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Aultman Hospital

19.07.2014 in

Project Overview:

EAS was contracted to design, construct and install a 14,000 SF mechanical penthouse with Central Utility plant and Air Handling units at Aultman Hospital in Canton, Ohio. To control overall project schedule and cost, the Owner, Construction Manager and the Architect decided to have the new mechanical penthouse constructed off-site at the EAS plant. The penthouse was designed, constructed, tested, dismantled and shipped to the final location in 40 bottom sections and 36 top, or “hat”, sections.

Project Highlights:

  • Nominal 455,000 CFM System was approximately 14,000 SF in footprint and 16’ high
  • EAS was informed that this construction method saved the hospital 3 to 4 months on their construction schedule
  • Estimated field construction man-hours required for the project: 120,000
  • Actual man-hours expended by EAS for off site construction and installation: 59,897
Technical Details:

When it comes to ensuring safe working practices on the job, no firm is more committed to safety than EAS. The company’s Experience Modification Rate (EMR) is one of the lowest in the industry. EAS requires its Field Superintendants to complete an OSHA 30-hour Outreach Training Course for Construction, and to receive the National Safety Council Standard First Aid with AED training. In addition, EAS requires each of its Foremen complete an OSHA 10-hour Outreach Training Course for Construction. All other employees must complete 8 hours of High Intensity Training for Safety (HITS) in addition to any Safety Orientation required for a specific project. EAS employs the 5 x 5 program, where each employee takes 5 steps back and surveys his/her work area for 5 seconds to determine if any unsafe conditions are present before beginning work. Each EAS employee is drug tested regularly and receives safety training before beginning any work.

Duke Eye Center

19.07.2014 in

Project Overview:

EAS was contracted to provide design assistance, off-site construction, shut down planning and installation for new penthouses to replace existing penthouses.

EAS was responsible for complete demolition of the existing penthouse and the “gutting” of another penthouse. Total shutdown was for a period of five (5) days over two weekends. The speed of this project could only have been achieved through an EAS Off Site Construction (OSC) approach. A traditional design-bid-construct contract method would have added substantial project cost and trade coordination issues.
Duke’s original plan was for 60 to 90 days of construction — EAS reduced that timeframe to two weekend shut downs.

Project Highlights:

  • 80,000 CFM System measuring approximately 66’ x 38’ x 12’ high
  • EAS had the task of removing one penthouse, with AHU’s that were installed in 1974 before installation of the new EAS penthouse could start
  • First shutdown commenced about 6:00 PM on a Friday afternoon
  • System start up took place about 6:00 PM on the following Sunday afternoon
  • Second weekend shutdown was for 2 days to demolish the AHU’s in a second penthouse that EAS took out of service from the first shutdown
  • During the first weekend shutdown, ductwork from the new EAS penthouse ran to the second penthouse to keep it operational
  • The job required two (2) 12-hour shifts per day, comprised of 32 men per shift
  • The second penthouse was skinned to the match the new penthouse leaving Duke with a 50’ x 30’ storage building for filters, etc.
  • EAS worked in a design/assist role with IES Engineers, the Consulting Engineer, and RND Architects, the Architectural Consultant
  • EAS provided phasing coordination, feasibility studies and budget development
  • Down time was limited due to good planning, coordination and communication
Technical Details:

EAS was contracted to design, construct off-site and install this Penthouse, with the major features listed below. These Penthouse components were installed, wired and / or-piped in the EAS plant

Hot Deck / Cold Deck Design to match existing HVAC Scheme

80,000 CFM Cold Deck Supply, using two (2) 75 HP Greenheck 44-QEP-3-III Supply Plenum Fans

58,000 CFM Hot Deck using (1) 100 HP Greenheck 44-QEP-3-III Supply Plenum Fans

Two (2) Return / Relief Air Fans at 36,000 CFM each, Greenheck Model 40-QEP-3-II Plenum Fans

One (1) Greenheck Model QE1-15-1 Vertical Exhaust Fan

Cutler Hammer Variable Frequency Drives

Ruskin Louvers

Heatcraft Cooling and Reheat Coil banks, 304 Stainless Steel

Tamco Relief Air, Return, Bypass, Return Air and Outside Air Dampers

Pre, Intermediate and Final Filters Sections

Schedule 40 chilled water and hot water piping systems with valves and accessories. At the shipping splits, there are flanged or grooved connections for the hot water and chilled water piping

Piping fiberglass insulation with canvass jacketing

Plumbing and floor drains

Fluorescent lighting system, Lithonia marine-type fixtures

BMS Control System – Factory Installed Site Controls contractor (Yamas) madethe tie-ins to the building BMS

Two (2) inch foam core panel system (R-value of 15.8) with extruded aluminum
no-through metal framing

W12 x 22-painted steel base

3 / 16” aluminum checkered plate flooring throughout penthouse

Return air and supply air chases connected to existing roof openings

Newark Arena

19.07.2014 in

Project Overview:

The arena is an 18,000-seat multi-purpose facility in Newark, New Jersey. The arena is home to the National Hockey League and a Major Indoor Soccer League. The arena was designed by HOK Sport and its construction was managed by Gilbane Building Company. EAS Off Site Construction was contracted to construct the penthouse for the arena. The construction of the penthouse occurred concurrently with arena construction schedule. The EAS Scope of Work was to provide all the layout, coordination and manufacturing of the entire penthouse in the High Point, North Carolina fabrication plant.

Technical Details:

EAS was contracted to provide this penthouse with the major features listed below. This penthouse is just over 6,100 square feet in size and all items listed were preinstalled, pre-wired and or pre-piped, as applicable, in the EAS plant:

Four (4) 900-Ton York Centrifugal Chillers
Four (4) 1000-Ton Baltimore Air Coil Cooling Towers (mount on penthouse
roof)
Four (4) Cleavor Brooks 10,000 MBH Boilers
Primary, secondary and condenser water pumps up to 150 HP
Bell & Gossett Heat Exchanger
Rolairtrol Air Separators
Chiller plant auxiliary equipment including surge tank, expansion tank, Wessel glycol make-up package, chemical treatment system
The Motor Control Center
ABB VFD Drives
Schedule 40 chilled water, up to 18” diameter, and hot water piping systems with valves and accessories. At the shipping splits, there will be flanged connections for the hot water piping and Victaulic connections for the chilled and condenser water piping.
Piping fiberglass insulation with PVC wrap
Plumbing and floor drains
150# Natural Gas Piping & accessories for boiler feeds
Space A/C AHU for chiller area
Hot water unit heaters for boiler area

Fluorescent lighting system
BMS Control System – Johnson Controls, Inc., with control wiring
2” foam core panel system (R-value of 15.8) with extruded aluminum no-through metal framing.

Bristol Myers Squibb

19.07.2014 in

Project Overview:

Nominal 84,000 CFM, 100% outside air system
Overall dimensions of 45’L x 75’ W x 9’ 7” H. and shipped in (12) sections
Penthouse system included unique supply and exhaust air control box installation

Project Highlights:

  • 100% of the reheat coil piping for the supply VAV boxes are located inside the penthouse. (This eliminates long runs of hot water piping throughout the building. Any potential future leaks are controlled and easily serviced in the penthouse.)
  • All supply and exhaust control box service, shut-off, repair, calibration, monitoring and observation are performed in the penthouse, not over classified space, and without access to critical environments
  • Heat recovery coil system in place, pre-piped, with recirculation pumps installed, wired and piped off site at the EAS plant
  • Once the penthouse was installed, architectural siding was added to match that of the building
Technical Details:

EAS was contracted to design, construct off-site and supervise the installation of this penthouse system, with the major features listed below. These system components were installed, wired and/or-piped off site in the EAS plant:

Four (4) Twin City 21,000 CFM, 60 HP, BC-SW 330. Class III Supply Air Fans

Four (4) Twin City 21,000 CFM, 50 HP, BC-SW 300, Class III, Return Air Fans

Eight (8) ECONO-flex Variable Frequency Drive, 4 @ 50 HP and 4 @ 60 HP, Type 12k enclosures

Heatcraft Cooling, Snow and Hot Water Heating Cools with copper tube, aluminum fins, 304 SS coil racks.

SS flashing &16 gauge SS intermediate drain pans

Camfill Farr 30% PreFilters , 85% Final Filters and HEPA filters

Bell & Gossett Pumps: Four (4) Snow coil pumps and two (2) cooling coil freeze protection pumps, Series 90

Two (2) heating coil pumps and one (1) heat recovery coil pump, Series 80 Ruskin CD 50, 60 and 120 control dampers

Four (4) Dri-Steem humidifiers, 2 are model US-LH-9 and 2 are model DM-7-60

Thirty-four (34) supply air volume control boxes, ranging from 5” diameter to 24×16 connections, with zone reheat coils, shutoff blast gate and test ports

Forty (40) exhaust air volume control boxes, ranging from 5” diameter to 16 x 24 connections, with shutoff blast gates

Schedule 40 chilled water and hot water piping with valve assemblies. Fiberglass insulation with jacketing

General space electric unit heaters

Lights within AHU sections and service vestibule are Lithonia Fluorescent lighting fixtures with low-temp electric ballast

Light switches with pilot lights and ground fault receptacles, 120 V, 20 each, all rigid aluminum conduit provided

Two (2) inch foam core panel system (R-value of 15.2) with extruded aluminum no-through metal framing, 0.050” smooth aluminum interior finish, 040 embossed aluminum exterior W 12 x 22 structural steel for base perimeter with C6 x 8.2 intermediate supports 3/16” aluminum checkered plate flooring throughout penthouse

Four (4) inch sprayed on polyurethane foam, 30.4 R-Value and 0.040” aluminum liner

Full sized access doors with 12’ x 12” double pane safety glass, Ventlok test ports, 3-point latching door mechanism

Floor Drains are 8” x 10” x 4” smooth aluminum with removable covers

Cleveland Clinic

19.07.2014 in

Project Overview:

EAS was contracted to construct, deliver and install (10) large-scale custom Air Handling Units for the hospital’s new Heart Center. (We are highlighting just AHU-9 in this case study.)

Project Highlights:

  • Nominal 110,000 CFM AHU System
  • Overall Dimensions: Lower Level: 57’ 10” x 33’ x 12’ 7” high. Upper Level: 32’ 6” x 31’ 8” x 8’ 8” high
  • The AHUs were constructed in eight (8) sections, four (4) lower and four (4) upper sections
  • All sections were shipped on EAS trucks, or under direct company supervision (EAS retains responsibility for the delivery and safe keeping of each section to the jobsite)
  • Lower level contains the outside air/return air mixing sections, pre-filters, carbon filters, humidifiers, cooling coils, sound attenuators (2 banks, before and after fans), supply fans and final filters
  • Upper level contains the relief air section, the return air fans and sound attenuators (2 banks, before and after the fans)
Technical Details:

Cleveland Clinic AHU-9 has the following major features:

Two (2) 56,911 CFM, 125 HP, Greenheck Model 49-QEP, Class III Plenum Supply Fans

Two (2) 51,487 CFM, 75 HP, Greenheck Model 44- QEP Class II Return Fans

Vibro-Acoustics Sound Attenuators, Model RFL-UVL-LF7 for the Supply and the Return

Two (2) DriSteem Maxi-Bank 8-60 humidifiers Tamco Outside Air, Intake Air, and Relief dampers; Series 1500 opposed blade, aluminum construction

Four (4) Ruskin fan inlet, isolation dampers Model CD-102, opposed blade, aluminum construction

Heatcraft cooling coils, Model 5WM1008B, and pre-heat coils, Model 8JA0701B, copper tubes, aluminum fins and SS casings

16 gauge 304 SS intermediate drain pan for cooling coils

Strionair Type Germicidal PreFilters, 95%

Flanders Vapor Clean Carbon Filters

Flanders Alpha-95, 95% Final Filters

Lighting using Lithonia Fluorescent 4-foot fixtures with low temperature start ballasts.

Steril-Aire UL lighting, Model DE Series UVC emitters

Hubbell light switches with pilot lights and ground fault receptacles, 120 V, 20 each, all rigid aluminum conduit

Two (2) inch foam core panel system (R-value of 15.8) with extruded no-through metal framing. Aluminum, 0.050” smooth interior finish and .040” textured aluminum exterior finish. no-through metal framing

W12 x 22 structural steel base for lower level and MC6 x 16.3 structural steel for upper level

Both bases with 4” of foam insulation (R-Value of 30) and with 0.063” aluminum skin

Full sized access doors with 12 x 12 double pane viewing windows

3/16” aluminum checkered plate flooring throughout penthouse

Floor Drains are 8” x 10” x 4” smooth aluminum with removable covers, each drain has all welded schedule 40 aluminum piping

Data Center – Confidential

19.07.2014 in

Project Overview:

EAS was the mechanical contractor for a new 135,000 square-foot build-out of data center and electronics lab space. EAS On Site mechanical contracting was contracted to provide the HVAC ductwork, piping and plumbing scope. The 5200-ton Chiller Plant was built by EAS Off-Site Construction and shipped to the project site and assembled by EAS.

Project Highlights

  • 80,000 SF of raised floor space
  • EAS Off Site Construction built the Chiller Plants with (4) 1,350-ton machines (3 Day One) in its High Point, NC plant
  • Order for the chiller plant was received the end of January. The Central Utility Plant shipped the last week of May, and began pushing chilled water by the second week of June
  • EAS coordinated with the MEP engineer on the design
  • EAS custom fabricated (17) nominal 75,000 CFM custom AHU’s for this project
  • EAS provided the mechanical mezzanine
  • The project was completed on an aggressive 9-month schedule

Technical Details:

EAS Off Site Construction built the Chiller Plants (3) 1300 Ton Chillers
Cooling tower platform built overhead with (3) Cooling Towers
(4) Primary C.W. Pumps, 40HP each, 2,222 GPM
(3) Secondary C.W. Pumps, 100 HP, 3333 GPM each
(3) Condenser Water Pumps, 60 HP, 2410 GPM each
Chemical treatment
Reverse Osmosis Machine and Atomizing Humidifier Pump Station
CEP walls & roof: 2” foam panel with Bone White finish; 12” structural base
Refrigerant evacuation system
Water storage tank
UV Sterilizer