i. analysis 1: design/assist subcontracts · leed certification: leed silver ci v2.0 dates of...

I. Analysis 1: Design/Assist Subcontracts I. MAE Research

II. Critical Industry Issue

II. Analysis 2: MEP Schedule Accelerations I. Construction Depth

III. Analysis 3: Structural Column Redesign I. Structural Breadth

IV. Analysis 4: Refrigeration System Redesign I. Mechanical Breadth

Analysis 1 Analysis 2

Analysis 3 Analysis 4

Outline

I. Project Background

II. Analysis 1: Design/Assist Subcontractors

III. Analysis 2: MEP Schedule Accelerations

IV. Analysis 3: Structural Column Redesign

V. Analysis 4: Refrigeration System Redesign

VI. Acknowledgements

General Contractor:

Barton Malow Company

Architect:

HKS Inc.

Project Delivery Method:

Design/Build

Project Size:

180,360s.f.

Lump Sum Cost:

$46,000,000

Location:

Annapolis, Maryland

Owner:

The United States Naval Academy

Renovation of 100+ year old kitchen facility

Function: Commercial Kitchen

LEED Certification: LEED Silver CI v2.0

Dates of Construction: November 2009 to August 2011

Temporary Kitchen Ready for Use 22-Mar-10

Conditioned Air Available 6-Dec-10

Roof Complete 11-Feb-11

Interior Complete 12-Jul-11

Substantial Completion 11-Aug-11

Early Occupancy 30-Aug-11

Final Project Completion 21-Dec-11

Outline







31,000s.f. Temporary

Kitchen

Significant Unknown

Conditions

State of the Art Cooking

Equipment

Tremendous Schedule

Risk with Overhead

MEP Installation

5 Phases for Demolition and Construction

Temporary Kitchen

Temporary Trailers

Renovation Area

Google Sketchup Model of Surrounding Area

Outline


II. Analysis 1: Design/Assist

Subcontractors

III. Analysis 2: MEP Schedule

Accelerations

IV. Analysis 3: Structural Column

Redesign

V. Analysis 4: Refrigeration System

Redesign


Galley Feeds 4,500+ Midshipmen 3 times a day

Phasing Temporary Kitchen with Permanent Kitchen

demolition and construction

Extremely important client for Barton Malow/HKS

Close oversight from NAVFAC

Temporary Kitchen

Temporary Trailers

Renovation Area

Google Sketchup Model of Surrounding Area

Temporary Kitchen

Outline



Subcontractors





Problem:

Tremendous schedule and budget risk in MEP coordination

and installation

Goal:

Determine if schedule/budget risk could be mitigated

through the use of Design/Assist subcontracts

Method:

Comparative analysis between the electrical Design/Assist

contract and the mechanical/plumbing Traditional contract

Outline



Subcontractors


Accelerations


Redesign


Redesign


BK Truland electrical contract

awarded in early October 2009

Electrical Drawings 100%

complete in early March 2010

Cost Escalation of $300,000 or

7.14% of original contract

King Hall Galley Electrical Timeline

King Hall Galley Electrical Cost Escalation

Outline



Subcontractors


Accelerations


Redesign


Redesign


J.A. Zimmer Mech/Plumb contract

awarded in early May 2010

Mech/Plumb drawings 100%

complete in early June 2010

Cost Escalation of $2,500,000 or

48% of original contract

King Hall Galley Mechanical/Plumbing Timeline

King Hall Galley Mechanical/Plumbing Cost Escalation

Outline



Subcontractors


Accelerations


Redesign


Redesign


Additional Benefits:

More Constructible Design

Safety

Schedule Risk Mitigation

King Hall Galley Overall Timeline

AIA: Design/Assist Best Practices

Outline



Subcontractors


Accelerations


Redesign


Redesign


Recommendation:

Utilize Design/Assist contracts for Mechanical/Plumbing in

addition to Electrical

Can reduce schedule and budget risk

Can expedite design

Considerations:

Internal case study

Need a committed “point man”

from Design/Assist partner

Checks and balances

MEP Cost Escalation Summary

“To construct efficiently you must design efficiently”

-Mike Miller, Southland Industries

MAE Research

AE 572 Project Delivery Methods

AE 597K Research Methods in

Architectural Engineering

Outline




Accelerations




Problem:

Six week schedule delay due to unforeseen

conditions

Goal:

Accelerate the MEP installation to make up the

six weeks of lost time

Methods:

Comparative analysis between a prefabrication

scenario, a hypothetical overtime scenario, and

the actual overtime scenario used on the project

Original Critical Path Temporary Kitchen Design

Temporary Kitchen Construction

Permanent Kitchen Design

MEP Overhead

Temporary Kitchen Design

Temporary Kitchen Construction

Structural Slab Correction

MEP Overhead

Permanent Kitchen Design

November 13, 2009

March 12, 2010

May 28, 2010

February 23, 2011

November 13, 2009

March 12, 2010

May 28, 2010

August 4, 2010

February 23, 2011

Actual Critical Path

Outline



Subcontractors


Accelerations


Redesign


Redesign


King Hall Galley Original MEP Summary Schedule

Original 301 day duration for MEP

Based on 5 days per week and 8

hours per day

Required overtime

Subcontractor agreement for

premium wage

Extra $20/hour

6A.M. to 10P.M. allowable hours

Scenario Duration (Days) Total Labor Cost

Original MEP Schedule Plus Real Overtime 271 $3,948,358.96

Scenario Total Cost Total Duration

Original MEP Schedule $3,633,358.96 301

Outline



Subcontractors


Accelerations


Redesign


Redesign


Case Study: Miami Valley Hospital

500,000s.f., 12-Story addition in Dayton, Ohio

$137 million total contract value

Prefabricated overhead MEP systems, patients rooms, modular

workstations, unitized curtain wall sections, and a pedestrian

footbridge

Cut 2 months from original construction schedule

Reduced overall original budget by almost 2%

Characteristics:

Plumbing contractor was able to increase productivity by 300%

Average hourly wages were $10 less per person than typical

Produced 8-10 mechanical racks per week

Utilized a 35,000s.f. pre-assembly site for $2.25 per s.f. per year

Rendering of Miami Valley Hospital

Outline



Subcontractors


Accelerations


Redesign


Redesign


Industry Research: Southland Industries

Saves approximately 35% of field labor time by prefabricating

mechanical racks in a warehouse rather than in the field

Utilized spooled fabrication

3-4 days for CAD

1-2 days for assembly

Spools can be manufactured in a variety of sizes

Benefits

Prefabricated modules delivered in a highly coordinated manner

Reduction in safety incidents

Reduction in budget risk

Reduction in schedule risk

Less construction waste

Increased confidence in project partners

Outline



Subcontractors


Accelerations


Redesign


Redesign


Prefabrication Plan

Utilize Davis Bacon Act for labor

wages

Conservatively estimate hour

wages at $5 less per hour per

worker

Utilize 8’x6’x2’ (LxWxH) modules

Rent 15,000s.f. facility for a total

cost of $33,750

$15,000 for extra transportation

costs

Prefabricate only the main runs for the MEP

distribution systems

Approximately 1/3 of total MEP distribution work

West Entrance Modular Delivery Plan

Outline




Accelerations




MEP Prefabrication Scenario Summary Schedule

24 days saved

$611,023 saved

Reductions in:

Safety Incidents

Construction waste

Scenario Total Duration (Days)

Original MEP 301

Prefabricate Main Runs 277

Scenario Labor Cost Contingencies Total Cost Total Duration

Original MEP $3,633,358.96 $0.00 $3,633,358.96 301

Prefabricate Main Runs $3,022,335.92 $28,000.00 $3,050,335.92 277

Outline



Subcontractors

III. Analysis 2: MEP

Schedule Accelerations


Redesign


Redesign


Productivity as a Function of Time (Thomas)

Research Study by Dr. H. Randolph Thomas and Dr. Karl A. Raynar

• Diminishing returns of working too much consecutive overtime

• Compare productivity as a function of consecutive overtime worked

• Compare efficiency as a product of consecutive overtime worked

Develop an overtime scenario where efficiency and productivity are not

lost

• Make up lost time without spending money on inefficient workers

Efficiency as a Function of

Time (Thomas)

Outline



Subcontractors

III. Analysis 2: MEP

Schedule Accelerations


Redesign


Redesign


Hypothetical Average Efficiency as a

Function of Time

4 week cyclical overtime schedule

• Utilize overtime while not overworking

• Work 3 consecutive 60-hour weeks followed by 1 40-hour week

• Average worker efficiency during overtime weeks is 93%

• Assume 40 hour work week recovers efficiency back to 100%

• Result is a 4-week cycle with an average of 55 hours worked per

week

1 2 3 4 5 6 7 8 9 10 11 12 13

Scenario Duration (Days) Total Labor Cost

Cyclical Overtime MEP Schedule 252 $3,831,474.79

Weeks

Hours

per

Day

Outline



Subcontractors


Accelerations


Redesign


Redesign


Methods Summary

Main Plumbing Run

Actual Overtime

• 30 days saved

• $315,000 more

Prefabrication

• 24 days saved

• $600,000 saved

Cyclical Overtime

• 49 days saved

• $800,000 more

Scenario Total Cost Total Duration

Original MEP Schedule $3,633,358.96 301

Outline



Subcontractors


Accelerations


Redesign


Redesign


Considerations:

Significant Assumptions

Recovery week may not bring

efficiency back to 100%

Design/Assist is crucial

First Recommendation

Prefabricate 45% of overhead MEP

Second Recommendation

Implement cyclical overtime for 28

weeks

MAE Research

AE 597K Research Methods in

Architectural Engineering

Outline





Redesign



Problem:

Masonry column repair was a very time consuming and

expensive process

Goal:

Determine if the schedule and budget could be reduced by

replacing the 6 masonry columns with steel or cast-in-place

concrete

Method:

Perform load calculations in order to size the steel and

concrete and then price the material and develop an

installation schedule

Column to be Repaired Layout of Columns

Outline



Subcontractors


Accelerations

IV. Analysis 3: Structural

Column Redesign


Redesign


39 day duration for repair

$24,850 for inspection and

construction cost

Multiple visits by structural

engineer

Huge risk with schedule and

budget due to unknowns Actual Repair Cost Summary Actual Repair Summary Schedule

Outline



Subcontractors


Accelerations


Column Redesign


Redesign


Factored Load = 139 kips

Steel Proposal W8x48

Concrete Proposal 12”x12”

square columns with 4-#5

rebar

Steel Proposal Cost Summary Cast-in-Place Concrete Proposal Cost Summary

Outline



Subcontractors


Accelerations


Column Redesign


Redesign






rebar

Steel Proposal Summary Schedule Concrete Proposal Summary Schedule

Outline



Subcontractors


Accelerations


Column Redesign


Redesign






rebar Scenario Duration (Days) Feasible

Original 39 Yes

Steel 34 Yes

Concrete 38 NoColumn to be Repaired

Outline



Subcontractors


Accelerations


Column Redesign


Redesign


Recommendation:

Utilize the scenario that was actually implemented

Most constructible option

Considerations:

Steel is shortest duration

Concrete was cheapest option

Construction logistics become significantly more complicated

Finished Column

Outline





V. Analysis 4: Refrigeration

System Redesign


Problem:

A dedicated 65 Ton capacity chiller is required to refrigerate

the galley’s 4 freezers and 11 refrigerators. The originally

specified unit creates sound pressure levels nearing 100dB

and was designed to be located adjacent to the existing

dormitory complex

Goal:

Analyze the replacement chiller and determine if a more

efficient unit is available

Method:

Research available chillers and develop a life cycle cost

analysis to determine the best options

Bakery Freezer

Original Chiller

Outline



Subcontractors


Accelerations


Redesign


System Redesign


Original Design

York Air-Cooled Chiller

Replacement Design

York Water-Cooled Chiller

Proposed Replacement

Trane Water-Cooled Chiller

Cost: $25,000

Capacity: 44.2 Tons

Input kW: 76.3

Cost: $37,290

Capacity: 42.2 Tons

Input kW: 44.5

Cost: $44,000

Capacity: 57.5 Tons

Input kW: 35.2

Others Considered

Carrier Water-Cooled Chiller

Cost: $37,235

Capacity: 75.4 Tons

Input kW: 53.7

Others Considered

Carrier Condenserless Chiller

Cost: $41,470

Capacity: 67.7 Tons

Input kW: 76.2

Outline



Subcontractors


Accelerations


Redesign


System Redesign

I. Acknowledgements

Infrastructure Changes Summary

Original Design:

• York by Johnson Controls Model YLAA Air-Cooled Scroll Chiller

Style A

Replacement Design:

• York by Johnson Controls Model YCWL Water-Cooled Scroll

Liquid Chiller Style A

Key Changes:

Supply Water Temperature

• Original = 85 degrees Fahrenheit

• Replacement = 65 degrees Fahrenheit

• Proposal = 65 degrees Fahrenheit

Re-route Plumbing

• Original = Located in East Courtyard

• Replacement = Located in Mechanical Room

• Proposal = Located in Mechanical Room

Outline



Subcontractors


Accelerations


Redesign


System Redesign

I. Acknowledgements

Option Description Tons Capacity kW kW/Day kW/Year

1 York Air-Cooled 44.2 100% 76.3 1831.2 668388

2 York Water-Cooled 42.2 100% 44.5 1068 389820

5 Trane Water-Cooled 75.6 100% 49.6 1190.4 434496

6 Trane Water-Cooled 57.5 75% 35.2 844.8 308352

Utility inflation rate of 3.78% per year was utilized

100% usage and 50% usage models were developed

$0.08 per kilowatt energy rate used

30 year life cycle analysis was developed

Cost per year and cumulative cost per year were analyzed

Maintenance costs assumed to be equal between the 3 different units

100% Usage Statistics

50% Usage Statistics

Outline



Subcontractors


Accelerations


Redesign


System Redesign


Proposed vs. Original

Break-Even Point

Proposed vs. Revised

Break-Even Point

Proposed vs. Original design breaks even at just over 8 years

Proposed vs. Revised design breaks even at just under 2 years

Original Unit

• 15 Year Cost - $1,039,293

• 30 Year Cost - $2,508,356

Revised Units

• 15 Year Cost - $858,640

• 30 Year Cost - $1,715,433

Proposed Unit • 15 Year Cost - $741,720

• 30 Year Cost - $1,419,453

Outline



Subcontractors


Accelerations


Redesign


System Redesign

I. Acknowledgements

All units run on 30% Propylene Glycol

All units use R-134a refrigerant type

Utilize the existing glycol system

Proposed unit can run off of the same

entering water temperature

Proposed unit is comparable in size and

weight

Relocation of Chiller New Delivery Route

Outline



Subcontractors


Accelerations


Redesign


System Redesign

I. Acknowledgements

Recommendations

Install Trane water-cooled unit to run at 75% capacity

Operate on modified infrastructure

Install in the same location as revised design

Considerations

$7,000 more in initial cost

Federal Government project

MAE Research

AE 598C Sustainable

Construction Project Management

Proposed Trane Chiller

Academic

Penn State AE Faculty

Dr. Robert Leicht

Bryan Franz

Michael Gilroy

Tyler Strange

Barton Malow Company

Michael Abbondante

Brian Cummings

Bob Grottenthaler

Jennifer Macks

Sarah Semaan

Industry

Smiley El-Abd

Tom Krajewski

Mike Miller

Brandon Rosetti

John Stavinski

Chris Taylor

The United States Naval Academy

Commander Alexander D. Stites

Results Summary

Analysis 1:Design/Assist for MEP Subcontracts

Design/Assist can expedite design and significantly

reduce budget risk

Analysis 2:MEP Schedule Accelerations

Utilize prefabrication and save 24 days and $600,000

Utilize cyclical overtime and save 49 days and spend

$800,000 more

Analysis 3: Structural Column Redesign

Utilize the existing plan for constructability and

logistics reasons

Analysis 4:Refrigeration System Redesign

Implement proposed chiller and save $300,000 vs.

revised design and $1.1M vs. original design over the

30 year life cycle analysis

i. analysis 1: design/assist subcontracts · leed certification: leed silver ci v2.0 dates of...

Documents