Elkhart General Hospital – Isolation Floor Renovation

Expanding Care Capacity

A hospital renovation of the sixth floor was significantly needed at Elkhart General Hospital. Beacon Health Systems’ goal was to create additional patient capacity while strengthening the hospital’s ability to safely manage infectious diseases. Our team delivered just that.

Through this hospital renovation, the team transformed a former medical surgical floor into a specialized isolation unit capable of isolating individual patient rooms or the entire floor when needed. In addition, the project included new patient rooms, nurse stations, conference space, a staff breakroom, mechanical rooms, and a vertical expansion to accommodate a new mechanical penthouse.

Because the work took place within an active healthcare facility, every decision required careful planning. From preconstruction through closeout, the team worked closely with hospital leadership to maintain operations, protect patients, and minimize disruptions. As a result, Beacon Health System gained a highly flexible healthcare environment designed to support changing patient needs while continuing to serve the community.

Renovating Without Disrupting Care

Unlike many renovation projects, construction at Elkhart General Hospital had to coexist with ongoing patient care. Therefore, the team approached every phase with operational continuity in mind.

First, the project required a complete gut renovation of the sixth floor while hospital activities continued throughout the facility. At the same time, strict infection control requirements demanded careful management of dust, noise, vibration, and airflow. Maintaining a clean and safe environment remained a priority from start to finish.

The site itself added another layer of complexity. The Elkhart River bordered the north side of the building, while limited access on the south side restricted staging and material deliveries. Consequently, the team had little room for traditional construction operations.

To overcome these challenges, Tonn and Blank coordinated closely with hospital staff, facility managers, designers, and trade partners. Regular communication allowed the team to adjust work plans as needed while keeping hospital functions uninterrupted. This collaborative approach helped protect patients and staff while maintaining project momentum.

Building More Off-Site, Working Less On-Site

Early in preconstruction, the team identified an opportunity to reduce activity around the hospital through prefabrication. Twenty patient rooms, twenty bathroom pods and exterior wall panels were made in our Off-Site Construction Facility. As a result, the project significantly reduced on-site labor, congestion, and disruptions. The team also eliminated weather-related delays by utilizing prefabrication during winter months which improved schedule reliability.

One decision delivered particularly strong value for the owner. By prefabricating the wall panels, the team avoided installing scaffolding around most of the six-story hospital. This approach generated approximately $400,000 in savings while reducing the impact of construction on patients, visitors, and staff. Only a limited amount of scaffolding was required on the west side of the building where crane access was restricted.

Meanwhile, crews finished the interior renovation. They built new patient rooms, support spaces, and clinical areas. They also kept strict infection control measures. The self-perform team installed prefabricated wall panels and bathroom pods. Crews provided layout and general conditions services. Along with door installation, hardware, cabinetry, and wall protection. They also installed bath accessories, headwalls, and FF&E.  Throughout the process, careful coordination ensured construction activities aligned with ongoing hospital operations, allowing patient care to continue safely with minimal disruption.

A Flexible Facility for the Future

Today, the completed Elkhart General Hospital renovation provides Beacon Health System with a specialized isolation floor designed to support both current and future healthcare needs.

Beyond the finished space, the project demonstrated the value of thoughtful planning and collaboration. By combining detailed preconstruction work and off-site construction, the team reduced disruptions. Which improved schedule certainty and delivered meaningful cost savings.

Most importantly, the renovation allowed the hospital to remain focused on patient care throughout construction. Resulting in a safer, more flexible healthcare environment. One that will support patients and staff for years to come.