We’re five months into the project and the giant hole between the Deli and the Next Door has a basement and a foundation sitting in it. By fall, steel girders and cement block will rise up and a building’s skeleton will emerge at the top of the driveway, wrapping around the Zingerman’s patio. No one could envision the expansion at the beginning;it had no form. It was just a list of desired outcomes. How did the outcomes become a plan? Month after month over the course of several years, a team of Deli Managing Partners, key staff, architects, design consultants, engineers and contractors scrutinized this site—the size of a postage stamp—weighing strategies on how to fit a feasible building into an affordable plan. Slowly, the process yielded a design with flow and a project with the right personality. The plan is in motion, the stage is set and we can start to see what will be there.

Decisions, Decisions…
Our goal has been to balance what we need to add, e.g. a family restroom on the Deli’s first floor, more space for tables, more space for browsing among oils and vinegars, with what we want to hold onto. Via Facebook, lots of helpful, enthusiastic responses have told us what people want to see. The same wall of meat and cheeses, lots of samples, the breadbox, tall wooden shelves, happy faces, the tile floor, an old style look, the tucked away patio. Thanks for your input and everybody can relax because it will all be there.

The Key
It’s a challenge to invent something new and improved, yet keep it familiar. We’ve used a process and a team. This journey of shared planning is called the Integrated Design Process or IDP, a way of making decisions, named and endorsed by the US Green Building Council. Each day’s work seen through the peek holes is the outcome of a long, multi-faceted planning process. Every detail of construction and design was vetted by the whole Build-Out Design Team. Our IDP’s objective was creating a less crowded, functionally green, Zingy building on the Deli’s cozy, charming site.

In Sync
Paul Saginaw saw the fit between IDP and Zingerman’s as a no brainer. “It’s producing good results because it’s how we’ve conducted ourselves in business. It’s actually a form of Bottom Line Change, the path we already follow. Luckily we’re comfortable with collaboration and trust it. It’s the recipe that all Zingerman’s businesses use when a change is needed that starts with soliciting input from anyone affected by a given change. Who needs to be informed and what’s the best way to go about making the change?

Benefits
The USGBC lists these IDP advantages:

• Time and energy invested up front avoids costly delays once construction begins.
• Communication is in place long before the first spade breaks the ground. The design conversation creates routine feedback loops between all parties that continue beyond the project’s completion to ensure ongoing performance.
• Every party has ownership of and accountability for the decisions. If anything goes awry (and something always does), instead of pointing fingers, we are committed to working together to fix it.
• Whole systems thinking is the by-product of having everybody in the room while decisions are being made. It’s how golden opportunities reveal themselves because collaboration naturally seeks out synergies. It’s how a conversation with Community High School about the use of a portion of its parking lot during construction resulted in an ingenious plan for a shared recycling center. An innovative vision of school-business-community interaction was born out of our garbage!
• Lifecycle costing gives the complete picture in contrast to most building design that only looks at up front costs, i.e. materials and labor, and includes the costs of maintenance, energy usage and replacement. With this approach, water cooled refrigeration and water cooled air conditioning systems that cost more up front actually end up 1) cheaper to run, 2) cheaper to maintain and 3) lasting longer—hurray!

Eye on the Prize
IDP utilizes vision as the unifying factor for the team. Our vision included preserving outside dining, increasing the number of restrooms, bettering our staff’s work environment, improving the services to our guests, and staying open every day during construction. The clarity and strength of the Deli’s vision of expansion has guided us through many decision-making stages. Utilizing IDP brought certain members of the team on board much earlier than in most construction projects. We had our contractor at the table from day one of design because we knew it would be a challenge to keep our doors open throughout construction. Conversations with the architect and the contractor made it possible to plan staging and accommodating our operations. If it weren’t for that early collaboration, we wouldn’t be serving corned beef sandwiches every day during construction.

Hard Choices
It’s normal to struggle with decisions during the process. We started with what we thought was best for our operations and for our guests, then dealt with all the non-negotiable factors impacting our layout and design, e.g. our site’s differing grades, little room to maneuver big equipment, historic codes, zoning regulations, building codes, setbacks, stormwater retention, etc. IDP has improved our design because of many eyes, differing voices, and multiple iterations of choices and strategies. A perfect example is the lengthy debate and dozens of renderings needed to decide where and how to span the 29-inch difference between the Deli’s old floor and the height of the Addition’s floor. Stairs? Ramp? Lift? Each option had its pros and cons. We considered the total floor space used, costs, ease of access for everyone including parents with strollers, and in the end, IDP convinced us that a wide set of steps and an adjacent lift was the best solution.

The Right Tool
IDP has allowed us to operate strategically, plan for efficiency and economy, and turn lemons into lemonade. Thanks to the Integrated Design Process, we have the warmest confidence that the outcome of this exciting project will be a familiar Zingerman’s Delicatessen, only more so.

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The Deli Build-Out is underway.
It’s already been a four-year process, and the project, as per the Zingerman’s way, has only become smarter and more inspiring over time. Every obstacle has been parlayed into an opportunity for innovation. Each Tuesday morning Deli partners, architects, contractors, consultants and staff work collaboratively to hone all the details of the design, the construction plan and the timetable. Deciding where to place a bathroom can take three hours because every impact is considered. What we will achieve, in the end, is an expansion of the historic Deli building that will retain all the best of our quirky, Zingy features, while becoming a better place to work, shop and eat. Our goal is to become a model of resource efficiency and sustainable building and working practices. And our vision is a building destined to serve and sustain, come what may, for the next 100 years! We’re super excited that the Deli’s expansion will be a LEED-NC (that stands for “new construction”) certified green building!  

Woot! Woot! This is big news! It means we are committed to factoring in the environmental impact of the Deli Build-Out into every decision we make, from sourcing through construction, in daily use and into perpetuity. We are making a profound and meaningful investment in our future well-being, a commitment to living and working with intention, foresight and a positive outlook… Plus we are taking a giant step towards fulfilling the sustainability pledge at the beginning of the 2020 vision for the Zingerman’s Community of Businesses.

What is LEED anyway?
The acronym LEED stands for Leadership in Energy and Environmental Design. Basically, it’s serious third party verification “that a building or community was designed and built using strategies aimed at improving performance across all the metrics that matter most: energy savings, water efficiency, CO2 emissions reduction, improved indoor environmental quality, and stewardship of resources and sensitivity to their impacts.” In a nutshell, it labels a new project as an environmentally responsible, profitable and healthy place in which to live and work. The US Green Building Council developed the LEED points system to make it possible for building owners and operators to identify and implement practical and measurable green design solutions to issues in construction, operations and maintenance. The choices we make will garner points that when added up will accredit us with a level of LEED certification—certified, silver, gold or platinum—based on an accumulation range of 1 to 100 total points (with 10 bonus points available).

What exactly does LEED measure?
To give you an idea of LEED specifications we’re examining and weighing as appropriate and feasible for us, take a look at the six main categories where the build-out plan aims to receive credit points:

1. Sustainable Sites: To get these credits, we minimize our building’s impact on ecosystems and waterways. It covers everything from encouraging downtown density and managing stormwater runoff to edible landscaping and responsible construction site management.

2. Water Efficiency: To get these credits, we implement smart water use inside and out.

3. Energy and Atmosphere (read ‘carbon footprint’): This is the big opportunity category for us because restaurants are energy intensive buildings. In the U.S., buildings use 39% of the energy and 74% of the electricity produced each year. Restaurants, per square foot, consume nearly three times more energy than the average commercial building. So our Build-Out has got to use a variety of integrated energy strategies. Efficient design and construction is a start. Purchasing energy star-rated appliances and lighting helps. Recapturing and reusing waste heat and installing water-cooled refrigeration systems means very little energy gets lost. We’ll also hire folks called commissioning agents who vet and balance our systems to monitor energy performance for years after we’re up and running. They make sure our systems operate as efficiently as designed.

4. Materials and Resources: This credit category makes us focus on what’s out there product-wise and material-wise that’s grown, harvested, produced and transported in a sustainable fashion. From framing (FSC certified lumber and concrete block made with fly ash) to finishes (countertops made of recycled paper pulp, old linoleum flooring), the Build-Out will end up with many smart, high performance, easy on the environment materials. We also know that the reuse of any salvageable materials and the responsible disposal of all construction waste earns additional points.

5. Indoor Environmental Quality: To earn these credits we have to consider all the strategies that give us top quality indoor air, maximize the use of natural light and make us all acoustically comfy!

6. Innovation and Design: This last category provides bonus points for innovative site-specific solutions that go the extra mile. It recognizes projects that use creative technologies and strategies effective above and beyond the LEED standards. Sounds very Zingy so we’ll see what we can come up with to earn points here.
If your curiosity is peaked, check out credits and the project certification process on the USGBC’s LEED website: www.usgbc.org. You’ll learn everything you want to know about the intent, the requirements, and the strategies for getting those credits.

How will LEED certification impact our look, feel and function?
Honestly, most of the differences will be invisible or super subtle. It’s a no brainer that improving indoor air quality and scrutinizing mechanical systems will make a more comfortable work environment. And we believe that taking full advantage of available natural light will have a positive impact on how we feel throughout our workday. Some of the mechanical and refrigeration systems are downright cool, doing amazing things like recapturing the heat from our ovens and compressors to use elsewhere. Other solutions, like adaptive re-use of materials and rainwater collection, are simply old fashioned thrift, harkening back to an older, less resource-intensive time. Green building is really just design that makes sense. It works well, and it works well for the long haul.

Won’t a green Build-Out be unbelievably expensive?
A LEED certified project often (but not always) costs more up-front, but…. B-U-T, the beauty is that it should quickly pay for itself in reduced utilities expenses and greater productivity—of the building, of the staff, and in sales. When the Build-Out Team considers an option, they look at the initial, up-front costs as well as the costs over time to run, maintain, repair and replace a piece of equipment or materials. The story again and again is that well-planned, green initiatives end up saving money overall… and a lot faster than you’d think. In part, this is because so much is looked at, measured and considered that otherwise gets overlooked. Like all positive change, there’s a lot of up-front work and time-consuming consideration and planning involved. But Zingerman’s was never afraid of a little hard work or a new idea. These are exciting, inspiring times at the Deli. Hold on to your hard hats, it’s going to be a great, cool, fun ride!

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When Zingerman’s Delicatessen opened in March 1982, as Paul Saginaw loves to say, “We just wanted to sell a great corned beef sandwich so that when you brought it up to your mouth and held it with both hands while biting into it, the Russian dressing would drip down your arms.”

Paul and Ari thought people might also want great ingredients to take home—great rye bread, great corned beef, great emmenthaler, and great Russian dressing, so in time, a world of food came to pack the Deli’s shelves and cases.

Why we’re building.
Over the past twenty-eight years, the number of guests coming to Zingerman’s has increased by a steady 10% each year. Between 2004 and 2009, the guest total grew from 310,000 to 450,000, a 38% increase! We bow down to our loyal guests, old and new, and to the hardworking Zingerman’s staff who has acrobatically met their needs in our maxed out space.

The kitchen isn’t the only place where operations are busting at the seams. We unload a lot of delivery trucks and store inventory in any nook and cranny. We produce our fair share of garbage but through composting and recycling, we divert well over a ton of garbage per week from county landfills. Our recycling bins overfloweth and take up space. And there’s the nagging question of where to fit more tables, a challenge obvious to any Zingerman’s guest. Plus we constantly ask ourselves how the heck can we include more people in our food tastings, fun classes and theme dinners. 

The build-out vision belongs to our trio of second generation Deli Managing Partners & Owners—Grace Singleton, Rick Strutz and most recently, Chef Rodger Bowser—who carry the mantle for the future of Zingerman’s Delicatessen on their shoulders. Their conclusion: we’ve run out of space and can’t wait any longer. With more room we will deliver a better experience to our guests and our staff (including more restrooms!). Our deli kitchen is causing wear on the building because the old brick walls were never designed for our volume of cooking, humidity and general kitchen use. So moving all kitchen operations out of the old and into the new will help us preserve our historic home.

Why not be greener?
Another added benefit of this project is the chance to green up our act, reduce our carbon footprint and become more efficient in our energy usage. With the space and opportunity to completely re-vamp kitchen and mechanical equipment, we can get as green as possible without disruption of service. The project is registered with the Green Building Association and our goal is to achieve LEED Silver at a minimum. Woot! Woot! The LEED point system measures the environmental sustainability of our design, construction, operations and maintenance. This is big news! It means that the environmental impact of the build-out is being considered in every decision—sourcing, construction, daily use and into perpetuity. (More green news to come!)

What a puzzle!
A construction project is a jigsaw puzzle. You glimpse the big picture on the box cover. Then begins the long ordeal of examining every piece to find its relation to all the others. Time and attention to detail get all the pieces to fit perfectly. The design team collaborating on this project brings a wide spectrum of opinions and skills to the table and it’s exactly what this gargantuan task requires!

It’s been a long haul. We truly appreciate the City of Ann Arbor and the Historic District Commission for recognizing the merits of the project and voting in September 2010 to grant us permission to clear the area we need to build the new 2-story structure that will house most everything on our wish list.

Who are the architects?
After interviews with many competent firms, we chose to work with Quinn Evans Architects whose Ann Arbor office is right around the corner on N. Main Street. Their renovation of Hill Auditorium and their collaborative work style made us feel we could partner well in tackling our challenging project.

Who are the contractors?
We brought Phoenix Contractors on board early in the process. Owners Bill Kinley and Mark Hiser along with site manager Chris Love help us address a multitude of potential construction roadblocks and snafus. We learn about the business of building-making as they learn the business of sandwich-making! Most importantly, their involvement ensures that the whole construction process will run more smoothly alongside our daily operations. (Remember, we’re open for business every day through construction!)

How the heck will it look?
The Deli’s front entrance will remain the same. From Kingsley you’ll have a nice view of a 2-story glass atrium that will connect the rear of the Deli with a simple 2-story brick structure (about 10,400 sq ft) on the site of the fire-damaged house on Kingsley. Our architects have integrated the historic “orange house” that currently sits at the top of our old driveway to become a centerpiece for the new brick structure. From the outside it will not have moved. From the inside, it will be an adjunct to our guest flow.

On the patio, we envision an open-air pavilion replacing our well-used big top tent for enjoyable outdoor dining and activities. The grounds will be leveled to tame the incline that currently challenges us. There will be a nice ADA accessible slope in the section between Deli and Next Door and level spots for tables. (Don’t tell me you never noticed how much the picnic tables are tipped!) Along with all these improvements come lots more edible landscaping and a green roof.

How will our guests benefit?
A ground floor restroom is at the top of the list for many. We project shorter and faster moving lines because of a better layout and a shorter waiting time due to greater kitchen capacity. Retail shopping will be easier and more efficient. There will be more seating options to suit your fancy and easy accommodation for large parties! Tastings, classes and special events galore will fit in our expanded space. And we are eager for much greater accessibility with full ADA compliance outdoors and indoors.  

How will the neighborhood benefit?
We’re staying put and contributing to the unique character of this multi-use neighborhood where businesses and residences have existed side-by-side for decades. We’ll increase the neighborhood green space and enhance a community gathering spot near downtown. We’ll address the impact of the commercial noise we generate and the commercial deliveries we receive in a comprehensive manner. And we anticipate adding over 60 new jobs to help fuel our local economy. We pride ourselves on being caring, committed, responsible corporate citizens in our community. The build-out allows us to dig our roots deeper into this place we love.

We’re in motion now. By early 2011, we’ll put a shovel in the ground. A tree was removed in November in preparation for eliminating the fire-damaged Kingsley structure affectionately referred to as “Smokey.” There’s already been prep work done in anticipation of the acrobatic lifting of our “orange house” from its foundation.

With construction fences up and traffic re-routed every which way, we will be doing back flips to maintain incredible service and offer a great experience to everyone who visits. We are committed to doing everything necessary to make it a blast for you to dine and shop as always. Check out the construction magic happening daily. Our mandate is to STAY OPEN THROUGH THE ENTIRE PROJECT.

The heart of Zingerman’s Delicatessen remains the same! The Deli “post build-out” will still be a hustling, bustling place to meet your friends, bring your family, enjoy great, full-flavored traditional foods and get the trademark Zingerman’s customer service experience. The menu will be the same, if not expanded. Servers will happily give you a taste of anything you want. There will be more elbow room to engage with retail staff, exchange food stories and recipes. The sandwich runner will still yell out your name. Morning regulars will still have spots to sit and read their New York Times. Bikers will have more bicycle parking and access to emergency repair tools. Students will have quiet spots to study. People will still converge for meetings. Even though there will be some nostalgia for the old cramped Deli, we think you will be very pleased with how the new space merges with the old, still feels familiar, and allows us to provide better service, better food, and an even better overall experience. Same great rye bread, same great corned beef, same great emmenthaler, same great Russian dressing and same great experience that Zingerman’s has provided since the day we opened our door.

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