The Waldorf Astoria New York demanded more than preservation. It required a deep understanding of architectural heritage combined with the ability to execute at the highest level of precision. Brought on by Suffolk Construction, CARVART delivered a comprehensive scope of custom fire rated doors, architectural metalwork, specialty partitions, and large-scale lighting elements across the hotel’s public spaces. Every detail was developed to reflect the elegance of the original Art Deco language while meeting modern code and fabrication requirements.
To achieve this, CARVART employed a combination of field scanning, material prototyping, and global coordination with vendors across the United States, China, and India. From guardrails and handrails that followed the building’s vertical lines to custom doors built through casting and extrusion, each piece was engineered to meet demanding site conditions and visual expectations. The result is a seamless blend of old and new, where legacy architecture is honored through modern craftsmanship and technical excellence.
CLIENT: Suffolk Construction
SCOPE: Custom fire-rated doors, architectural metalwork, partitions, light fixtures, and historic refurbishments including guardrails and handrails—engineered and fabricated to match original detailing with modern performance.
Reviving one of New York’s most iconic properties required more than technical skill—it called for architectural empathy. At every turn, CARVART was tasked with recreating historic design elements while adapting them to modern codes, materials, and fabrication capabilities. With limited documentation and highly detailed site conditions, the work demanded creativity, collaboration, and constant recalibration.
Historic Replication: Every element—from doors to lighting—had to mirror the original Art Deco detailing with precise material and form recreation.
Multi-Scope Complexity: CARVART managed over eight major scopes, from metal doors and railing systems to custom lighting, across various elevations and timelines.
Fabrication Logistics: Components were cast, extruded, and finished across multiple international vendors in the U.S., China, and India.
Real-Time Adjustments: Site conditions rarely aligned with drawings—installers had to collaborate daily with fabricators to recalibrate on the fly.
CARVART began by establishing a cross-disciplinary strategy—melding 3D scanning, archival research, and vendor coordination to re-engineer legacy pieces with modern precision. Our process was built around respect for the original while ensuring performance for decades to come.
3D Field Scanning: Site scans and digital modeling enabled replication of existing conditions and design motifs across doors, fixtures, and railings.
Mockups & Prototypes: Multiple full-scale mockups were fabricated and reviewed to match historic proportions, finishes, and textures.
Custom Material Solutions: Brass extrusions, cast components, and custom cladding finishes like Champagne Gold were developed to meet visual and code requirements.
Vendor Coordination: Global material sourcing and fabrication was meticulously coordinated across time zones to maintain schedule and quality control.
Adaptive Field Installation: With no “square” baselines, installers adjusted spacing, brackets, and transitions in real time to align seamlessly across each floor.
Historic Integration: Custom metal doors and railings were installed flush within ornate claddings, reinforcing the project’s immersive character.
Lighting Fabrication: Custom foyer light boxes and angled fixtures were designed to integrate with ceiling conditions and reflect original design cues.
Unified Detailing: Across more than eight scopes, CARVART maintained a consistent visual language—from faux doors and guardrails to entry vestibules and castings.
Waldorf Astoria Case 