Off-Site Fabrication Brochure - Whiting

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SCIENCE + TECHNOLOGY
STANFORD COMPARATIVE
MEDICINE PAVILLION
PALO ALTO, CA
Following a 10 year master planning exercise,
the Stanford University School of Medicine found
that their research facilities were over capacity.
Future trends showed this lack of space would
increasingly limit them. As a result, the School of
Medicine identified the immediate need for a
short-term solution and a long-term facility plan.
This would allow their research to progress
continuously while waiting for a large scale,
long-term solution to be implemented.
The University’s demand was for a facility that
could be built quickly. This stop-gap measure
would provide time to raise the necessary funds
to implement their long term strategies. However,
the speed of delivery and limited lifespan of the
project required balance with the level of quality
that is expected of a Stanford facility where cutting
edge discoveries would be fostered. Whiting-Turner
was brought on in a preconstruction capacity to
support their analysis.
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STANFORD COMPARATIVE
MEDICINE PAVILLION
PALO ALTO, CA
After performing a cost analysis of traditional
on-site construction methods versus a modular
facility in Palo Alto, CA, we concluded that the
modular scenario was much less expensive.
There was doubt that constructing a facility in
pieces in the Midwest and shipping it across
the country would be less expensive than
constructing it on-site. However, this was
not the case.
24 modules were constructed in Iowa, complete
with all interior finishes, MEP infrastructure, and
fixtures. The modular fabricator was able to build
the modules in a way in which the MEP rough in
was happening simultaneously with interior finish
construction. This accelerated the schedule
even further. Many visits were performed by
Whiting-Turner, the 3rd party commissioning
agent, and Stanford to perform quality control
inspections and monitor progress.
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STANFORD COMPARATIVE
MEDICINE PAVILLION
PALO ALTO, CA
While the modules were being fabricated in
Iowa, Whiting-Turner was preparing the site and
foundation for the modules. When the modules
arrived via truck, they were immediately picked and
set in place by crane. There were two different
delivery and set dates for the modules, allowing the
mechanical area to be constructed during this time.
The modular manufacturer had the capability to
supply the air handler and exhaust fans as part of
a package. However, Whiting-Turner found it more
cost effective to buy the mechanical equipment
directly and locally subcontract the installation.
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November December
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Site Design & Construction
Create Site Permit Drawings
STANFORD COMPARATIVE
MEDICINE PAVILLION
PALO ALTO, CA
Submit for Building Permit
Construct Foundations
Set Modules 1-16
Set Modules 17-24
Modular Design &
Construction
Create 100% CD's
Fabricate Modules 1-16
Fabricate Modules 17-24
Two schedules were developed in order to compare traditional construction
methods with a modular approach. It was found that the modular approach
could save as much as 5 months off of an 18 month construction schedule.
There were two major contributing factors to the time savings. First,
fabrication of the modular buildings could run concurrently with the
underground utilities, site work, and foundations activities. Second, one
contractor in a controlled environment would be fabricating the modular
sections, which would increase production and allow for substantial
learning curves. The as-built schedule (above) confirms exactly that.
While the local county permit was being procured for the site and
foundation, the modules were already being fabricated.
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The results of the analysis showed that a building
of this size with this particular program would be
built quicker and cost less to construct as a
modular building. However, there was still one
project risk that had not been identified, the county
influence. County plan checks and inspections
have proven to be a strain on the execution
of Stanford projects, so there was a chance
venturing into unfamiliar modular construction
techniques with the county could result in major
schedule impacts. After doing some investigation,
it was found that the modular buildings are under
the jurisdiction of the California Department of
Housing and Community Development, and that
the county would only review and inspect site
plans and foundations. Meetings were held with
the county to clarify the delineation of plan check
and inspection responsibilities. After all parties
were better informed on the subject, Stanford felt
that they had mitigated the county influence risk
to the schedule and that the project should
proceed as a modular facility.
STUDENT HOUSING
MUHLENBERG COLLEGE
ALLENTOWN, PA
Problem Statement
Muhlenberg College needed to replace some
temporary housing that was built in the 1980s. The
existing dormitories were single-story, wood frame,
trailer-type construction.
The objectives of the replacement
dormitories were:
1. Improve the quality and type of housing
for the students.
2. Increase the overall bed count
3. Replace existing trailers with five apartmenttype, 3-story buildings.
Challenge
How do you replace the existing student
residences without having to displace the
students during construction?
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MUHLENBERG COLLEGE
ALLENTOWN, PA
Solution
Do it over summer break with modular
type construction!
In the fall of 2006, Whiting-Turner was retained
by Muhlenberg College to help plan, procure and
manage the replacement dormitories during the
summer of 2007. The field work commenced
immediately after the students left for summer
vacation (May 15th), and had to be completed
and ready for occupancy when they returned
(August 15th).
The architect designed a very traditional full-size
brick exterior skin with steep roofs. Following
traditional construction methods, this project
would take 10-12 months to build in the field
from ground up.
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MUHLENBERG COLLEGE
ALLENTOWN, PA
Working with the modular builder, we convinced
ourselves that doing full-size brick in the factory
was possible. We also had to minimize the
erection or assembly time in the field. Therefore,
we determined that we had to find a large enough
crane to pick all the modular boxes, roof and
bridges from one location.
Lastly, we came up with the idea of building the
roofs on site in advance and placing them as soon
as the modular boxes were set. This was a key
element because in just three days we were able
to erect each building and have it weather tight.
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MUHLENBERG COLLEGE
ALLENTOWN, PA
Working 12-14 hour days, seven days a week, we
were able to prepare the site including foundations
to begin setting modules by June 14th (four weeks
after existing buildings were vacated). Between
June 14th and mid-July, we set 90 boxes, five
roofs and five bridges. By the first week of August,
we had received our TCO, allowing Muhlenberg
College time to deliver furniture before
students arrived.
This project was only possible due to off-site
construction techniques (modular) and all the
pre-planning. The site was very tight and on a
hillside, adding to the complexity and difficulty
of the project.
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HEALTHCARE
MERCY MEDICAL CENTER
RIVERSIDE METHODIST HOSPITAL
HEALTHCARE
MERCY MEDICAL CENTER THE MARY CATHERINE BUNTING CENTER
BALTIMORE, MD
The project team successfully solved many
challenges on the new construction of the
700,000 SF, 20-story replacement nursing tower.
Whiting-Turner chose to use Virtual Design and
Construction (VDC) to aid in the coordination
process. The project included two bridges, a
two-level tunnel connection to the existing hospital,
and sustainable elements such as three green
roofs. These Building Information Modeling (BIM)
tools gave the team a leg up when it came to
coordinating trades. However, the ability to
prefabricate materials off-site and ahead of time
proved to be as much, if not more of an advantage.
Working with the mechanical, electrical, pneumatic
tubing, and fire protection trades, we were able to
identify various areas of work that could benefit
drastically from prefabrication.
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MERCY MEDICAL CENTER THE MARY CATHERINE BUNTING CENTER
BALTIMORE, MD
Prefabrication offered several benefits, including:
1. Greater quality due to fabrication in a more
controlled environment
2. Schedule advantages due to the ability to begin
work earlier (in some cases, before a slab was
even poured).
3. Cost advantages by eliminating rework due
to field mistakes or poor quality.
A major initiative was the multi-party
prefabrication for the patient headwalls. Using
VDC, the contractors were able to coordinate
and standardize the electrical and medical gas
connections to each headwall. Modular Services,
Inc., which manufactures headwalls, was able to
prefabricate the entire wall section of the patient
rooms including studs, electrical conduit/outlets,
medical gas piping/outlets, and strapping. The
prefabricated wall sections were packed into a
crate in three pieces. Once they arrived on site,
they were hauled onto the material hoist and to
the appropriate patient room where they were
uncrated and installed.
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MERCY MEDICAL CENTER THE MARY CATHERINE BUNTING CENTER
BALTIMORE, MD
The MEP trade contractors were able to take
advantage of prefabrication in other areas as
well. The mechanical contractor was especially
successful prefabricating equipment piping
connections in the mechanical areas, including
the main HVAC pumps, chillers, cooling towers,
and AHU’s. All piping was fabricated in their
shop, trucked to site, and rigged into the building
for installation.
The pneumatic tubing contractor was also
especially successful with prefabrication. The
system included a main carrier “shuttle zone”
which was dedicated to routing the carriers to the
correct tube. The system consists of five diverters
facing another set of five diverters with tubing
connections between each diverter. The system
is very sensitive and was built to stringent
tolerances. The contractor used the BIM tools
to coordinate the entire system, and built the
majority of the system off-site. By fabricating
and testing ahead of time, the pneumatic tubing
contractor ensured that the system would
operate properly when started up in the field.
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MERCY MEDICAL CENTER THE MARY CATHERINE BUNTING CENTER
BALTIMORE, MD
The estimated headwall prefabrication cost
savings for material was approximately $1,500 per
patient room. With 190 rooms, this came out to a
savings of $285,000. In addition, the project was
able to turn over the building to the hospital three
months ahead of schedule.
With the industry becoming more competitive,
and with our clients pushing for shorter schedules
and lower costs, we now consider new
construction techniques on all healthcare projects
to help us meet these demands. The use of BIM
for prefabrication gives us the assurance building
systems will arrive at the site with better quality,
cost certainty and result in a reduced overall
project schedule.
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HEALTHCARE
OHIO HEALTH NEUROSCIENCE INSTITUTE
AT RIVERSIDE METHODIST HOSPITAL
COLUMBUS, OH
This design-build project is a 400,000 GBSF
neuroscience/cardiac patient tower with 224
individual private beds (several ICU), a linear
accelerator, MRIs, interventional radiology,
ORs, CTs, outpatient clinics and many other
support service areas. The project also includes
renovation of the existing surgery suites,
development of a new campus main entry and
loop road, construction of a 500-car, 200,000 SF
addition to an existing four-story parking garage,
construction of a 7.5MW emergency generator
plant, a central plant expansion consisting of the
addition of a new steam boiler, associated
distribution piping, and several acres of site work
enhancements including roads, walks, hardscape,
landscape, green roof and rain gardens.
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OHIO HEALTH NEUROSCIENCE INSTITUTE
AT RIVERSIDE METHODIST HOSPITAL
COLUMBUS, OH
Prefabrication is a key component of our LEAN
delivery process. By collocating the design and
construction team, we were able to streamline
communications and the decision-making process.
Adding design-assist mechanical and electrical
subcontractors to the team enabled us to create
a design that emphasized the prefabrication of key
project components.
Relationships grew between the multiple
disciplines. Whether it was the landscape
architect, cost estimator, structural detailer or
executive leader, all team members were sitting
within 20 feet of one another with no walls or
barriers between them. Everyone worked toward
the common goal of a successful project.
LEAN construction principles continued with
collocation of the MEPT trades in a correctlysized, off-site, prefabrication facility that was close
to the project site. The completed prefabrication
assemblies were delivered from the off-site
facility to the jobsite in a “just in time” fashion.
This contributed to a cleaner and safer jobsite.
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OHIO HEALTH NEUROSCIENCE INSTITUTE
AT RIVERSIDE METHODIST HOSPITAL
COLUMBUS, OH
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Overhead racks were designed and built to
handle all MEP services, including space for
future needs. These racks were assembled on
the warehouse floor using a “Trimble” GPS tool
with coordinates extracted from the BIM model.
The MEP racks included the adjacent head of wall
assemblies (metal studs insulation and gyp. board)
including the fire caulked penetrations of services
extending beyond the racks. Work was done at
“bench height”, eliminating the need to use lifts
or ladders. The manufacturing process also
included the construction of 224 patient
bathroom “pods”, and 224 patient headwalls.
The prefabricated pods were constructed as
five-sided units, complete with all wall & ceiling
framing, in-wall/above-ceiling utilities and drywall
hung on the interior side. This helped to stabilize
the pods for loading, shipping and handling. The
headwalls were also fabricated in a similar fashion,
with an emphasis on the in-wall utilities. Metrics
were collected on the labor efficiencies, schedule
improvement and reduction of waste.
OHIO HEALTH NEUROSCIENCE INSTITUTE
AT RIVERSIDE METHODIST HOSPITAL
COLUMBUS, OH
Cost and constructability information was conveyed
to the designers on a real time basis during the
course of the design, eliminating waste and
creating responsible, buildable documents.
Time - by employing an off-site pre-fabrication
strategy the WT-CK design-build team was able
pull key construction activities off of the project's
critical path. The primary patient floor above ceiling
MEPT services (racks) were built concurrently with
and/or ahead of the Patient Tower superstructure
construction. The pre-fabricated racks were then
installed, as a finished product, as soon as the
structure would allow, completing approx. 60% of
the above ceiling work with in a 2-3 day time frame.
The same concepts / principles held true for the
Patient Room "bathroom pods" and headwalls.
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Efficiency - the pre-fabricated racks were built using
the same 10-12 man composite crew through the
course of the project, compared to a 16-20 man
crew required for a similar field installation.
Additionally, the entire above ceiling
OHIO HEALTH NEUROSCIENCE INSTITUTE
AT RIVERSIDE METHODIST HOSPITAL
COLUMBUS, OH
rack pre-fabrication effort (1,680 LF of 16' wide racks)
generated less than a 30 cubic yard dumpster's worth
of waste.
Quality - The layout and engineering of the rack
structure and services created an inherent
organization of systems and consistency of both
services and equipment locations. This creates an
improved serviceability for the owner's routine
maintenance in the future. All piping systems
were tested prior to shipment to the mitigate any
leakage issues in advance. All headwall components
were constructed then checked
(at the shop prior to shipment) and double checked
(in the field after installation) with the templates to
ensure an exact fit with the finished architectural
headwall panels.
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Safety - All of the pre-fabrication elements were
constructed in a controlled environment at "bench
height" in lieu of overhead lifts and ladders which has
contributed to the project's low lost time accidents
(30% less than the industry average for projects of
this similar size and duration).
HOSPITALITY
GRAND FLORIDIAN RESORT & SPA
LAKE BUENA VISTA, FL
The new hospitality development at Disney’s
Grand Floridian Resort & Spa expands on the
flagship hotel at the Walt Disney World Resort,
and continues the growth of the Disney Vacation
Club. The resort includes 147 villas, and is located
near the spa and wedding pavilion, adjacent to the
monorail and the existing resort. This lake front
resort also includes enhancements to the resort
pools, children’s water-play area and many
other resort amenities.
The entire renovation happened while the resort
was operational with the monorail delivering guests
to the Magic Kingdom through the jobsite every five
to ten minutes. This required innovative techniques
like VDC coordination, enhanced model-based
site logistics and fully embracing multi-trade
prefabrication and off-site modular strategies.
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GRAND FLORIDIAN RESORT & SPA
LAKE BUENA VISTA, FL
The project team embraced the BIM tools
to analyze many opportunities to enhance
the schedule and reduce on-site labor while
maintaining the highest quality required for a
project of this magnitude. We empowered a team
of design-assist subcontractors to prefabricate
the guest bathrooms for the 92 master villas.
The team collaborated to design the assembly into
three modular components. They were built in an
off-site warehouse designed by Whiting-Turner.
The “pods” were fully framed with sheet rock and
all of the mechanical, electrical, plumbing, and fire
protection systems were installed in the warehouse.
This controlled environment enhanced the quality
of the installation and was much more efficient than
traditional “stick-built” techniques. Once the pods
were complete and inspected for quality control,
they were shrink wrapped, loaded on a truck, and
delivered to the jobsite. The assemblies were
loaded onto a custom rigging platform and
installed in the building.
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GRAND FLORIDIAN RESORT & SPA
LAKE BUENA VISTA, FL
Team collaboration and the use of the BIM tools
resulted in other prefabrication opportunities.
All of the main mechanical distribution for the
project was located in the attic space of the roof.
It was assembled on large racks, delivered to
the jobsite straight from the shop, and lifted into
place before the roof trusses were installed.
This installation resulted in reduced labor on the
jobsite and schedule reductions. In addition, all
of the MEP systems, exterior framing and skin
on the 45’ tall cupola were installed on the ground,
before lifting the crown onto the new resort over
150 feet in the air.
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GRAND FLORIDIAN RESORT & SPA
LAKE BUENA VISTA, FL
Embracing multi-trade prefabrication on this project
accelerated the construction schedule, improved
quality, and eliminated waste from many of the
traditional challenges of a hospitality project. Using
BIM and LEAN manufacturing technologies,
Whiting-Turner was able to design and build a
beautiful addition to Walt Disney World’s flagship
property with limited interruptions to the guests
and operations staff.
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