Vista Pointe at Port Imperial

Turning Complex Design Into a Buildable System

Set along New Jersey’s Hudson River waterfront overlooking the Manhattan skyline, Vista Pointe at Port Imperial is a luxury residential development featuring sophisticated architecture, a radius façade, multiple building angles, and a complex multi-story structural system.

Working with Toll Brothers and the project team, Klover delivered a large-scale load-bearing cold-formed metal framing solution driven by BIM coordination and off-site prefabrication. Across eight levels, Klover fabricated 413 wall panels totaling more than 115,000 square feet while integrating an extensive structural steel package and coordinating 51 sequenced tractor-trailer deliveries.

Project Snapshot

Location: West New York, New Jersey

Market: Multifamily / Residential

Project Size: Approximately 151,000 SF

Construction Type: Load-Bearing CFMF

Prefabrication: 413 Wall Panels / 115,469 SF

Logistics: 51 Sequenced Tractor-Trailer Loads

Delivery: BIM Coordination, Engineering, Prefabrication & Structural Steel Integration

Services Provided

• BIM Coordination
• Load-Bearing CFMF
• Cold-Formed Steel Engineering & Detailing
• Prefabricated Wall Systems
• Exterior Load-Bearing Wall Panels
• Interior Structural Walls
• Shaft Wall Assemblies
• Corridor & Demising Walls
• Curtain Wall Support Framing
• Architectural Feature Framing
• Structural Steel Fabrication
• Sequenced Manufacturing & Logistics
• Panel Installation Coordination

The Challenge

Vista Pointe combined the scale of a major residential development with building geometry that demanded precision.

A radius façade, multiple building angles, structural transitions, and locations where load-bearing walls did not stack vertically created complex dimensional and structural conditions that needed to be resolved before manufacturing could begin.

Unlike conventional field framing, prefabrication moves critical decisions earlier. Dimensions, openings, loads, connections, structural interfaces, and installation requirements needed to be coordinated before material entered production.

At the same time, hundreds of panels and an unusually large structural steel package had to be fabricated, transported, and delivered to a constrained project site in exactly the sequence required for installation.

The Solution

Klover used a BIM-driven process to connect design coordination directly with manufacturing.

The BIM and design teams coordinated panel geometry, openings, connections, structural transitions, and non-stacking wall conditions before fabrication. Where walls did not align vertically through the building, those conditions were identified early so Klover could work with the project team to resolve the structural relationships and intended load paths.

Once coordinated and approved, digital information from Klover’s BIM and detailing process was transferred directly to state-of-the-art roll-forming equipment.

This BIM-to-fabrication workflow allowed coordinated project information to drive the production of cold-formed steel components with a high degree of dimensional accuracy before those components were assembled into complete wall panels in Klover’s controlled prefabrication facility.

Klover’s prefabricated scope began at Level 3 and continued through eight levels of the building, ultimately producing 413 panels totaling 115,469 square feet.

Integrating Cold-Formed Steel and Structural Steel

The wall system was only one part of the structural solution.

Klover also coordinated and fabricated an extensive structural steel package that included shear wall end posts, embed plates, structural jambs and headers, wide-flange beams, tube steel posts, canopy supports, galvanized brick relief angles, plates, angles, kickers, and specialty connection assemblies.

Bringing these components together required continuous coordination between engineering, BIM, fabrication, logistics, and field installation.

Instead of treating cold-formed steel panels and structural steel as isolated scopes, the systems were coordinated as interconnected parts of the overall building structure.

Solving Problems Before They Reach the Field

Vista Pointe also demonstrated the value of having project-specific problem solving happen during fabrication rather than after installation.

When transportation movement began affecting a light-gauge attachment around certain window openings, Klover’s fabrication team identified the issue and developed a welded attachment solution. Previously manufactured panels were reviewed and corrected where necessary before reaching final installation.

Oversized pour stops created another challenge. Their projection from the panels made them vulnerable to bending during loading, transportation, and lifting. Klover developed additional cold-rolled channel reinforcement around the lifting locations to stabilize the assemblies during handling and erection.

Both conditions were identified and addressed during production, preventing fabrication issues from becoming larger field problems.

413 Panels. 51 Loads. One Coordinated Sequence.

Producing the panels was only part of the equation.

Transporting more than 115,000 square feet of prefabricated assemblies required 51 tractor-trailer loads, with every panel manufactured for a specific location within the building.

Panels were loaded and shipped according to the planned erection sequence so crews could receive assemblies in the order they were needed.

With limited staging space available onsite, manufacturing, loading, transportation, and installation had to operate as one connected process.

The result was a tightly coordinated flow from BIM to fabrication to truck to field.

Project Impact

• 151,000 SF luxury waterfront residential development
• 413 prefabricated wall panels
• 115,469 SF of prefabricated wall assemblies
• Prefabricated scope spanning eight levels
• 51 sequenced tractor-trailer deliveries
• Load-bearing exterior and interior CFMF systems
• BIM-driven digital information connected directly to roll-forming technology
• Integrated structural steel fabrication package
• Complex radius façade and multiple building angles
• Non-stacking structural wall conditions coordinated before fabrication
• Project-specific fabrication challenges identified and resolved before becoming larger field issues
• All Klover work completed without a single OSHA Recordable incident

Why This Project Matters

Vista Pointe demonstrates what prefabrication can become when it is treated as more than simply moving construction indoors.

The real advantage begins earlier.

Design information, engineering, BIM coordination, fabrication, structural steel, logistics, and field installation become parts of one connected construction process. Problems can be identified earlier, components can be manufactured with greater control, and hundreds of assemblies can arrive at the project in the sequence required to build.

For Klover, Vista Pointe represents the scale and complexity that a coordinated prefabrication platform can support, transforming a sophisticated architectural and structural design into a repeatable, manufacturable, and buildable system.

Klover Differentiator

From BIM to Building.

Klover connects digital coordination with manufacturing and field execution.

By bringing BIM, engineering, cold-formed steel prefabrication, structural steel integration, logistics, and installation planning together early, Klover helps project teams solve complexity before it reaches the field and build with greater safety, quality, efficiency, and certainty.