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118901 Builders_118901 Builders 7/13/15 10:47 AM

National Guard to set up a 60-bed tent hospital

(called a Mobile Medical Unit) in St. John’s

parking lot. The hospital’s medical staff began

seeing patients at the tent hospital just a week

after the tornado. The tent hospital was later

replaced by portable buildings with walls and

ceilings made of insulated panels. The portable

buildings would offer additional protection

against the harsh winter weather.

In September 2011, McCarthy began

installation of a third, more secure temporary

facility: a 165,000 square foot modular

“component” hospital consisting of 224 steel

and concrete modules engineered in Southern

California. The component hospital opened in

April 2012 and served the community while the

permanent hospital was being built.

On January 29, 2012, demolition of the old

hospital began and a groundbreaking ceremony

was held for the new hospital. The new facility

is located approximately three miles southeast

of the old hospital on a highly-accessible, 100-

acre site just south of I-44.

On January 31, 2012, the St. John’s

Regional Medical Center name was formally

changed to Mercy Hospital Joplin as part of a

corporate rebranding.

PROJECT TEAM

McCarthy was Construction Manager at

Risk for Mercy Hospital Joplin. In July 2011,

they began working with Mercy and other

members of the team to determine the various

factors that would go into the design of the

replacement hospital. They completed the

program in November 2011. The program

management team included Archimages, Inc. of

St. Louis; HKS Architects, P.C., of Dallas; and

Heideman Associates of Ballwin, Missouri.

April-June 2015 MODERN BUILDER 1

720 Oak Street

Kansas City, MO 64106-1608

phone: (816) 531-4741

www.buildersassociation.com

Scott KellyChairman of the Board

Gregory A. DunnVice Chairman of the Board

Scott HoisingtonAssistant Chairman of the Board

Dirk D. SchaferAssistant Chairman of the Board

Phillip W. ThomasImmediate Past Chairman

Don GreenwellPresident

Bill Wien, EditorStacy Connelly, Advertising Sales

Volume 68 Number 2

Official Publication of

6-7 BAC Local 15 Pre-ApprenticesGraduate; Annual Contest Held

In this issue . . .

20-21 Boulevard Event Boosts Scholars

12-13 Phil Schultze Takes the Helm as2015-2016 KC AGC President

9

16-17 Students Learn About Careers inConstruction at iBuild

In this issue . . .

KC AGC Members ReceiveNational Safety Recognition

18-19 The Builders’ Association HoldsScholarship Golf Tournament

McCarthy Delivers Storm-HardenedMercy Hospital Joplin On Time and Under Budget

On Sunday, May 22, 2011, an EF-5

tornado with 200 mph winds began

tracking eastward toward Joplin,

Missouri. The sirens sounded in Joplin at 5:11

p.m., and a half-hour later, at 5:41, the tornado

touched down on the western edge of the city.

When it reached St. John’s Regional Medical

Center it blew out windows, tore off portions of

the roof, and irreparably damaged the building

infrastructure.

Of the 183 inpatients and 117 coworkers at

St. John’s that day, five patients and one visitor

perished. Most of the severely-injured patients

were taken to nearby Freeman Hospital, which

experienced minimal damage.

Gurneys were found five blocks away.

Seventy miles to the east, in Dade County,

residents reportedly found X-rays from St.

John’s in their driveways. Fortunately, patient

records were backed up electronically at

Mercy’s data center in Washington, Missouri.

THREE TEMPORARY HOSPITALS

Arriving in Joplin just days after the

tornado, McCarthy Building Companies, Inc.

worked with volunteers and the Missouri

(continued on next page)

MAIN LOBBY

A gourmet coffee bar located on the first floor of the hospital (in back of the main lobby) is one of severaldining options at Mercy Hospital Joplin. The terrazzo stairs with glass-panel railing are part of Mercy’sefforts to promote healthy lifestyle elements into the new facility.

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COVER PHOTO: The main entrance to thepatient tower is on the east side and featuresimpact-resistant sliding doors and metalpanels which form a two-story cross. Theexterior is storm-hardened with a precastconcrete shell, impact-resistant glazing,and a precast brick and EIFS facade. Thehorizontal windows at the eighth floor encloseapproximately 45,000 square feet of shellspace for future expansion. Visible abovethe eighth floor is the penthouse enclosurehousing mechanical equipment protected byheavy walls of hurricane-strength boards.

FACILITY IS DESIGNED AND BUILT TO BE STRUCTURALLY RESILIENT

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118901 Builders_118901 Builders 7/13/15 10:47 AM Page 3

Mercy Health System, is one of the nation’s

largest Catholic healthcare systems.

Safety was a top priority throughout the

project. In June 2014, McCarthy hosted an

OSHA Fall Safety Stand-Down event at the

Mercy Hospital construction site. The stand-

down was attended by more than 450 workers

and included presentations and training on fall

safety. McCarthy achieved a 1.44 total project

incident rate (well below the national average of

3.6) and a .14 lost-time incident rate during 2.8

million worker hours through March 31, 2015.

Mercy Hospital Joplin is an 890,000 square

foot structure designed for 260 beds, all of which

are private beds for better efficiencies and

utilization than St. John’s, which contained semi-

private beds. Although the new hospital has

fewer beds than the former facility, the latter

averaged only about 200 patients a day. Also,

when Mercy teamed up with McCune-Brooks

Regional Hospital following the tornado, they

gained 25 beds there. (McCune-Brooks, a

smaller hospital about 15 minutes north of

Mercy Hospital Joplin, is now known as Mercy

Hospital Carthage.) Behavioral health beds are

located in another Mercy facility in Joplin.

Construction costs accounted for $345

million of the project’s total $465 million cost,

which included approximately $9 million in

upgrades designed to harden the new hospital

against natural disasters.

FAST-TRACK SCHEDULE

Following the tornado, the hospital was

planned, designed and constructed in only 46

months. “This was approximately half the time

you would normally anticipate for a similarly-

sized hospital,” stated Ryan Felton. HKS issued

its certificate of substantial completion on

January 18, 2015. The hospital opened its doors

to patients on March 22, 2015.

“The new hospital was originally over

budget at approximately 1.5 million square

feet,” said Steve Meuschke. “During the

program phase, Archimages, as part of the

collaborative health care design team, worked

with various hospital department users to define

the total square footage and scope of the project.

The department users reported back to the

consultants and designers on the amount of

As Construction Manager at Risk,

McCarthy provided preconstruction services,

established a budget, developed the schedule,

and managed the project from start through

completion. The McCarthy team included Ryan

Felton, Project Director; Mike Stapf,

Preconstruction Director; and Steve Meuschke,

Senior Project Manager.

HKS, the Design Architect and Architect of

Record, was represented by Norman Morgan,

AIA, Principal-in-Charge, and Tim Solohubow,

AIA. Archimages, Inc. was represented by Greg

Garner, Principal/Design Coordinator, and Jim

Huber, RA, Principal.

Jamison Bloebaum, P.E., Heideman

Associates, was the Mechanical Engineer of

Record, and Tim Koenig, also with Heideman

Associates, was the Electrical Engineer for the

design of the hospital. John Farnen, Executive

Director, Mercy Strategic Projects, was the

Owner’s Representative. The Owner, Sisters of

2 MODERN BUILDER April-June 2015


Mercy Hospital Joplin(continued from page 1)

space they would need to operate their

respective service lines efficiently. As a result,

the new hospital contains roughly the same

square footage in one building as the old St.

John’s facility contained in four separate

buildings, and was completed under budget.”

To accomplish the fast-track schedule,

McCarthy collaborated with the project team to

create 10 different bid packages. This helped

determine what materials would be needed and

when, and allowed construction to begin just

three months after design got under way. The

packages included: 1) mass grading; 2) final

grading; 3) foundation; 4) steel; 5) flatwork,

landscaping, and exterior signage; 6) exterior

skin; 7) ground, first and second floor fitout; 8)

road improvements; 9) patient tower fitout; and

10) clinic fitout.

McCarthy was also able to accelerate

construction by having the headwalls and

restroom walls prefabricated in a warehouse and

installed in the patient rooms later on during

construction.

The mass grading/excavation package

included demolition of 18 houses on the 100-

acre site as well as portions of the old

Messenger College facility. (Messenger College,

the national collegiate institution of the

Pentecostal Church of God, relocated to Texas

in 2012.) The package also included removal of

100 tons of rock (much of which was blasted

out) and one million yards of dirt.

“The lower level, about 80,000 square feet,

was blasted down to elevation while the

mechanical was being designed,” noted Steve.

“We were just about to start the foundations

when we were notified by the mechanical

engineers that an additional four feet would be

needed for the ductwork.”

During a six-week period in the early

summer of 2012, the McCarthy team worked

night shifts and weekends to recover the time

lost time excavating the additional four feet.

“The foundations were ready and we were back

on schedule when the steel arrived the day after

Labor Day 2012,” said Ryan Felton. “That was

a milestone I won’t forget.”

Checkerboard composite metal decking and

Subcontractor Members ofThe Builders’ AssociationWho Worked on Mercy Hospital Joplin• Ambassador Steel• Apac-Missouri, Inc. – Missouri Division• Desco Coatings, Inc.• Doherty Steel, Inc.• Enterprise Precast Concrete, Inc.• Flooring Systems Inc.• Flynn Midwest, LP• GOEDECKE• Hayes Drilling, Inc.• Johnson Controls, Inc.• D.H. Pace Co. Inc.

dba Overhead Door Co. of Springfield• PCI (Performance Contracting Inc.)• Pro Balance Inc.• Roberts Loading Dock Equipment Company• Wm. J. Zickel Co.

A stone Stations of the Cross sculpture on the south wall and travertine stonefrom St. John’s Regional Medical Center were among the many elementssalvaged and incorporated into the new chapel at Mercy Hospital Joplin.

Photo of the old St. John’s Regional Medical Center on May 22, 2011, justafter the tornado. A helicopter lies on its side in the parking lot. Demolition ofthe old hospital began on January 29, 2012.

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April-June 2015 MODERN BUILDER 3



a lightweight concrete floor slab system were

installed to minimize vibration within the

building’s long floor spans, noted Ryan. Steel

frame connection technology was employed to

help eliminate cross-bracing and x-bracing and

maximize floor-to-ceiling heights – creating

more space to run the MEP systems, he added.

The worker peak was reached during the

winter of 2014, when there were roughly 850

tradesman on site, according to Steve Meuschke.

“At that time we were wrapping up the building

exterior, starting drywall on the interior, and

pushing towards the finish line at the Central

Energy Plant,” he recalled.

DESIGNED FOR PERMANENCE

“In the design of the new facility, Mercy

incorporated design features to make the facility

more resilient. Mercy’s goal was to protect the

lives of those in our new facility and to provide

a place of refuge for the community. Mercy also

wanted to make sure our facility stays open to

provide services to the community when they

need it most,” said John Farnen.

roof, which had been weighed down by gravel.

During the tornado, the rock became projectiles

that shattered windows.

Each floor of the hospital has a special

hallway with reinforced walls and ceilings as

well as heavy storm barriers which can be

closed for added safety. Rods in the door

hardware penetrate the cement above for added

stability. All passenger elevators connect to the

basement where widened corridors provide

refuge for co-workers and patients. Hallways

and stairwells have battery-operated lights that

will automatically turn on. Critical life-support

systems such as ventilators have their own

battery backup.

CENTRAL ENERGY PLANT

The hospital is connected by a 450-foot

concrete underground tunnel to a 30,000 square

foot Central Energy Plant (CEP) containing all

of the MEP systems. The CEP was built into a

hill on the east side of the hospital to minimize

exposure to the elements, and has a hardened

concrete exterior, stated Steve Meuschke. All of

the main utilities feeding into the hospital via

the tunnel, as well as the electrical feeds from

the local utility, are redundant; if one substation

The damage from the tornado would be

carefully analyzed so the new hospital could be

designed and constructed to protect against

future tornadoes. During testing of the windows,

an air cannon was used to blast wooden 2x4s at

high speeds to simulate the effect of flying

debris during a tornado, noted Ryan.

At St. John’s, only the laminate glass used

in the behavioral health unit had survived. Based

on this experience, custom-made windows with

laminate films were designed to withstand

damage from winds up to 250 mph, 140 mph, or

110 mph. The 250 mph-rated windows were

installed in the intensive care units to maximize

safety for the most vulnerable patients. The 140

mph impact-resistant glazing was used on the

bridge (which connects the patient tower and

clinic tower on floors 3-5), and the 110 mph

windows were used in the common areas. The

glass is framed into an aluminum curtain wall,

which is securely fastened to the building in

order to better absorb the impact of a

catastrophic storm.

Precast concrete finishes, as well as the

lightweight concrete slab installed beneath the

roof, help harden the exterior. The new roofing

system is a safe alternative to St. John’s ballasted

Mercy Hospital Joplin, south elevation. The clinic tower is at left (west) and the patient tower is at right (east). The main entrance is on the east side of thepatient tower. The Central Energy Plant is located to the east of the hospital (out of view) and is connected to the hospital via an underground tunnel. Oncologypatients have their own designated entrance (left foreground) to the Cancer Center. The advanced linear accelerator is on the southeast corner (at right), and ishoused in a structure with false windows and a 4'-thick concrete exterior. The helicopter pad is out of view on the north side, facing I-44.

View of the main cafeteria on the second floor of the patient tower. The woodceiling and fireplace create more intimate seating areas and help break upthe larger dining area. The fireplace is electric for safety.

Second floor view from the hospital main entry to the clinic main entry at theother end of the gallery (concourse). At right is the Mercy Gift Shop. Thesoffits help create a sense of intimacy.

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4 MODERN BUILDER April-June 2015

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goes down in a tornado another substation will

be available. The CEP also houses two

generators, either of which can power the

hospital independently. The new generator

system will enable the hospital to operate for 96

hours in the event of a power failure.

ENERGY SAVINGS

The new facility incorporates a number of

energy-saving systems. These include a

proprietary system which optimizes chiller run

times and water temperatures based on loads,

and a boiler exhaust heat recovery system which

uses exhaust heat from the boilers to preheat

boiler heating water.

Fanwall technology is used in the outside

air units. The use of many small fans with

smaller motor sizes (instead of one large fan)

provides redundancy, expedites maintenance,

and allows each fan to operate at peak

efficiency. Heat wheels in the 100% outside air

units remove heat from the return air in the

winter and use it to reheat the incoming supply

air. During the summer months, the heat wheels

act to remove heat from the incoming supply air.

Daylight harvesting is used in the main

atriums as well as in the public dining area


The advanced linear accelerator allows doctorsto treat patients with customized, high-energyradiation in an abbreviated period of time. Thefaux ceiling panels provide patients a morerelaxing, comforting environment.

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located along the exterior of the building on the

first floor. Motion sensor controls in the staff

and other nonpatient areas cause lights to turn

off when spaces are not in use. LED lighting is

used both for interior down lights and under-

cabinet light fixtures, and programmable LED

lighting is used for the parking lot fixtures.

“Mercy Hospital Joplin was a project like

no other – one that really would and is changing

a community. HKS and McCarthy gave the

community of Joplin a sense of hope as they

rebuilt. The new hospital has definitely been the

most rewarding project of my career, and we

could not have done it without the collaboration

and partnership of McCarthy,” said Norman

Morgan, AIA. p


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