Technical Assignment 3 - Pennsylvania State University€¦ · For the excavation of the LSM building, the building perimeter was excavated roughly 24 feet below finish grade. The

Technical Assignment #3

Alternate System and Methods Analysis

Aaron Trout HGS – Large Scale Manufacturing Facility

November 15, 2004

Aaron Trout Senior Thesis 2004 Construction Management

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Table of Contents Alternate System and Methods Analysis ........................................................................- 3 -

1. Executive Summary ............................................................................................- 3 - 2. Site Layout Planning...........................................................................................- 4 -

2.1. Description of Key Features .......................................................................- 4 - 2.2. Site Plans.....................................................................................................- 5 -

3. Temporary Utilities.............................................................................................- 8 - 4. Detailed Systems Estimate................................................................................- 10 -

4.1. Description / Assumptions........................................................................- 10 - 4.2. Detailed Estimate ......................................................................................- 11 -

5. General Conditions Estimate ............................................................................- 15 - 6. Research and Analysis Methods .......................................................................- 17 -

6.1. Research....................................................................................................- 17 - 6.2. Building System Analysis.........................................................................- 19 -

Appendix...................................................................................................................- 20 - A. Detailed Estimate Takeoff ............................................................................- 20 -


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Alternate System and Methods Analysis

1. Executive Summary This technical assignment will provide a greater understanding of the Large

Scale Manufacturing Facilities building systems and related construction costs. Site Layout Planning, Temporary Utilities, a Detailed Estimate of the superstructure, a General Conditions Estimate, and Research and Analysis Methods will be described in greater detail throughout this assignment.

For the site layout, three separate site plans were developed. An excavation, superstructure, and finishes site plan were all developed for these phases of construction. The site plans all depict the building and the project site with equipment, activities, and flow of work for that specific phase of construction.

One of the first things that must be completed on any project is an analysis of the temporary utilities needed for the erection of the superstructure. The temporary utilities are divided up into requirements for electric, water, staging, lighting, and heating. For each of these there are certain actions and processes that need to be developed and implemented.

In order to better understand the structural system of the LSM project a detailed estimate must be performed. This entailed completing a takeoff of all the materials required to erect the structure and assigning unit costs for the materials and labor required to erect each item. The superstructure consists of spread footings, a slab on grade, slabs on deck, concrete and steel columns, concrete and steel beams, and metal decking.

All projects are required to have a General Conditions estimate. This estimate shows the unit costs of actually starting the project and running it. Some of the primary constituents of the estimate are staffing, equipment rental, safety supplies, and temporary utilities.

As thesis progresses, research on current industry issues and analyzing a building system for the LSM project will become a main focus. Due to the increasing prices of steel there needs to a way to offset this cost. One possible solution is to have a steel fabricator help out with the design of the project, possible eliminating coordination issues and providing ideas for value engineering. Another topic for research is related to incentive programs on job sites. These programs can help provide safer jobsites as well as help projects run more smoothly and meet deadlines. For an analysis on building systems, by possibly changing the steel members in the LSM facility to concrete a major cost savings could be obtained. By also determining the cost of changing the cellar columns and beams to steel, a greater cost loss or saving could be determined. These topics will be researched and developed as more research is performed on the LSM Facility.


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2. Site Layout Planning

2.1. Description of Key Features Excavation Site Plan

For the excavation of the LSM building, the building perimeter was excavated roughly 24 feet below finish grade. The sides of the excavation pit were sloped according to OSHA standards for soil retention, and a temporary fence was placed around the pit. The access roads only encroach the site a little due to the extensive amount of traffic. There are two temporary stockpiles located on the western and eastern sections of the site which are used to store dirt that will be used as fill. There are three ramps which dump trucks can enter the pit and collect dirt to be hauled off site. The excavation proceeded in a northern direction. There was no excavation site plan provided by Gilbane to compare to.

Superstructure Site Plan For construction of the superstructure, concrete pump trucks were used to pour the slab on grade and the cellar walls. The trucks were located in the areas where the cranes are shown on the drawing. These were not shown in order to eliminate confusion on the drawing. Three cranes were utilized to install the structural steel. Two 400 ton crawler cranes were used to install the majority of the structural members on both ends of the building. The crane on the western side of the building was later moved to the eastern side of the building to assist the other crane. A 200 ton truck crane was used to complete the western side of the building. There are two steel storage/lay down areas located on the eastern and western sides of the building. If required there was an extra material storage area on the northern end of the site for steel. The steel was installed in the southern end of the building first and then moved towards the north. There was no excavation site plan provided by Gilbane to compare to.

Finishes Site Plan The finishes plan was difficult to depict in a general site plan for the building. Each floor was laid out in a specific manner to meet the floors extents and demands. The general flow of finish work flowed in a northern direction. Most of the materials are brought into the building from the southern entrances. Large deliveries that contain materials to service the northern end of the building are delivered to the northern end of the building on the loading dock. Also scaffolding was placed on the eastern side of the building to deliver heavy materials and equipment to the first and second floors. Materials are placed throughout the building where space is available. There were no specific storage places inside the building; many times these materials needed to be moved for the flooring contractor and still will need to be moved at a later time. There was no excavation site plan provided by Gilbane to compare to.


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2.2. Site Plans


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3. Temporary Utilities Electric

Prior to the site receiving temporary electrical service energized and fed throughout the building, all field operations were powered by small generators. The generators were moved from location to location as work was required. Once the temporary electrical service was set up, 1220 amps at 480 volts was used for all on-site operations except for the tower crane. The tower crane was powered by a large generator that was capable of providing 400 amps at 480 volts.

Water

The water supply system was split up into two phases. Prior to completion of the permanent water supply system to the building, phase one of temporary water was obtained by renting a water meter from Washington Suburban Sanitary Commission and using a fire hydrant in the nearby street. This was fed into a manifold at the edge of the jobsite that allowed for several size hoses to be run for various building operations. A heat trace was required during the winter months to prevent freezing. Phase two of temporary water occurred when permanent water was available to a fire hydrant located on the east side of the site. A temporary 2in. water line was installed to the hydrant under the paved parking lot and ran up to the cooling tower roof area on level one of the building. A new manifold was installed there allowing several hose connections of various sized to be made. This new location proved to be more convenient for all of the trades, and when any leaks occurred the excess water would drain into the cooling tower roof drains. A heat trace was also used at this location during the winter months to prevent freezing.

Staging In order to provide clan lay down areas for materials and staging, gravel was placed on site in specific locations. Gilbane was required to do constant coordination between the trades to prevent subcontractors from delivering too much material to site prior to needing it. This was important because there was very little lay down areas on the site.

Lighting

Initial site lighting was located on the tower crane which was powered by the generator for the crane. As construction of the building progressed temporary lighting was fed by the crane’s generator. This continued until the permanent temporary power was available in the cellar. At that time all interior lighting was switched over to incandescent lights powered by the temporary electrical service which were hung throughout the building.


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Heating Temporary heat was provided in two separate ways. During the first winter while concrete was being poured, heat was provided to the building by propane gas. The gas was stored in a bulk tank outside the building which held roughly 10,000 gallons. Gas was then distributed into the building by the use of steel piping, and heat was generated by unit heaters that could be moved around as required. The last 100ft. to the unit heaters was flexible hose. This winter, Gilbane plans on using natural gas which will be delivered to the site through the permanent gas line from Washington Gas. The mechanical contractor installed four taps immediately outside the building structure. These taps will feed four heaters which will be located around the building. The heaters will flow forced hot air into the structure through temporary ductwork.

Ventilation No provisions were made on the site. Cooling No provisions were made on the site.


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4. Detailed Systems Estimate

4.1. Description / Assumptions

Description The charts displayed on the following pages show a detailed estimate of the Large Scale Manufacturing Facilities superstructure. In order to develop the estimate, the 2004 R.S. Means Cost Works program was used to acquire unit costs for materials used in constructing the LSM Facility. The detailed estimate includes concrete spread footings, cast in place cellar walls, a slab on grade, two slabs on deck, elevated slabs, concrete and steel columns, concrete and steel beams, and metal decking. A location factor was also used so that appropriate unit costs could be obtained for material, equipment, and labor costs. Rockville, MD was not listed in the database; College Park, MD which is the closest location to Rockville, MD was selected. All take-off are located at the end of this technical report in the appendix.

Assumptions

- Since actual location was not listed a location that closely resembled market costs was used

- If items were not specified exactly in the Unit Costs, an alternative was chosen that would closely resemble the specified product

- For beams and columns that were not listed in the Unit Costs, the correct value was interpolated from given costs

- If correct dimensions were not listed, alterations to total unit cost or quantity were made to make up the difference

- Due to the large size of the building and varying beam layouts, a common layout was devised between two column lines and copied in the east-west direction. (For example if between column lines J and K there are multiple W24x55 beams and a few W21x62 beams, the assumption was made that all of the beams are W24x55)

- Not all beams and girders were taken into account, only large structural members were included in the estimate.

- For all concrete columns, reinforcement was considered to be average - Structural steel for pipe racks was not taken into account


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4.2. Detailed Estimate


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5. General Conditions Estimate


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* As per Gilbane’s request, all items listed on this General Conditions estimate are not exact values. These durations and unit costs were acquired from ICE 2000 estimating software and knowledge of the LSM project.


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6. Research and Analysis Methods

6.1. Research

There are currently two separate topics which I am considering researching as my thesis progresses. The first deals with the involvement of steel Fabricators in the early stages of a project; primarily in Design-Build projects. The other topic which I am considering is the use of incentive programs by Clients, Construction Managers/General Contractors, and Subcontractors in the construction industry. I feel that both of these topics are issues that are affecting the construction industry now and will continue into the future.

Steel Fabricators

Problem An apparent issue in the construction industry is the inflating cost of

steel. This affects all contractors and clients throughout the nation by increasing project costs and making bidding much more competitive. One possible solution to reduce this cost could be to have a steel fabricator join the project team during the design phases. I have recently started to perform research for a professor at The Pennsylvania State University that deals with this topic.

Goal My goal for this research topic is to determine what if any benefits can

be obtained by having a steel fabricator involved in a project early. This includes at what time a fabricator should be brought on and what the fabricator should be involved with. By bringing a fabricator on early, many coordination issues can be resolved early as well as help with any Value Engineering that might be applied to a building.

My research is directed towards construction managers and general contractors. It is also important for owners/clients to be knowledgeable of my findings. This will benefit both the fabricator and the owner. If the fabricator is able to help with value engineering and coordination there is a better chance that fabricator will be hired as well as be able to make a better profit on the job. The owner can benefit by direct cost savings and with projects that have a tight schedule this will help the project by being completed on time by the coordination efforts of the fabricator.

Research Steps & Sources of Information In order to obtain information for my research I plan on sending out

surveys to fabricators around the nation. From this I hope to get a better understanding of what work they actually perform on Design-Build projects. I have not yet refined what type of information I am exactly looking for, so I am still in the process of developing a schematic survey.


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Incentive Programs Problem Incentive programs are not an issue affecting the construction the

industry, rather a technique used to provide safer and more productive construction sites. More and more owners and companies are applying incentive programs to their projects and are receiving positive outcomes.

Goal My goal is to determine what types of incentive programs are the most

beneficial. Along with this, there has to be reasonable goals set so that these milestones or requirements can be met. I feel that is a general incentive program can be established many construction jobs will no longer have issues with safety and meeting milestone and completion dates.

This research will be directed towards all entities within the construction industry. Everyone can have the opportunity to benefit from incentive programs. The owner can benefit by having certain milestones met that typically unrealistic or difficult to obtain. Construction Managers and General Contractors can benefit in multiple ways; schedules can be met, safety records can be kept high, and their relationships with subcontractors can be strengthened. Subcontractors can benefit by getting work done in time hence getting paid, receiving incentives (i.e. money or gifts), and also creating a good image for the company.

Research Steps & Sources of Information In order to obtain information for my research, I plan on speaking with

industry members that I have had contact with the past few years. I would like to actually visit these companies and set up an interview to obtain information. Sending out a survey will most likely be my first action to get some general feedback on incentive programs. Some questions that I will pose to industry members are:

All: - Have you ever used an incentive program or been on a project that

has used one? - Has the incentive program been beneficial, and in what way?

Owner/CM/GC: - Have you received incentives yourself from the owner? - Have you received repeat work from these programs?

Subcontractors: - Have you ever received an incentive on a job? - Have incentive programs made your productivity increase? - Do you feel that incentives for safe jobsites are necessary?

These are just some basic preliminary questions that I feel will provide a good starting point for my research.


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6.2. Building System Analysis

I intend on analyzing the structural system of the LSM Facility. The structural system consists of both steel and concrete members due to value engineering that was performed on the building. The building was initially designed to be an all concrete structure, but the first and second floor members were changed to structural steel.

Initially when Gilbane and HGS decided to make this change, it reduced to total cost of the project. Recently the prices of steel increased greatly, and this could have had a negative impact on the project cost. I plan on performing two separate analyses on the building’s structural system.

The first will be changing the cellar columns and first floor beams to structural steel. By doing this I will be able to determine if they could have saved more money by changing the system to steal, or if they would have lost money due to the increasing steel prices. The second analysis will be changing all of the structural steel members to concrete. By doing this I will be able to determine if HGS actually did have cost savings or if they lost money due to the increased steel prices.

From my research I will also be able to apply the fabrication theory to this building system analysis and possibly forecast how much could have been saved by bringing the steel fabricator in at the appropriate time.


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Appendix

A. Detailed Estimate Takeoff

Spread Footings (4000psi) Type Size (ft) CY Number Total CY

F1 14.5 14.5 3.5 27 7 191 F2 14 14 3.5 25 20 508 F3 13.6 13.5 3.33 23 9 204 F4 13 13 3 19 14 263 F6 12.5 12.5 3 17 10 174 F7 12 12 3 16 19 304 F8 11.5 11.5 2.5 12 4 49 F9 11 11 2.5 11 9 101 F10 10.5 10.5 2.5 10 9 92 F11 10 10 2.5 9 10 93 F12 9 9 2.5 8 21 158 F13 8 8 2.5 6 11 65 F14 7 7 2.5 5 11 50 F15 10 10 3 11 2 22 F16 6 6 2.5 3 1 3

Total: 203 157 2276

Slab On Grade (4000 psi)

Location Area (sf) Thickness (ft) CY Sector 1 14506 0.667 358 Sector 2 24020 0.667 593 Sector 3 23828 0.667 589 Sector 4 23667 0.667 585 Sector 5 18172 0.667 449

Total: 104193 2574

First Floor Slab on Deck (5000 psi)

Location Area (sf) Thickness (ft) CY Sector 1 14506 1.667 896 Sector 2 24020 1.667 1483Sector 3 23828 1.667 1471Sector 4 23667 1.667 1461Sector 5 18172 1.667 1122

Total: 104193 6433


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Second Floor Slab on Deck (4000 psi)Location Area (sf) Thickness (ft) CY Sector 1 14506 0.5 269 Sector 2 24020 0.5 445 Sector 3 23828 0.5 441 Sector 4 23667 0.5 438 Sector 5 18172 0.5 337

Total: 104193 1930

Elevated Slabs

Length Width Height CY Number Total CY Cellar

18.5 11.58 0.917 7.3 5 36.4 17.5 7.5 0.417 2.0 3 6.1 21.25 5.67 0.417 1.9 1 1.9

6.5 3.17 0.417 0.3 8 2.5 10.67 6 0.417 1.0 1 1.0 4.67 1.83 0.417 0.1 3 0.4 11.6 3.5 0.417 0.6 3 1.9

6 6 0.417 0.6 3 1.7 12 7 0.417 1.3 1 1.3 9 4.5 0.417 0.6 3 1.9

41.33 9.67 0.333 4.9 1 4.9 17 6.92 0.333 1.5 2 2.9

42.67 10 0.333 5.3 1 5.3 15.83 9.33 0.333 1.8 1 1.8

First Floor 22 14 0.417 4.8 1 4.8 24 14 0.417 5.2 2 10.4 26 14 0.417 5.6 3 16.9 30 14 0.417 6.5 2 13.0 32 14 0.417 6.9 2 13.8 36 14 0.417 7.8 1 7.8

Second Floor 24 14 0.417 5.2 2 10.4 30 14 0.417 6.5 1 6.5 34 14 0.417 7.4 2 14.7 36 14 0.417 7.8 1 7.8 40 14 0.417 8.6 2 17.3

Metal Decking

Location Type Area Second

Floor 1-5/16" Form Deck 104193Roof 1-1/2" Metal Deck 104193


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Cellar Walls (4000 psi)

Location Length

(ft) Height

(ft) Thickness

(ft) CY North Elevation 304 20.33 1.5 343 East Elevation 405 20.33 1.5 457 West Elevation 405 20.33 1.5 457 South Elevation 304 20.33 1.5 343

Total: 1602

Cellar Columns (5000 psi)

Size Area (ft) Height (ft) CY Number Total CY 36" x 30" 7.5 22 6 3 18 30" x 36" 7.5 22 6 1 6 30" x 30" 6.25 22 5 76 387 30" x 24" 5 22 4 16 65 30" x 18" 3.75 22 3 4 12 24" x 30" 5 22 4 2 8 24" x 24" 4 22 3 36 117 18" x 36" 4.5 22 4 1 4 18" x 30" 3.75 22 3 6 18 18" x 18" 2.25 22 2 4 7

Total: 40 149 644

First Floor Columns

Size Length (ft) Number Total LF W 14 x 90 26 44 1144 W 14 x 99 26 9 234

W 14 x 109 26 7 182 W 14 x 120 26 9 234 W 14 x 132 26 5 130 W 14 x 145 26 19 494 W 14 x 159 26 10 260 W 14 x 176 26 6 156 W 14 x 193 26 6 156 W 14 x 211 26 1 26


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Second Floor Columns

Size Length (ft) NumberTotal

LF W 14 x 48 12 12 144 W 14 x 61 12 16 192 W 14 x 61 20 20 400 W 14 x 90 20 66 1320

W 14 x 145 20 1 20

First Floor Beams (4000psi) Type Size Length (ft) Number Total LF 1B1 18 x 24 13 1 13 1B2 24 x 27 30 1 30 1B3 24 x 38 30 1 30 1B4 27 x 40 32 1 32 1B5 27 x 40 32 1 32 1B6 24 x 38 21 1 21 1B7 27 x 60 30 1 30 1B8 20 x 40 32 1 32 1B9 18 x 24 9 1 9 1B10 24 x 27 34 1 34 1B11 30 x 30 30 1 30 1B12 27 x 27 34 1 34 1B13 27 x 30 30 1 30 1B14 12 x 24 10 1 10 1B15 12 x 24 22 1 22 1B16 12 x 24 12 1 12 1B17 24 x 27 30 1 30 1B18 24 x 27 30 1 30 1B19 30 x 27 30 1 30 1B20 30 x 27 30 1 30 1B21 20 x 30 36 1 36 1B22 24 x 30 36 1 36 1B23 24 x 30 36 1 36 1B24 24 x 38 18.5 1 19 1B25 18 x 28 13 1 13 1B26 24 x 27 30 1 30 1B27 24 x 38 30 2 60 1B28 27 x 40 32 1 32 1B29 18 x 24 28 1 28 1B30 27 x 27 35 2 70 1B31 18 x 30 30 1 30 1B32 27 x 30 31 1 31 1B33 12 x 18 14.5 1 15 1B34 12 x 18 12 2 24 1B35 18 x 24 28 2 56 1B36 18 x 24 12 2 24


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Second Floor Beams Roof Beams Sector 1 Sector 1

Size Length

(ft) Number Total

LF Size Length

(ft) Number Total

LF W 10 x 22 15.5 23 357 W 12 x 14 21 9 189 W 10 x 26 15.5 24 372 W 12 x 150 32 6 192 W 16 x 40 14.5 8 116 W 18 x 10 14.5 5 72.5 W 18 x 46 14.5 2 29 W 18 x 10 15.5 32 496 W 24 x 62 40.5 3 122 W 18 x 18 14.5 2 29 W 24 x 68 40.5 16 648 W 18 x 35 40.5 69 2795 W 27 x 84 40.5 24 972 W 18 x 40 41 13 533 W 30 x 99 45.5 17 774 W 21 x 44 42.5 24 1020 W 33 x 118 32 6 192 W 24 x 55 52.5 5 263 W 36 x 150 40.5 7 284 W 24 x 62 32 13 416 W 36 x 160 32 17 544 W 27 x 84 32 10 320 W 36 x 194 32 11 352 Sector 2

Sector 2 W 8 x10 15.5 18 279 W 12 x 19 15.5 15 233 W 12 x 14 21 19 399 W 16 x 26 21 13 273 W 18 x 35 32 3 96 W 24 x 76 40.5 30 1215 W 18 x 35 40.5 36 1458 W 27 x 84 32 3 96 W 18 x 40 43 18 774 W 27 x 84 43 15 645 W 24 x 62 32 9 288 W 33 x 130 32 9 288 W 27 x 84 32 6 192 W 36 x 160 32 6 192 Sector 3

Sector 3 W 16 x 26 33.5 37 1240 W 24 x 55 38 70 2660 W 16 x 31 37 37 1369 W 24 x 62 37 30 1110 W 18 x 35 37 41 1517 W 24 x 62 33.5 30 1005 W 18 x 35 38 43 1634 W 30 x 99 32 19 608 W 21 x 44 43 37 1591 W 30 x 99 43 31 1333 W 21 x 50 32 13 416 W 33 x 130 32 7 224 W 21 x 62 32 7 224 W 36 x 160 32 6 192 W 24 x 68 32 6 192 W 36 x 210 32 6 192 W 24 x 76 32 13 416

Sector 4 Sector 4 W 24 x 55 33.5 15 503 W 16 x 31 37 18 666 W 24 x 62 37 15 555 W 16 x 36 33.5 18 603 W 27 x 84 45.5 15 683 W 21 x 44 45.5 18 819 W 33 x 141 32 3 96 W 24 x 68 32 3 96 W 36 x 150 32 3 96 W 24 x 76 32 3 96


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Documents

Technical Assignment 3 - Pennsylvania State University€¦ · For the excavation of the LSM building, the building perimeter was excavated roughly 24 feet below finish grade. The