The exterior podium façade (a low-rise)

With only a few days’ notice to commence work, KHS&S demonstrated a formidable show of readiness, swiftly assembling over 45 crewmembers on-site within just a few days. Typically, KHS&S would have a preconstruction period to gear up for a new project. However, on the Fontainebleau, it was “go time” from day one. This was made possible through the substantial support from corporate shared resources in Anaheim, California; the production facility; HR and all the various departments necessary to back a project of this magnitude.

The project began as a $500,000 contract to build out WARB’s temporary construction offices, and then evolved over time into a substantial contract worth more than $120 million.

Throughout the project’s twists and turns, one constant presence and a reservoir of institutional knowledge was Brandon Kephart, area operations manager for KHS&S. That continuity proved invaluable.

Alongside Adam Bragg, project executive at KHS&S, Kephart built a formidable team from the ground up, leveraging the vast, company-wide resources available.

Once office construction was in full swing, WARB sought to tap into KHS&S’s expertise in the exterior façade work, a segment the company had previously been involved in. Ultimately, WARB contracted with KHS&S to complete the low-rise exterior façades, contributing an additional $50 million to the contract value.

Being in the right place at the right time, combined with the company’s extensive experience in resort and casino construction and theming, resulted in a series of additional contracts throughout the company’s several years on the job. The massive, six-acre pool deck, for instance, started as a design-assist project and expanded into KHS&S taking charge of the entire area, contributing an additional $52 million to the contract. From there, the opportunities to contribute continued.

The core field team, consisting of superintendents and foremen, had been with the company for many years, instilling a high level of confidence within the group.

Bragg attributes the team’s success to keeping an open mind about the ever-evolving scope, a resilient and disciplined staff, having an in-house construction design team, learning to pivot on short notice and the team’s ability to adapt to frequent design changes.

Even as the majority of the work wrapped up, the project’s total scope and value remained a moving target as KHS&S continued to be available on-site, ready to contribute its expertise wherever needed, continuing to make a difference.

By Scope of Work

Grand porte cochere: a jaw-dropping Las Vegas marvel comes to life

After months of anticipation, the day everyone had been waiting for arrived. The precise removal of over $1 million worth of multilevel scaffolding beneath the Fontainebleau Las Vegas porte cochere was nothing short of an historic moment. No one could predict the outcome without absolute certainty, given that this engineering marvel had never been attempted before by any of those involved.

Picture a self-standing structure, engineered initially to an unknown deflection point, composed of an astonishing 38 miles of Howick-rolled steel, with no predefined grid to guide the construction, suspended a breathtaking 60 feet above the ground.

From the outset, the KHS&S team adhered to a simple mantra says repeatedly–“trust the numbers.” While they maintained that trust throughout, they still diligently verified and triple-checked that everything aligned correctly, adjusting as necessary. Usually, a project will have a floor, ceiling or slab to pull points from and check points against, but that wasn’t the case with the freestanding porte cochere.

The grand and iconic porte cochere exceeded everyone’s wildest expectations. KHS&S’s core values of being solution-oriented and results-driven were on full display.

The integral role of 3-D scanning technology in bringing this project to fruition cannot be overstated. Without this technology, the project would have been a non-starter, according to Jeremy Evans, manager of construction design at KHS&S.

Here’s the critical factor: the initial steel model was created under ideal conditions. However, once the shoring was removed, the steel exhibited deflection, with some sections settling by up to 14 inches. Although such deviations aren’t rare, the extent of the steel’s shift needed to be factored in and adjustments were made to ensure precise installation of every subsequent element.

Once it was clear that the steel had settled, the real-world scan of the as-built steel was conducted to ensure proper cladding coverage. This became a pivotal part of the computational design aspect of the project. With the actual steel locations finally confirmed and in place, the cladding was adjusted to fit seamlessly.

The scan also exposed a potential issue with the support steel for 97 decorative fins. These fins, meticulously manufactured and shipped from England, boasted millimeter precision, with a mere 1/16-inch tolerance for installation.

Leading the scanning effort from the construction design team was Jose Burrola Diaz, who, along with others from the department, also worked on the layout.

If KHS&S had not employed steel scanning, the misalignment that occurred when the shoring was dismantled would have led to a misfit. The steel contractor managed to realign the support steel within the specified tolerance, allowing for the proper installation of the fins.

Moreover, the extensive use of scanning technology by KHS&S wasn’t exclusive to its work. Other trades also used it, ensuring pinpoint accuracy throughout the project.

Thanks to regular visits by FWC’s senior project engineer, Neil Paulson, who would make frequent visits to the project site to streamline built conditions, the team had another experienced perspective on-site, which gave them even higher confidence in the overall outcome.

The project required over 2,000 hours of computational design, coordination, drawing layout, 3-D scan conversions and modeling, making it a remarkable achievement in modern engineering and construction. Even the suspended dance floor installed by Leading Edge Scaffold required multilevel elevations to account for the arc of the structure.

With 4,000 structural attachment clips that connected to the main steel at each of the studs, 13,895 feet of coping cap and eight different degrees of angles, the structure slowly came together, piece by pains-taking piece.

Craig Couch, KHS&S production innovation manager, and his team at the prefabrication facility in Rancho Cucamonga, California, worked swiftly to keep the on-site team on schedule. Described as a huge Ikea set to assemble, the materials started with the connecting joints–called knuckles–that were all color-coded, assembled and then shipped out from the facility to the job site with a panel ticket of instructions to be assembled.

Each module had six parts that were set out with clips on the beam and then stick-framed by following alignment holes, using the most ordinary of tools.

Like a huge jigsaw puzzle, the sequencing of the knuckle assemblies slowly began to take the shape of what would become the finished porte cochere.

One of the biggest compliments received was the trust that the general contractor and project ownership conveyed by instructing the teams to follow KHS&S’s lead. Even the architect ended up scratching their model and used the plan developed by KHS&S because, once the job was underway, it became evident that the only way to make the project work was to give KHS&S the reins to get the job done. The KHS&S team, which was comprised of 36 carpenters, 40 plasterers, four laborers and 12 members of field management, completed the porte cochere in a fast-paced seven months.

WARB asked for a sensational, jaw-dropping first impression, and KHS&S delivered in opulent Vegas style–a true achievement shared by the entire team.

Unparalleled Craftsmanship 

KHS&S’s masterful quality is on display throughout the sprawling, 25-acre Fontainebleau Las Vegas resort. Among the many impressive features constructed and installed by KHS&S is an intricate, gilded birdcage that’s suspended 32 feet above the ninth-floor pool deck within the center bar and includes tiered elements that can be lowered over the entire back-bar area when not open for business.

This remarkable project demanded over 2,500 hours of development and fabrication labor, and the sprung steel structure alone weighs 25,000 pounds. To ensure a seamless installation process, KHS&S crews carefully assembled and disassembled components at an off-site facility, leaving no room for surprises during on-site installation. A total of 325 adjustable brackets were custom-made and welded to the structure, allowing for precise alignment and attachment of the FRP components.

When Bergman Walls & Associates, the world-class architecture and interior design firm behind the Fountainebleau Las Vegas, first shared its vision for the main pool bar at the resort with KHS&S, Chris Wilson, technical design manager at KHS&S, started to work on how to bring the vision to reality.

The architectural plans were examined from a constructability vantage point, considering every element, including what materials to use, along with various means and methods for how to put the cage together.

Although this was a one-of-a-kind piece, there were similar elements KHS&S had experience working with that would influence the approach and, after consulting over many meetings with engineers and vendors, achieved a streamlined view of the end goal.

From the fabrication to logistics to coordinating schedules and then agreeing on an off-site prefabrication process as the most logical approach, Wilson and Brent Canfield, director of vendor management at KHS&S, created a game plan. Starting with full project mockups at the KHS&S Archetype Studio, Kevin Wirsch, senior art director and director of specialty finishes at KHS&S, and his team, built a partial, full-scale mockup to determine texture, size and materials.

Determining off-site how the structure, skin and cage would be built, sequenced and attached to the structure below, including how to hide every attachment, meant 99 percent of any issues were managed long before the material was shipped to the field for installation.

The inner framework was forged from roll-formed, 6-inch-diameter, 1/2-inch-wall steel pipes. These were artfully shaped into seven elliptical arches and seven elliptical valleys, all interconnected by 3.5-inch-diameter pipe ridges and trussed legs. Each arch and valley comprised five distinct radii, ensuring the necessary profile to fit the interior and exterior FRP skin.

The rigorous planning for a project of this magnitude leaned heavily on experience and the assistance of off-site solutions to inspect every element thoroughly, guaranteeing a flawless execution during field installation. The team invested extensive hours employing cutting-edge technology, such as 3-D modeling and scanning, and held countless meetings to map out the assembly process precisely.

Trimble and Faro laser scanning technology was used extensively to obtain accurate 3-D data and improve project efficiency. The precise measurements ensured that the pieces fit together seamlessly during assembly.

And that’s where things really got tricky. Each panel or segment has its own interaction with another panel or segment that may or may not be attached to the structure. It was a very involved process to work through and required collaboration at every turn. Fabrication partners AMC (decorative steel), DMI (fiberglass skin and structure), JJones (structural steel) and Ensign Consulting Engineers proved invaluable resources throughout the project.

A dry fit of all the parts at DMI’s facility allowed KHS&S to account for a variety of unexpected factors, such as one area being changed out in the install sequence and adjusted. In fact, some of the KHS&S team who would be doing the install spent time at DMI’s site, working with the fabricators for a test run. Nothing was left to chance.

Not surprisingly, given the level of advance off-site coordination and the experienced team involved from concept through installation, once on the job, the install was done without any issues.

Prefabrication off-site not only enhanced quality control, but also permitted the implementation of stringent quality measures. The construction of various components, from elliptical arches and valleys to the FRP elements, away from the job site significantly improved the final product’s quality and minimized the risk of defects or errors. Only after surpassing KHS&S’s rigorous standards were the various components transported to the Fontainebleau for final assembly above the center bar.

Considering the center bar project’s size, complexity and location, utilizing off-site solutions for the construction of the gilded cage was a well-thought-out decision.

Dream Big 

Fontainebleau Las Vegas pays homage to the iconic, 1954 Fontainebleau Miami Beach mid-century, modern architectural style with a contemporary twist, thanks to a collaboration of talented architects and designers. KHS&S played a crucial role in realizing this vision, delving into the inventive minds of the designers to revive and modernize the ornate and geometric elements that defined 1950s architecture.

Heading the remarkable thematic finishes at the resort was Wirsch. He credits every department within the Fontainebleau project, from estimators, preconstruction and construction design to project management and vendor management, for the success of all the theming elements. This project required top-notch efforts from the entire team, and across the board, KHS&S delivered.

Prior to transferring the thematic elements to the construction team on-site, the process started with the design-assist phase. KHS&S’s theming department collaborated closely with W.A. Richardson Builders and a team of designers to ensure the best approach in realizing their vision while staying within budget. This method emphasized communication between design and construction teams, allowing them to address real-world challenges early in the planning stage, thereby reducing costs, improving constructability and expediting construction.

Carissa Wood, thematic project manager at KHS&S, highlighted the benefit that the design-assist process brings to integrating thematic features into a project of this magnitude.

To infuse a touch of France into the Las Vegas resort, a remarkable waterfall sculpture was created, representing Napoleon’s iconic, bicorn hat worn during the Battle of Waterloo. Peter Arnell, a renowned American designer and branding pioneer, conceived the masterpiece. The 35-by-25-foot, themed sculpture features an 8-foot waterfall cascading from each side of the hat, with the base pond paying tribute to Claude Monet’s famous water lilies painting.

Through the design-assist process and numerous meetings with Arnell and WARB, the hat was constructed as an FRP sculpture, composed of 40 individual pieces and thematically painted to resemble a bronze sculpture. The lower base pond was crafted using GFRC cast products to mimic travertine. The journey started with a digital model, transitioning to a full model with molds taken to create the 40 panels, all while coordinating the engineering of the internal steel structure. The assembly on-site involved extensive coordination with MEP trades for electrical and plumbing, preceding thematic painting.

In honor of Fontainebleau Miami Beach, which was established in 1954, Arnell designed a 45-by-25-foot, abstract sculpture featuring the numbers five and four in an organic mosaic as a bas-relief wall. GFRG panels were used to mold individual, trapezoidal shapes. The panels were adorned with 1,200 square feet of gold leaf gilding in a satin sheen at the KHS&S Archetype Studio. Once delivered on-site, they were mounted on the casino elevator shaft and two artisans meticulously fine-tuned the gold leaf finish to achieve a seamless level of detail, creating a captivating, glowing, jewelry-like sculpture.

The Gigi’s Grotto private pool area boasts 9,000 square feet of rockwork inspired by the rustic white, blue and golds of Santorini, Greece. The rockwork was sculpted out of plaster and thematically painted, a process that demanded an elevated level of detail. The project began with the landscapers’ footprint, which guided the formation of the rockwork around the existing landscape and poolside cabanas. An 8-by-12-foot mockup displayed the rockwork and its integration with the cabanas. Once approved, KHS&S had the creative freedom to construct the rockwork, relying on the expertise of its artisan team. The rockwork was constructed with a rebar frame, with lath and plaster sculpted over the top and finished with a white, Santorini-themed texture.

The entire pool deck is laden with a series of planters, softening the overall-white backdrop. The planters were topped with a 9.5-inch-wide GFRC cap, requiring more than 10,000 linear feet of material. Technicians applied the final shape following an innovative scanning technique that mapped the entire pool deck. By using this approach, KHS&S was able to excel in accuracy, as well as reduce production errors and rework.

The poolside center bar spans 50 feet across and 25 feet high, arraying seven barreled vaults to create an art piece that is both beautiful and functional. The smooth inner and sanded outer skins were built over a 6-inch structural, tube steel frame, surrounded by brass framing and white fabric awnings to enhance the overall look, but also carry the audio-visual aspects of the bar. The entire element was built off-site and placed on the pool deck with the precision and quality of a Swiss watch, Wirsch added.

Complementing the talented on-site staff, the core theming team comprises 15 traveling artisans, including sculptors, plasterers and thematic painters, serving as a corporate resource that supports all KHS&S offices. The work of these artists and all KHS&S team members at Fontainebleau Las Vegas has set a new standard in their avant-garde recreation of the luxury and glamour of the 1950s.

An Oasis to Exceed All Expectations, Redefining the Poolside Experience

Perched on the ninth floor is Fontainebleau Las Vegas’ magnificent, $275 million pool deck. Seven luxurious pools adorn the six-acre oasis, each with a distinct vibe. With four bars, two restaurants and topiary garden gaming space, it is a destination for sun worshippers and those who just want to mingle.

Unquestionably one of Las Vegas’ most inviting poolscapes, KHS&S was initially engaged with a design-assist contract–no construction–for the center bar; the jewel box of the pool deck, gaming area and Gigi’s Grotto private pool escape. As the KHS&S team walked the pool area with W.A. Richardson Builders and Bergman Walls & Associates to discuss design and materials, WARB field principal Matt Gayheart says, “Go ahead and build it all”–not just design-assist for the three initial projects, but all 14 unique pool deck venues. The team quickly ramped up to a crew of 30, which expanded to more than 150 during peak construction, in addition to six structural engineers for the $50-plus million scope. In all, it took more than 250,000 work hours to complete.

As a solution-driven company, KHS&S superintendent Joe Morgan and project manager Dru Patterson worked with the Archetype Studio and design-assist team, led by Wirsch, to determine the ideal materials, finishes and products to achieve the desired look while bringing the most value to the job.

Most of the pool deck structure was in place. However, areas of the deck were demolished to accommodate the new design. Miles of waterproofing were required so that if there were any pool leaks, no water would damage the floors below. This required the steel structure to be surveyed and scanned to create a base CAD model.

With more than 300 submittals and over 60 structural engineer shop drawings, the Total Hilti Station layout system was used to control and manage all drawings for WARB, KHS&S, subcontractors, the architect and interior designers. The CAD-based technology created a 3-D layout with precise accuracy, revealing where each item was to be constructed and installed. It was critical that all sub-work blended seamlessly to achieve “first time fit and finish” and avoid budget overruns, as well as limit delays and rework from the final punch walk.

Morgan and Patterson quickly established that all subcontractors would need to take full responsibility for their scope while still collaborating and coming together as a team working toward the same goal. With no preconstruction, coordinated logistics plan or organized schedule, the teams united to create, execute and continuously adapt a plan to meet the 17-month timeline.

During the project, KHS&S was asked to pick up an additional $6 million scope on the pool deck, creating 20 additional drawings. Add in 500 confirmed RFIs throughout the work, and the field quickly learned how to adapt on the fly and develop solutions to keep the job moving forward in this dynamic setting.

Unlike most projects that use similar materials and finishes, each pool deck venue was unique, utilizing KHS&S’s full scope of services, including custom FRP, GFRG, GFRC, cast, carved plaster, rockwork, faux finishes and metal light housings. Trellises, gates, fences, handrails and 31 custom cabanas were just some of the many features. In addition to on-site work, the job included more than 100,000 work hours of off-site prefabrication, encompassing $20 million of custom materials.

Patterson described it as working on multiple mega-mansions at a retail pace, where you use the architectural drawings, renderings and interior designers to accomplish the look.

All elements were conceptually estimated, based on design intent from custom shop drawings. Through the value analysis process, many elements were constructed using alternate methods and materials. The 14-foot walls of the LIV Day Club originally called for GFRC panels with three backlit, stainless-steel orbs in each of the 80 panels. To reduce production time and generate savings, KHS&S replaced the GFRC material with custom foam to shape the frames, achieving the same quality and look.

Decorative, mushroom-shaped pillars were originally designed to be constructed with FRP but were created with plaster, saving months of production time. Likewise, millwork and beams that could not be exposed to the outdoor elements were built from aluminum and faux whitewashed for the appearance of real wood.

These are just many of the examples that became commonplace throughout the project. Through the benefits of value analysis and the team’s innovative and solution-driven approach, it is hard to distinguish between the rendering they were challenged to replicate and the finished product.