technical assignment #1 existing construction conditions€¦ · power, storm drainage, site...

Technical Assignment #1

Existing Construction Conditions

Brian Nussbaum Abington Memorial Hospital

October 8, 2003

Brian Nussbaum Construction Management

Abington Memorial Hospital Abington, PA


October 8,2003Faculty Consultant: Dr. Horman

Table of Contents

A. Executive Summary

3

B. Project Delivery System

4

C. Project Schedule Summary

4

D. Project Cost Evaluation

5

E. Site Plan

8

F. Local Market Conditions

9

G. Subsurface / Soils

9

H. Client Information 9

i. Appendix 1: Organizational Chart 11

ii. Appendix 2: Project Schedule Summary 13

iii. Appendix 3: Site Plan Phase 1 15

iv Appendix 4 Site Plan Phase 2 17

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Brian Nussbaum

Abington Memorial Hospital Abington, PA Construction Management Primary Faculty Consultant: Dr Horman 10/8/03


A) Executive Summary The following existing construction conditions were performed for the Abington Memorial Hospital expansion. I was able to obtain a considerable amount of information about the project while I worked on the site with the construction management team. Through this information, as well as several correspondences with members of the management team, I was able to produce the existing construction conditions of this job. In further research, I hope to learn more about the established joint venture contract and value engineering ideas implemented, as well as the selection of the systems in the building. The organizational chart was created based on the contractual relationships of the primary parties involved with the construction of the hospital. This does not include all of the subcontractors or consultants used on the job. At the time this diagram was developed, there were several contracts that have not been awarded; therefore they are not included on the organizational chart. The summary of the construction schedule was created by selecting particular activities that are vital to the construction process. Included is a description of the foundation, structural, and finishes sequences. The total estimate for the building was compared to estimates created by D4 estimating software and R.S. Means, according to the specific building characteristics. The discrepancies between the resulting estimates and the actual budget are analyzed. The site plans were created from the actual site plans used on the site. The implemented site plan was composed of four phases, from June 1, 2002 to June 1, 2005. Included within is the site plan broken down into two phases. The original site plans incorporated phases for the construction of the parking garage, which is not included in this study. Local market conditions, subsurface conditions, and information on the owner are also included.

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B) Project Delivery System

The delivery system used on this project is a typical construction manager at-risk system. The owner of the project is the Abington Memorial Hospital. Robert D. Lynn and Associates act as the architect, but also have an electrical/mechanical engineering department. The structural engineering was done by outside consultants, A.W. Lookup and David Blackmore Associates. The construction management team is a joint venture between L.F. Driscoll and Intech Construction. The reasoning for the joint venture is described later in this report.

The Abington Memorial Hospital (AMH) holds one contract with the architect and another with the Joint Venture. The contract between the hospital and the Joint Venture is a guaranteed maximum price contract (GMP). The contract between the owner and the architect is also a GMP contract. The owner also holds a contract with a geotechnical engineer, as a result of poor soils conditions discovered during excavation, which will be discussed in further detail later in this report.

All contracts with the subcontractors are held by the Joint Venture and are all GMP contracts.

(Please see Appendix 1: Organizational Chart) C) Project Schedule Summary The foundation of the building could not be constructed until an extensive amount of excavation and site work was completed. In December of 2002, a bulk excavation was performed on the east side of the building. Lagging and tie-backs were installed to support the ground beneath the existing hospital. Excavation, lagging, and tie-backs were then performed on the west side of the building. Some waterproofing was performed in specified areas of the foundation. The poured concrete foundation sections were completed in succession along with the basement walls. This process took a total of 79 days to complete. The structural system of the building is composed of a steel frame with concrete slab on deck. Each framed floor is divided into derricks, each with around 100-120 pieces of steel. Dividing the steel frame into derricks successfully organized the steel delivery and erection. The steel was staged on the building frame itself. With each floor containing more than 50,000 square feet, there was sufficient room on the deck to stage the steel for the following derrick. The entire structural frame of the building is composed of 28 derricks. The average duration for an entire derrick to be erected was 6.5 days. The frame was scheduled to be plumbed, bolted, and welded by floor after the following floor had been erected. This meant that each floor was not prepared until two to three weeks after it was erected. The finishes and fit-out of the building had a total duration of 561 days. The studs and hollow metal walls were installed by floor, starting from the top of the building. Once completed, the drywall and ceilings were installed, followed by the remaining finishes. The durations of the studs, drywall & ceilings, and finishes are 40, 60, and 75 days per floor, respectively. The elevators are scheduled to take 175 days to install; therefore, the installation of the elevators will be occurring while the rest of the building is being finished. Once the finishes for the hospital addition are completed, the renovations of the existing hospital’s emergency room trauma center are completed. This has a total duration of 125 days and is the last activity of the overall project.

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(Please see Appendix 2: Project Schedule Summary) D) Project Cost Evaluation

* Note: The costs for this evaluation were taken from the original budget for the hospital

• Total Cost (TC)

o Building Construction $ 94,637,534 o Renovation Work $ 3,847,555

$ 98,485,089 • Square Footage

o Building Construction 360,260 sq ft o Renovation Work 29,300 sq ft

389,560 sq ft

• Actual Construction Cost (CC) $ 91,384,257

Not included in this total: demolition, site utilities, site lighting, site power, storm drainage, site improvements, landscaping, paving and surfacing, sheeting/underpinning, site preparation, earthwork

CC / sq ft

$ 91,384, 257

389,560 sq ft = $ 234.58 per sq ft

TC / sq ft

$ 98,485,089

389,560 sq ft = $ 252.81 per sq ft

• Major Building Systems Cost

o Mechanical $ 17,105,090 $ 43.91 / sq ft o Electrical $ 13,204,855 $ 33.90 / sq ft o Plumbing $ 5,933,395 $ 15.23 / sq ft o Fire Protection $ 1,446,925 $ 3.71 / sq ft o Elevators $ 1,175,000 $ 3.02 / sq ft

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D4 Cost Evaluation

D4 Estimate of Probable Cost Code Division Name % Sq. Cost Projected ============================================================ 00 Bidding Requirements 3.38 7.78 2,799,244 01 General Requirements 8.18 18.85 6,787,527 02 Site Work 5.65 13.01 4,682,893 03 Concrete 9.40 21.66 7,796,119 04 Masonry 3.28 7.54 2,716,004 05 Metals 7.21 16.62 5,981,955 06 Wood & Plastics 3.03 6.97 2,508,679 07 Thermal & Moisture Protection 3.03 6.97 2,509,881 08 Doors & Windows 5.55 12.78 4,600,890 09 Finishes 9.88 22.76 8,194,445 10 Specialties 1.14 2.63 945,501 11 Equipment 2.10 4.83 1,739,026 12 Furnishings 1.16 2.68 964,660 13 Special Construction 0.78 1.79 642,884 14 Conveying Systems 1.75 4.03 1,451,804 15 Mechanical 20.47 47.15 16,974,000 16 Electrical 14.03 32.31 11,631,600 ============================================================

Total Building Costs 100.00 230.3531

$82,927,112

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R.S. Means Estimate New Building Renovation

Step (Hospital, 4-8 story) (Hospital, 2-3 story) a. Square Footage 360260 29300 Cost per Square Foot $125.65/sqft $162.76/sqft Use $125.65 (300,000 sqft)

Interpolate between 25,000 and 40,000 sqft

b. Perimeter Correction 1028 N/A Use 1200 l.f. (300,000 sqft) (1200-1028) * $1.00/100 l.f. Deduct $1.72/sqft -c. Building Height Correction

Total Building Height (sum all floors) 80.5' N/A

R.S.Means (6 stories*12'/story) (6 stories*12'/story) = 72' 80.5' - 72' = 8.5' * $1.00/ft Correction Factor Add $8.5/sqft - d.

Basement Floor Area Correction 56570 sqft N/A

$23.05/sqft * 56570 sqft $1,303,939 -e. Cost of Building ($125.65/sqft + $8.5/sqft)*360,260sqft $162.76/sqft * 29,300 sqft (without Basement Correction) Total Cost per Square Foot $125.65/sqft + $8.5/sqft - $1.72/sqft $132.43 $4,768,868.00

Total Cost (w/o Basement Correction) $132.43/sqft * 360,560 sqft

$47,709,232 -f. Total Building Cost $47,709,232 + $1,303,939

(before Location and Historical Factors) $49,013,171 $4,768,868

g. Location Correction Factor $49,013,171 * (1.11) $4,768,868 * (1.11) Philadelphia, PA (1.11) $54,404,620 $5,293,443 h. Historical Correction Factor $54,404,620 * (0.997) $5,293,443 * (0.997) Nov 2002/Jan 2003 $54,241,406 $5,277,563 144.08/144.5 = 0.997 i. R.S. Means Estimate $54,241,406 $5,277,563 j. Total R.S. Means Estimate $59,518,969

The estimate above was developed using R.S. Means Square Foot Cost, 24th edition, 2003. The

estimate for the Hospital Addition was created using a hospital of 4-8 stories high (pages 144-145). The renovation to the existing hospital was created using a hospital of 2-3 stories high (pages 142-143).

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A D4 estimate was performed and the resulting cost was considerably less than that of the actual building. There was a difference in total building costs of about fourteen million dollars. The majority of the difference can be found in the costs of the estimated mechanical and electrical costs. The actual cost of construction for the mechanical division would include the mechanical cost and the plumbing cost. The total cost for the actual mechanical division would be $23,038,485, a six million dollar difference from the D4 estimate.

The majority of the projects selected from the D4 database had a cost significantly less than the Abington Memorial Hospital. When selecting relevant projects, I tried to select projects with a cost per floor similar to that of the AMH in order to get a comparable square foot cost.

While performing an estimate using R.S. Means, it was necessary to split the project into two separate buildings: a 360,260 sq. ft. hospital addition and a 29,300 sq. ft. hospital renovation. Using these two separate square foot cost estimates, an estimate was made for each building type and then combined. The resulting estimate was considerably less than that of the actual hospital’s estimate.

In order to perform this estimate, there were several assumptions which had to be made. When estimating the hospital addition, the costs for a hospital with 4-8 stories were used. For the renovation, a hospital with 2-3 stories was used. Based on the total square foot area, the costs per square foot for the hospital and renovation were $125.65 and $162.76, respectively. In actuality, the cost per square foot of the renovation would be more likely to resemble that of the addition since they are being constructed concurrently.

The combined R.S. Means estimate was around $40 million dollars less than that of the actual hospital. This is a very large discrepancy, which most likely derives from several factors. For one, the exterior wall of the hospital is composed of face brick backed by 6” cold-formed metal frames, as opposed to the researched “face brick with structural facing tile.” The difference in the façade system may have been a significant source of error in the estimate, given the size of the building. Another reason for the large difference in the estimates is the inclusion of the multi-story walkway to the garage, extensive excavation and landscaping, and the state-of-the-art medical equipment being installed in the building. The magnitude of the building’s size and cost far exceeds the records in D4 software database and the tabulated values in R.S. Means.

E) Site Plan The site used for this building was a large site, which housed several apartment buildings prior to their demolition. The former site had a road that ran through the site, which had to be removed for the construction of the hospital. There were also a number of doctor’s offices along Highland Avenue, which were used as construction management offices during construction and will be demolished after the hospital is constructed. Also located on the site, is the newly constructed 900-car parking garage.

Having such a large site made it easier on the construction managers to layout the site; there were no site congestion issues that had to be dealt with. For the majority of construction, there were two main entrances to the site: one along Old York Road (Route 611) and along Keith Road, on the east side of the site. Old York Road is a heavily trafficked street, which allowed easy access to the site. However, there were very few problems associated with the heavy traffic on the road.

(Please see Appendix 3: Site Plan Phase 1, & Appendix 4: Site Plan Phase 2) F) Local Market Conditions

The Abington Memorial Hospital project is an entirely union job. Given the

magnitude of the project, the trades in the area are readily available for the required work.

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The construction managers on the project do not expect that there will be a problem obtaining work with any particular trade. The Philadelphia area does not have many high profile jobs being constructed concurrently with the Abington Memorial Hospital expansion. The construction of the Philadelphia Phillies ballpark may pull select trades from the hospital, but the hospital’s construction schedule is late enough that available labor should not be affected.

Philadelphia is known for having strict labor unions. All work on this job must be performed by a union member. This aspect of the job is managed closely and there have been no significant problems with labor unions on this job.

G) Subsurface / Soils Conditions The previous site of the hospital addition was occupied by the Garden Apartment buildings, surrounded by asphalt pavement and grass lawns. These building have been demolished in order to provide space for the expansion. The site grades slope down from east to west and vary from +353 in the southeast corner to +341 in the northwest corner. In order to provide the required floor elevation of +335, there had to be a significant amount of excavation. The soil was tested by a geotechnical engineer hired by Abington Memorial Hospital after contaminated soil was found. During excavation in February 2003, contaminated soil was discovered where an underground fuel tank was located. This fuel tank was used to service the existing hospital. The construction manager then notified the hospital and suggested that the hospital hire a geotechnical engineer. The work done by the geotechnical engineer, Boucher & James, Inc. suggested an over-excavation of 10’ to 12’ below the footings to remove the contaminated soil. Fourteen test borings were taken on the soil under the hospital expansion. The geotechnical engineer recommended cuts of 1’ to 13’, based on the areas of excavation and required elevation. A lagging system of wood timbers and H-piles was used for soil retention. A new fill composed of sand and gravel was used to backfill the excavation. The silt previously on site is very difficult to compact and was specified as not to be used as a backfill. Based on the soils reports, it was determined that rock would not be hit during excavation and that building settlement will be less than ½ inch, which is acceptable for the limits of this particular structure. Ground water was not encountered in a test boring that extended down to an elevation of +321. It was concluded that ground water would not be a problem during the placing of the foundation concrete. The soils report on the project was made available to bidders. H) Client Information

The owner of the expansion project is the Abington Memorial Hospital. AMH is a

fully-accredited, non-profit, and educational hospital facility. The hospital has 508 beds and serves Montgomery, Bucks, and Philadelphia counties. The hospital, founded in 1914, has undergone several additions and renovations. The current Abington Memorial Hospital facility was completed in three main phases. The first of these was the construction of a three-story, 65,000 square foot medical office building along with a 1,500-car parking garage. The second phase of the hospital was the excavation and construction of a 272-foot long underground tunnel used to connect the medical office building to the main hospital facility. The latest construction was the addition of a building known as the “Toll Pavilion.” This was a 342,000 square foot addition which contains a state-of-the-art operating suite, critical care units, same-day procedures units, and a labor-delivery-recovery facility. The demolition required for the construction of the hospital addition took place while the hospital was still in use and needed to be carefully considered as to not disturb the ongoing hospital activities.

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The current addition to the Abington Memorial Hospital is being managed by a joint venture between L.F. Driscoll construction and Intech Construction. Both of these companies have previously completed work for the hospital. L.F. Driscoll was the construction manager for the three phases of the hospital, including the construction of the Toll Pavilion. Intech has completed over $25 million dollars in renovations and additions to AMH. Having been both general contractor and construction manager, Intech has completed a cancer treatment center, a pediatric care unit, dental clinic, trauma center, and triage unit. Abington Memorial Hospital’s previous experience with L.F. Driscoll and Intech is the reason for the creation of the joint venture, which was suggested by the hospital.

Abington Memorial Hospital is constructing this 360,000 square foot addition to respond to both short and long-term needs. The hospital expects to have all of the new patient rooms filled upon completion. Out of the eight operating rooms being constructed, four will immediately be fitted for operation. AMH expects all of the new amenities to be used in the future. There is a need for all the facilities being constructed, both immediate and long term.

AMH has high expectations of the proposed hospital facility. With such a long schedule, the hospital highly values both cost and quality. According to the hospital’s standards, there is no true order of importance between cost, quality, and schedule. If necessary, the construction schedule would be prolonged before the cost is increased or the quality reduced.

One example of this took place

when the shape of the structural beam cantilevers would not conform to the shape of the existing hospital. These W10x12’s were fastened to the frame of the new building’s structural system and are intended to provide structural support in the area between the new and existing buildings. The result of this poor design is that the cantilevers would not be installed with the erection of the steel frame and would be fastened at a later time. This had cost implications, due to the additional labor required. In this instance, the hospital chose to sacrifice the schedule and bear the additional cost of the situation.

The Abington Memorial Hospital took specific considerations when developing the schedule of construction. The schedule was developed based on the systems being installed and the risks that come with their installation. The scheduling of the emergency room was an important consideration because it is not dependent on an elevator. The ER is located on the ground floor and the equipment does not need to be installed using an elevator. This allows the ER to be equipped and operational before the floors above. The areas of the building will open according to their function. The design of the building was set up according to how AMH plans to open these areas. For example, the emergency rooms on the ground floor will be operational before the nursery on the fourth floor. The construction of the hospital addition is being funded by Abington Memorial Hospital. The majority of the funding will come from equity and timed releases of bonds. With an approximately anticipated schedule, the hospital has adequately prepared for the cost of the addition.

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Appendix 1:

Organizational Chart

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Abington Memorial HospitalOwner

Judith Kratka

Robert D. Lynn AssociatesArchitect / Engineer

Bob Mainwaring

Joint VentureIntech / L.F. DriscollConstruction Manager

Kevin Kreibel

A.W. LookupConsultant /

EngineerPaul Weidorn

Boucher & James

Geotechnical Engineer

David Blackmore Associates

StructuralConsultant

Samuel Grossi & SonsSteel Contractor

Gene Grossi

Madison ConcreteConcrete Contractor

Rick Stone

Gerngross Corp.Plumbing Contractor

John Gerngross

Hamada, Inc.Thermal, Moisture

Protection ContractorJohn Mitchell

H.T. SweeneySite Construction

Terry Sweeney

Carr & DuffElectrical Contractor

Bob Casey

A.T. ChadwickMechanical Contractor

Al Adams

J.P. RaineyElectrical Contractor

J.P. Rainey

GMP Contract

Note: All subcontractors hold a GMP Contract with CM

GMP Contract

GMP Contract

Appendix 2:

Project Schedule Summary

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Abington M

emorial H

ospitalC

lassic Schedule Layout

07-Oct-03 18:27

Activity ID

Activity N

ame

Original

Duration

Rem

aining D

urationS

chedule %C

omplete

Start

Finish

A1010

Procurem

ent1

1100%

02-Sep-02

02-Sep-02

A1000

Design P

hase - GM

P D

oc...1

1100%

04-Oct-02

04-Oct-02

A1060

Foundations79

79100%

12-Feb-0302-Jun-03

A1020

Site W

ork - Rem

ediate Soil

4343

100%24-Feb-03

23-Apr-03

A1030

Transformer Y

ard67

67100%

03-Mar-03

03-Jun-03A

1070S

teel Erection / B

olt-up83

8396.39%

02-Jun-0324-S

ep-03A

1090S

lab on Metal D

eck67

6743.28%

12-Aug-03

12-Nov-03

A1040

Site W

ork - Backfill &

Grade

2020

100%19-A

ug-0315-S

ep-03A

1080S

lab on Grade

1414

100%28-A

ug-0316-S

ep-03A

1050S

ite Utilities

2222

0%16-O

ct-0314-N

ov-03A

1100B

asement C

MU

2626

0%31-O

ct-0305-D

ec-03A

1160M

EP

Rough-in

103103

0%14-N

ov-0306-A

pr-04A

1110Install E

.I.F.S. P

anels68

680%

17-Nov-03

18-Feb-04A

1120B

rick77

770%

10-Dec-03

25-Mar-04

A1150

Perim

eter Rough-in

3030

0%11-D

ec-0321-Jan-04

A1130

Window

s & C

urtain Wall

7575

0%09-Jan-04

22-Apr-04

A1140

Roofing

4040

0%29-Jan-04

24-Mar-04

A1170

Fit-Out

299299

0%05-M

ar-0427-A

pr-05A

1210E

levators178

1780%

11-Mar-04

15-Nov-04

A1200

Punchlist

167167

0%05-O

ct-0425-M

ay-05A

1190S

ite Concrete &

Landscap...33

330%

02-May-05

15-Jun-05A

1180E

.R. Traum

a Renovations

128128

0%16-Jun-05

12-Dec-05

3Q

4Q

1Q

2Q

3Q

4Q

1Q

2Q

3Q

4Q

1Q

2Q

3Q

4Q

1Q

2Q

3Q

42003

20042005

2006

Procurem

entD

esign Phase - G

MP

Docum

ent Com

pleteFoundations

Site W

ork - Rem

ediate Soil

Transformer Y

ardS

teel Erection / B

olt-upS

lab on Metal D

eckS

ite Work - B

ackfill & G

radeS

lab on Grade

Site U

tilitiesB

asement C

MU

ME

P R

ough-inInstall E

.I.F.S. P

anelsB

rickP

erimeter R

ough-inW

indows &

Curtain W

allR

oofingFit-O

utE

levatorsP

unchlistS

ite Concrete &

LandscapingE

.R. Traum

a Renova

Actual W

orkR

emaining W

orkC

ritical Rem

aining Work

Milestone

Sum

mary

TAS

K filter: A

ll Activities

© P

rimavera S

ystems, Inc.

Page 1 of 1

Appendix 3:

Site Plan Phase 1

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CLOSED SIDEWALK

CLOSED SIDEWALK

CLOSED SIDEWALK

CLOSED SIDEWALK CLOSED SIDEWALK

PARKING

PARKING

PARKING GARAGE

HOSPITAL PARKINGUPPER LEVELS

CONTRACTOR PARKINGLOWER LEVELS

BASEMENT LOADING DOCK

FUEL OIL

TANKS

HOSPITAL ADDITION

TOWERCRANE

EXISTING HELIPAD ON ROOF

HOIST

HIGHLAND AVENUE

TIRE WASH

ELECTRIC MAIN

SEWAGE MAIN

MOCKUP

TOOLSHED

SUB TRAILORS

CM OFFICES

TRAFFIC FLOW

TRASH CHUTE

SITE FENCING

N

PHASE ISuperstructure

11/2002 – 8/2003

OLD YORK RD (RT. 611)

KEI

TH R

OAD

EXISTING

HOSPITAL

T R A N S F O R M E R Y A R D

Appendix 4:

Site Plan Phase 2

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CLOSED SIDEWALK CLOSED SIDEWALK

CLOSED SIDEWALK

PARKING

PARKING

PARKING GARAGE

HOSPITAL PARKINGUPPER LEVELS

CONTRACTOR PARKINGLOWER LEVELS

BASEMENT LOADING DOCK

FUEL OIL

TANKS

HOSPITAL ADDITION

TOWERCRANE(REMOVED 4/2004)

EXISTING HELIPAD ON ROOF

HOIST

HIGHLAND AVENUE

TIRE WASH

TIRE WASH

ELECTRIC MAIN

SEWAGE MAIN

PARKING TO BEDEMO-LISHED

MOCKUPN

TOOLSHED

SUB TRAILORS

CM OFFICES

TRAFFIC FLOW

TRASH CHUTE

SITE FENCING

OLD YORK RD (RT. 611)

KEI

TH R

OAD

PHASE IIFinishes

8/2003 – 2/2005

EXISTING

HOSPITAL

T R A N S F O R M E R Y A R D

technical assignment #1 existing construction conditions€¦ · power, storm drainage, site...

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