The Construction Zone masters architecture’s toughest sites, from cliffs to beachfronts
Since 1992, The Construction Zone has established a reputation for creating unique modern architecture without compromising form or function. Based in Phoenix, Arizona, the design-build firm draws inspiration from the Sonoran Desert, using the subtle patina of steel, the muted reflections of glass, and the varied textures of stone and wood. The Construction Zone offers a comprehensive range of services, including architecture, pre-construction services, interior design, and general contracting. From bespoke steel window systems to the highest quality millwork, The Construction Zone brings architecture to life across the US with a diverse portfolio of residential and commercial projects, tailoring each solution to meet its clients’ specific needs and site. Andy Byrnes, Owner, relates the events leading to the establishment of the company and its subsequent expansion. 
Cross country collaboration
“After graduating from Tulane Architecture School, I moved to Phoenix and took on a few oddball, small industry-related jobs before launching the company with the intent to build architecture. I believed this would be an interesting way to build the business, specializing in modern and unique architecture. In those early days, our work was about 80 percent construction and 20 percent design-build. Over the years, we have shifted toward our own design-build projects, undertaking more complex endeavors that made it difficult to find the appropriate subcontractor and trade base. As a result, we expanded our capabilities to include our own concrete work, rammed earth construction, glazing and window systems, steel work, and millwork. We experienced steady growth to the point where we reached a staff headcount of 125 by 2008. However, the economic downturn forced us to scale back significantly; we went from around 125 employees down to about 45.
“A pivotal change occurred when we began accepting projects around the country rather than limiting ourselves to the Phoenix, Scottsdale, and Paradise Valley areas. Initially, we were not interested in travelling for work, as we were already busy in our local area. But a lot of the architects we collaborated with over the years had projects in remote locations that lacked contractors with the necessary skill sets to be able to construct these unique buildings. From around 2010 to the present, we have traveled extensively across the country to build special structures, both through design-build projects and collaborations with other architects,” he elaborates.
Extensive experience
Andy then goes on to explain how the company has mastered the art of building on any type of terrain, showcasing projects that exemplify this capability. “In Phoenix, and particularly in Paradise Valley, hillside construction on very rocky and craggy sites is common. Hence, this is an area where we have become highly adept thanks to our collaboration with a skilled excavation and dirt work contractor who understands how to carefully take the mountain apart in a way that we can put it back together again after construction is complete. This process can be quite tricky. While jobs in other parts of the country may present less challenging access issues, they often involve more complex ground conditions. For example, in some parts of Texas, the dirt is so unstable and full of clay that we have to employ specialized foundation systems. We needed to use another unique foundation system when faced with similar ground conditions issues while building on the beach for a project in the Hamptons. Additionally, we have undertaken work in North Dakota where we dealt with extreme temperature variations. Overall, we find that out-of-town projects are typically less difficult in terms of site access and staging, but they often require a deeper understanding of the regional requirements necessary for successful construction in those locations.”
As he reflects on his extensive experience in the industry, Andy reveals his favorite aspects of architectural design. “I have learned a lot working alongside so many exceptional architects from across the country and all over the world. In line with our focus on constructability, I particularly enjoy when a building expresses its structural integrity and thereby the logic behind what is holding it up. Materiality is another interesting aspect of architecture. For me, architecture is all about the interaction between different materials and how you execute the transitions from one to another. It is not difficult to build a big giant wall from a single material, but the real challenge lies in integrating different systems and finishes while ensuring proper alignments. Ultimately, it is the intentionality behind the execution that is of interest to me.
“This design philosophy is exemplified in a project The Construction Zone recently completed in Flagstaff, Arizona,” Andy continues. “Built as a personal retreat from the heat of Phoenix, modest materials were executed in such a way that the whole became more than a sum of its parts. We chose to build the house from insulated concrete forms (ICFs) to buttress against the harsh winter conditions. In select places on the interior, we were able to leave the concrete core exposed expressing the character of the structure. The spaces are clad in economical tongue and groove wood boards, which give an intimacy and warmth to the architecture while providing continuity through the project. This material choice is elevated and given a level of refinement with our signature hot rolled steel detailing and selective use of accent materials.”
The Construction Zone’s journey reflects a commitment to innovation and adaptability in the face of challenges. By embracing work in challenging environments, the company not only redefines architectural boundaries but also proves that exceptional design can thrive anywhere, regardless of obstacles.