Duke Eye Center


Durham, North Carolina


Off Site Construction – Penthouse Replacement

Off Site Manufacturing

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