KAI provided MEP/FP engineering and sustainability consulting on the recently completed $210 million expansion and renovation of the Cervantes Convention Center at America’s Center in Downtown St. Louis.
The AC Next Gen project, jointly funded by the City of St. Louis and Explore St. Louis, was completed in November 2024 with the goal of modernizing and enlarging the America’s Center Convention Complex to attract major conventions and events to the region. This was the first project is the first expansion of the Convention Center since the early 1990s.
The America’s Center complex is situated next to the Dome at America’s Center, former home of the NFL’s St. Louis Rams and current home of the UFL’s St. Louis BattleHawks. Originally opened in 1977 as the Cervantes Convention Center, the facility is named after former St. Louis City Mayor Alfonso J. Cervantes and is bordered by Washington Avenue and Cole Street.
Recent upgrades significantly enhance the facility’s functionality and capacity, including a 75,000-square-foot expansion of contiguous exhibit space, 30,000 square feet of adjacent service and support spaces, in addition to the expansion and enhanced functionality of the loading docks along Cole Street. The Washington Avenue entrance modernization is currently under construction.
KAI’s engineering scope included the design of a new 1,400-ton chiller plant, a 7.5 MBH boiler plant, replacement of two existing 50,000-CFM air handling units, replacement of two 13.8 KV substations, installation of three new 13.8-kV substations, four new air handling units, a new energy recovery unit (ERU) and a new 2,000-GPM fire pump.
Since the original chiller plant was not equipped to support the expanded facility, KAI’s engineering team designed a new chiller system that could be constructed without interrupting ongoing convention center operations.
“To ensure continuous functionality, we engineered connections between the new and existing chiller plants, allowing either system to seamlessly support the other during maintenance or service shutdowns,” said KAI Mechanical Group Leader Peter McDonnell, PE, LEED AP BD+C. “This carefully coordinated approach minimized disruptions during construction and ensured reliable climate control throughout the facility.”
KAI Engineering also designed a separate boiler plant for the expansion and incorporated system upgrades, including new gas lines and seismic shut-off valves. Throughout the design process, the team collaborated closely with commercial insurer FM Global to meet the project’s stringent guidelines, surpassing standard code requirements.
“By aligning with FM Global’s quality standards, the design addressed long-standing operational goals for Explore St. Louis while adding value through enhanced reliability and reduced insurance premiums,” said McDonnell.
The expansion, constructed on the site of a former parking garage and spanning two city blocks, required extensive utility relocations and public street improvements. This included the removal of a street blockade and the narrowing of Cole Street to accommodate a new 80,000-square-foot enclosed loading dock with parking for 20 full-size semi-trailer trucks and ramped access to the exhibit hall floor.
“KAI Engineering collaborated closely with architect Fentress Studios, a Populous company, and civil engineer David Mason + Associates to safely relocate impacted utilities and maintain infrastructure integrity while supporting the project’s overall goals,” said McDonnell. “I’ve built my career on delivering large-scale, complex public projects, and this expansion stands out as a milestone in my St. Louis experience. It is one of the largest projects I’ve worked on locally in 23 years, and I’m proud to have played a role in a transformational investment that strengthens our city’s convention and tourism future.”
The multi-year renovation and expansion created thousands of skilled trade, construction and hospitality jobs, contributing to St. Louis’ $5.8 billion convention and tourism industry.
Photos Courtesy of Tom Paule
