Zoombezi Bay Water Slide Attraction 2011
Category: Other Construction: Less Than $2 million
Contractor: Thomas & Marker Construction Co.
Design Firm: PGAV Architects, Destinations, Planners
Client/Owner: Columbus Zoo and Aquarium
Start & End Date: 2/10 – 5/11
Project Amount: $2,500,000
Project Description: The water slide was part of the 2008 Master Plan expansion and the project was originally intended to use a conventional design-bid-build delivery system using Thomas & Marker as the CM. Early project estimates were $1 million over budget, so Thomas & Marker proposed a hybrid delivery system that incorporated design-build advantages and continued to utilize the original system. The slide project had two milestone dates – the submittal delivery and the equipment/material delivery. Thomas & Marker became involved after the initial milestone date of Dec. 15 passed when the slide supplier advised the Zoo that delivery – not installation – would be mid June due to fiberglass plant capacity issues in the Philippines. Because the zoo had already promoted the grand opening, Thomas & Marker began negotiations with the slide supplier which eventually agreed to air freight the slide from the Philippines and complete erection by the original completion date – one day before the grand opening. Further challenges were presented including a shift in the site layout and a critical error in some of the foundation anchor bolt placements. Because the site was a selective demolition and reuse of existing features, utilities were critical and it became apparent that a minor 3-foot adjustment to the purposed placement of the new water slide would provide greatest value and a cost savings. Later, an error in the foundation anchor bolt placements was discovered. The foundation pedestals were off by a couple of inches, making it structurally unsound. The project team re-made eleven of the 38 foundations to ensure safety and the project opened on time.
Cheetah Hunt Steel Roller Coaster at Busch Gardens
Category: Other Construction: Under $2 Million
Contractor: ADENA Corp.
Design Firm: Intraride, LLC
Client/Owner: SeaWorld Parks & Entertainment, LLC dba Busch Gardens Tampa
Start & End Date: 10/10 – 3/11Project Amount: $2,000,000
Project Description: The ADENA contract for the steel erection and the mechanical component installation was part of the over $20 million attraction that includes live cheetahs roaming throughout the Edge of Africa exhibit. The Cheetah Hunt is Florida’s first triple-launch coaster and Busch Gardens longest coaster. It was created to give park guests the opportunity to run alongside the exotic and real Cheetahs. ADENA constructed the roller coaster using 100 percent of their own personnel. They began unloading and cataloging parts in the autumn and erection began several weeks later. The coaster is launched three different times throughout the ride with linear synchronous motors. Launch One is at 30-MPH up to the 102-foot Windcatcher Tower only to drop 130-feet into the rides’ first of four subterranean trenches. Over the course, riders reach Launch Two and are shot out at 60-MPH to explore overbank turns. Riders eventually are launched for a third time at 45 MPH on a run through Rhino Rally Canyon. The final mechanical components were installed in the spring between endless bouts of rain. The ADENA crew performed their work around other rides in operation and as tourists and guests enjoyed the park. The park personnel requested that the construction work and equipment be disguised or hidden as each portion of the roller coaster was erected. Ride parts had to be brought in at night and erected or placed the following day. ADENA was able to keep the owner happy and the wildlife safe as crews worked through the beautiful habitat. The coaster was constructed over six months and the project was completed on time.
The Ohio State University Student Academic Services Building/Lane Ave. Parking Garage
Category: Commercial $25 - $100 million
Contractor: Miles-McClellan Construction Co., Inc.
Architect: Acock Associates Architects
Client/Owner: The Ohio State University
Start & End Date: 4/08 – 12/09
Project Amount: $44,000,000
Project Description: Miles-McClellan was hired as the Construction Manager of the facility, which sits on the gateway to the north campus area. The new Student Academic Services building houses five departments and the attached parking garage is the largest garage on campus. A utility tunnel was constructed below the facility and ties the new buildings to the existing utility tunnels of the university. Lane Ave. was also widened and work was coordinated with the City of Columbus. Work began with the digging of the basement, utility tunnel and the lower deck of the parking garage. These sections sit below the water table so a slurry wall was required. The building features a five-story cantilever that extends nearly 44 feet from the front entrance. It’s the most recognizable feature of the building and provides visual interest and appeal, but there were considerable challenges. Since the structural steel cantilever had to be installed prior to the concrete deck pouring and the installation of the exterior masonry, the steel beams of the cantilever had to be installed 3 inches higher than the desired finish elevation at the far end. The three inch elevation difference was determined by calculating the estimated weight of the concrete and brick and the deflection of the steel beams. To safely install the exterior brick veneer, it had to be pre-loaded to level out the cantilever during installation. All exterior bricks were placed on their designated deck and cubes of brick were removed one at a time as each brick was installed on the cantilever. By preloading the decks, the team was able to prevent the concrete floors and brick veneer from cracking under the additional weight of newly applied brick. The attached parking garage is a post-tension, cast-in-place garage with a stainless steel mesh and brick storefront exterior. This garage sets the new design standard for future University garages and all new builds will feature exterior metal and lighting to mask the look of a typical concrete garage.
Highlands Park Family Aquatic Center
Category: Other Construction: $2 to $100 Million
Contractor: Thomas & Marker Construction Co.
Design Firm: Meyers & Associates.
Client/Owner: City of Westerville
Start & End Date: 8/10 – 5/11
Project Amount: $7,000,000
Project Description: The original complex was built in 1973, and the new aquatic center is a $7 million project that consisted of a complete demolition of the original facility and construction of a new state-of-the-art outdoor aquatic complex. The original facility had five buildings and seven swimming pools to demolish. Thomas & Marker identified and implemented a plan to deconstruct the exiting facilities in an effort to achieve Silver LEED standards, and ultimately the goal to recycle or reuse 75 percent of the waste generated was achieved. The aquatic center is adjacent to protected wetlands, active soccer fields and within a residential neighborhood so consideration of each of these communities was a consideration throughout demolition and construction. Thomas & Marker implemented an Indoor Air Quality Management Plan which consisted of controlling emissions, installing temporary ventilation systems, construction dust reduction, and restrictive use of combustion equipment indoors. In the field, LEED efforts continued by relaying standards and expectations to each team member during the initial site safety orientation and then through the weekly jobsite meetings focusing on continuing education and accountability. The completed swimming amenities include an eight lane, 25-meter competition pool with a diving well, a large leisure pool, a toddler pool with zero depth entry and small fountains, two 30-foot water slides, a lazy river and large and small spray grounds. New buildings on the site included a 1,700 sq. ft. concession building, a 2,700 sq. ft. main restroom facility, as well as a concession building and foot pump house.
Mount Carmel East – Generator Building
Category: Healthcare: Less Than $10 Million
Contractor: Danis Building Construction Co.
Architect: Moody Nolan
Engineer: Heapy Engineering, LLC
Client/Owner: Mount Carmel Health Systems
Start & End Date: 3/10 – 3/11
Project Amount: $3,749,416
Project Description: The nearly 8,000 sq. ft. generator expansion was a multi-phased project providing back-up power to the entire Mount Carmel East campus. The expansion housed three new generators with extra space for a future generator and other electrical equipment. Along with the normal obstacles of a tight budget and schedule, this project included constructing a new power generation building on an existing hospital campus adjacent to the ambulance entrance, helipad, and the back yards of Mount Carmel’s neighbors. The project also affected every aspect of the hospital, so pre-planned tie-ins were required to place the hospital’s emergency, critical and normal power on the generators. An extensive shutdown sequence was created by subcontractor Claypool Electric, while Danis performed general trades and management. Planning for this started three months in advance and resulted in multiple meetings per week to ensure all work was organized and communicated to prevent unplanned disruptions to the hospital. There were over 90 tie-ins which included normal power, emergency power, critical power, and power for existing support equipment including boilers, chillers and fire pumps. The building itself consisted of colored masonry block. Sixty percent of it was “sound” block interspersed within curtain walls to help eliminate the noise of the generators since the building was next to a residential neighborhood. There are four rooms on the lower level – a generator room, paralleling switchgear room, substation and ATS room. All were designed with future expansion in mind so that another generator and equipment could be added. The scope of work did not stop after the building was complete because the new power plant had to be tied into the existing hospital while maintaining hospital operations.
Holy Trinity Lutheran Church
Category: Institutional: Less Than $5 million
Contractor: R.W. Setterlin Building Co.
Architect: WSA Studio
Engineer: SMBH; Bird & Bull; Scheeser Buckley Mayfield
Client/Owner: Holy Trinity Lutheran Church
Start & End Date: 5/10 – 4/11
Project Amount: $1,641,735
Project Description: As the construction manager-at-risk for the church’s expansion and renovation project, R.W. Setterlin provided both preconstruction and construction services. During the preconstruction phase, Setterlin worked closely with the church to value engineer the design into alignment with the church’s budget and engineer cost reductions. The project consisted of a 6,000 sq. ft. addition as well as a renovation of approximately 1,100 sq. ft. of existing space. From the start, this project was about overcoming challenges. The restrictive nature of Upper Arlington’s building and zoning codes forced specific zoning approvals and variances, in addition to an easement being vacated. Because the church remained in daily use, the parking lot had to remain clear and available. The church is in a residential area so there was no lay down or storage space and all material deliveries had to be carefully planned and scheduled by the project manager. A priority was keeping noise and debris to a minimum while not disturbing any neighbors’ property. An unforeseen condition was the existing roof structure, which was different than what was shown on the plans and had to be reinforced. This led to structural and roof designs changes. Also, in the area of the building where the new addition was to tie into, there was a basement not shown. The Setterlin team handled these conditions by proposing effective solutions without negatively impacting the budget or schedule. The impressive new sanctuary encompasses intricate woodwork, beautiful wood slat ceilings, a mix of modern lighting and natural daylight, and furnishings that are traditional in appearance but very flexible. The sanctuary’s configuration can be easily reworked with movable pews, and the audiovisual system provides more flexibility than traditional setups.
Miami Valley Hospital Heart and Orthopedic Center
Category: Specialty Contracting, Mechanical: More Than $10 Million
Contractor: TP Mechanical Contractors, Inc.
Client/Owner: Miami Valley Hospital South
Start & End Date: 9/09 – 1/11
Project Amount: More Than $30,000,000
Project Description: The Miami Valley Hospital’s Heart and Orthopedic Center is a new 12-story tower on the main campus that provides more than 484,000 square feet. The tower is six floors of cast-in-place concrete topped with structural steel and clad with precast and curtain wall. The new tower’s focus is a comprehensive heart center featuring imaging services, cardiac testing, catheterization labs and heart surgery suites. As the plumbing and mechanical contractor, TP Mechanical invested 193,000 man hours to complete the project. The scope of work included the plumbing system, medical gas system, HVAC piping, ductwork, fuel oil piping and all associated equipment such as steam boilers, chillers, air handling units and medical gas compressors. TP Mechanical self-performed 80% of the mechanical labor on the project. All of the utilities in the corridors on the fourth through ninth floors were prefabricated using an offsite warehouse. Prefabrication was key to the coordination and sequence of the rack work. Every trade prefabricated and preassembled as much as possible, which helped maintain an aggressive schedule through Lean construction. All of the construction waste at the prefab warehouse was captured and recycled. The cutoff pieces of pipe were placed in crates and used either onsite or back at the prefab shop in Cincinnati. The scope of this project also included Energy and Environmental Design and LEED Certification. As part of these initiatives, a heat recovery system was used to extract energy from the hot air exhaust which saved energy in both winter and summer months. Also, wells were tapped into an aquifer system to produce condensing water for the chilled water plant.
Riverside Methodist Hospital – 7 Yellow Renovation
Category: Renovation: Less than $4 Million
Contractor: Danis Building Construction Co.
Architect: Shremshock Architects, Inc.
Engineer: VMP Engineering, Inc.
Client/Owner: Ohio Health
Start & End Date: 8/10 – 5/11
Project Amount: $1,966,600
Project Description: As the main oncology patient care area in the hospital, “7 Yellow” accommodates both patients and families while cancer treatment and recovery is monitored. All services for nursing, administrative and support staff operations had to be maintained and operational at all times during the renovation. The project consisted of about 17,000 sq. ft of patient care renovation which was executed in phases to allow for patient care to continue on half of the floor. The structure was constructed in the late 1950’s and is one of the oldest structures on campus. Danis personnel self-performed selective demolition, infection control and prevention tasks. Of prime importance was the Infection Prevention & Control Program so the Danis superintendent worked closely with the hospital’s project manager and safety department to establish a system that would satisfy their needs. The separation between patient care spaces and renovation areas was a temporary construction barricade which needed to double as the main infection control barrier while maintaining safety for the patients, staff and public. The building was a concrete structure and most interior partitions are non-load bearing red clay block walls covered with full-depth plaster. With upgraded patient room head walls in the project, all new utilities had to be channeled in the plaster and block. Extreme care was taken to avoid cutting too deep in the clay blocks since they were very brittle from age. Danis set up a rail and circular saw with a self-contained dust collection system to allow precise cuts, minimum dust exposure and increased productivity. Danis also completed general trade items such as in-wall blocking, installation of door frames, doors and finish hardware, fire proofing and caulking.
Licking Memorial Hospital Data Center
Category: Specialty: Less Than $1 Million
Contractor: Echo 24, Inc.
Client/Owner: Licking Memorial Health Systems
Start & End Date: 12/09 – 12/10
Project Amount: $583,368
Project Description: Echo 24 was contracted to install fiber optic cable into the hospital’s newly constructed data center. Before groundbreaking, Echo 24 re-routed the existing fiber optics and multi-pair copper cables through manholes on the hospital grounds so that the cables would not be under the footprint of the new data center when construction began. It was a delicate operation because service to the old data center could not be compromised by an error. The project consisted of over 3,000 strands of laser optimized multi-mode fiber optic cable and nearly 170,000 ft. of fiber installed inside the data center. An existing five-duct bank on the west side of the hospital was to be used but it didn’t connect to the entrance facility in the Critical Care Pavilion. Also, the entrance terminated to a hand hole that was not large enough to accommodate additional ducts and cabling, so Echo 24 engineered a solution to build a manhole out of concrete block around the existing conduits and cables. This was constructed by a masonry contractor and accommodated the ducts without disrupting service to the existing cables. Once the pathways and internal cabling was in place, Echo 24 was ready to move services from the 15 buildings through the pavilion, including 28 outside plant cables – all in service. The plan was to methodically relocate cables over six weekends in order to minimize downtime. The first five weekends went as planned. But during the final weekend, the 12 cables in a conduit 450 feet under the parking lot could not be removed without causing permanent damage. Echo 24 recommended a solution, however again the hand hole wasn’t large enough to accommodate the change so a new masonry manhole was built. Once the outside plant reconfiguration was completed, ground was broken on the data center and the design team created a three-foot raised floor design to accommodate the cable tray. The data center cabling was designed around 50 micron multimode. The fiber design to each of the network cabinets had a 24-strand multimode fiber trunk installed in one of the pathways and another 24-strand multimode trunk installed in the second pathway for redundancy to the core switches. The installation of the fiber trunks was seamless and the data center interior was completed a week early.