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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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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
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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
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Mercy Hospital Joplin(continued from page 2)
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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118901 Builders_118901 Builders 7/13/15 10:51 AM Page 5
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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
Mercy Hospital Joplin(continued from page 3)
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
118901 Builders_118901 Builders 7/13/15 10:51 AM Page 6