The project involved work to an existing 162,000-sq.-ft., single-story warehouse and office building in an LI zone to consolidate two existing facilities that at the time of the project were located out of state. The building houses research and development, laboratory, microscopy, offices and support spaces focused on the metal casting and fabrication business. The project included (2) air cooled chillers, pre-action and a clean agent fire protection system. Specialized requirements included a warehouse housing manufacturing and testing equipment.
The scope required a total of (17) new fume hoods, oxygen and nitrogen piping at the lab benches. Some of the labs are ISO 17025 certified. Much of the equipment, including a pilot beverage can production line, was relocated from existing remote facilities out of state. This required many trips and careful coordination of the highly specialized equipment. Unique utility requirements are duplicated in the new facility. A majority of the equipment required substantial MEP infrastructure and significant base building modifications such as structural enhancement for overhead equipment, mechanical systems and roof top equipment.
Since the schedule was tight, DPR strongly emphasized the benefits of prefabrication of the key elements and subcontractor trades.
For example, the electricians had their junction boxes prefabricated with conduit sticking above the ceiling in order to better coordinate with other MEP systems above the ceiling.
Additionally, the mechanical subcontractor prefabricated the spool pieces for the chilled water lines for easier, faster and more accurate installation.
Electricians ran the MC cables for the temporary lighting in such a way that permanent light fixtures could be installed using those same cables, which saved a significant amount of time towards the finishing stage since those cables were already in place. These lean construction methods helped to achieve the goal of staying on schedule and on budget.
The entire team participated in the BIM coordination meetings and OurPlan scheduling meeting. OurPlan breaks each individual activity into day-to-day tasks and takes the input from field foreman and makes them accountable to the completion of these tasks. Every morning the team got together for 30 minutes to go over the tasks and update their status and the reasoning behind any task incompletions. This allowed the schedule to be managed at a micro level and ensured that all tasks were completed.
DPR Construction contributes to the bottom line of the client and the community by working with high quality subcontractors and involving all team members in the construction process. By enlisting the expertise of knowledgeable subcontractors, DPR builds relationships, shares knowledge and develops Best Practices for the industry. Owners are included in these Best Practices so they can further perpetuate the principles of Lean Construction and the benefits of BIM, prefabrication and other team coordination plans.