Alabama 11, June 1, 2022

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Cullman Regional Hospital Undergoing $30M Expansion

By Cindy Riley CEG CORRESPONDENT

In north central Alabama, construction continues on a four-story tower and expanded emergency department at Cullman Regional Hospital. The $30 million project will increase the hospital’s bed capacity from 145 to 175 and double the size of the hospital’s critical care unit.

“Population growth in Cullman County has been significant over the last 10 years, and that growth is anticipated to continue,” said Jennifer Malone, the hospital’s director of marketing. “It’s important for Cullman Regional to invest in and expand its facilities today, so that we’re able to care for our growing community.”

The project will extend the west bed tower by 84 ft., which will enable the hospital to add 13 new critical care and 12 medical/surgical patient rooms. The project includes previously completed renovations to existing spaces which created five additional beds, for a total of 30 new beds.

“Both the ED and the tower expansion projects are addressing current and future capacity needs,” said Malone. “Our community is growing and having these projects under way now means we will be able to continue to meet the region’s healthcare needs.”

Malone noted the significance of doubling the size of the critical care unit.

“More critical care beds enable Cullman Regional to provide that level of care to more patients. This will be essential for the community as the population grows, and if we see another surge in COVID hospitalizations.” see HOSPITAL page 8

The $30 million project will increase the hospital’s bed capacity from 145 to 175 and double the size of the hospital’s critical care unit.

Novelis to Build $2.5B Aluminum Mill Near Bay Minette The first fully integrated aluminum mill in the United States in the past 40 years will be constructed on the 3,000-acre South Alabama Mega Site north of Bay Minette in Alabama’s Baldwin County. The factory will produce metal for drink cans and aluminum for vehicle production.

Novelis Inc., a sustainable aluminum solutions provider based in Atlanta, will invest $2.5 billion into the new low-carbon

recycling and rolling plant.

The Associated Press reported May 11 that work already started at the site, near Interstate 65, and the company said it expects the construction project to be a 30month-long effort, culminating in an estimated plant opening in 2025.

Novelis, with more than $17 billion in net sales, is a subsidiary of Hindalco Industries Limited and the main metals company of the

Aditya Birla Group, a multinational conglomerate with headquarters in Mumbai, India.

“Through this investment, we are making a demonstrative commitment to continue to grow alongside our customers and meet their needs for low-carbon, highly sustainable aluminum solutions,” said Steve Fisher, president and CEO of Novelis in a statement.

The plant will be primarily powered with renewable energy, use recycled water and be a zero-waste facility, according to a news release from the Baldwin County Economic Development Alliance (BCEDA). In addition, BCEDA noted that Novelis is committed to being a carbon-neutral company by 2050 or sooner and plans to reduce its carbon footprint by 30 percent by 2026. see MILL page 4

Page 2 • June 1, 2022 • www.constructionequipmentguide.com • Alabama State Supplement • Construction Equipment Guide

Montgomery’s Whitewater Park Remains On Schedule Montgomery, Ala.’s new under-construction whitewater rafting park has a hefty $65 million estimated price tag due to skyrocketing building costs, inflation and labor shortages brought on by the pandemic, WSFA-TV reported Feb. 23.

The project’s pre-construction budget was about $40 million in March 2019, according to a Montgomery County commissioner, but all the unplanned extra costs have now put it an estimated $25 million over budget.

“We stayed committed to seeing the project through, but again, the timing’s horrible,” said Doug Singleton, a District 5 commissioner.

He told Montgomery’s WSFA 12 News that building the massive entertainment district in the middle of the pandemic has not come cheap.

“We spent nearly $1 million just on cleaning and supplies and testing,” Singleton explained to the TV station.

With inflation reaching its highest point in 40 years, the cost to buy and ship materials proved to be much more than originally anticipated.

Singleton noted that the city and developer spent $15 million more than planned just on materials, as well as almost $750,000 more than expected on international shipping costs and went $6.85 million over budget to compensate for labor shortages.

“I wish we had known [because then] we would have delayed or done something different.”

The question remaining is how the development team will offset the over-expenditure. Singleton said he is confident federal funds allotted to the city, county and state through the American Rescue Plan will help.

“We’re still working through that, but I feel very, very optimistic because it’s all COVID-related and it’s all revenue loss-related,” he noted. “We’re not going to tap into the taxpayers’ dollars and we’re not raising taxes to finish this proj-

ect out.”

Singleton said he does not think they will go over budget more than the estimated $25 million and that the offset in cost is not projected to affect the park’s projected completion date of May 2023.

“We stayed committed to seeing the project through, but again, the timing’s horrible.”

Doug Singleton District 5 commissioner

He added that money from the city’s reserves and funds given to the project from the state and the Poarch Band of Creek Indians also will help offset the over-expenditure. “[When it is finished], though, we will have the premier outdoor recreation facility in the United States,” he predicted.

Project Seen as Economic Driver for Montgomery Despite the budgetary woes, Montgomery’s whitewater rafting facility is beginning to take shape.

The park, being built at 1020 Maxwell Blvd., near the Alabama River, is projected to bring in nearly 300,000 visitors annually and have a $40 million yearly economic

impact.

Crews broke ground at the site eight months ago, and it has been full steam ahead ever since, WSFA 12 News reported.

Plans call for the Montgomery Whitewater Project to be a world-class, Olympic-standard whitewater and outdoor activities center, designed to dramatically improve economic conditions west of downtown along the Interstate 65 corridor.

The project’s website touts it as a “recreational park that will host an Appalachian River like experience all within walking distance of downtown Montgomery.”

The 120-acre facility will be one of the few recirculating whitewater parks in the country and also is slated to showcase several similarly challenging and complementary features. In addition to whitewater rafting and kayaking, the park will give visitors the choice of enjoying zip-lining, mountain biking, ropes courses and climbing.

The city of Montgomery is pinning a lot of economic hopes on the whitewater park.

“This project will create a space for our residents to enjoy and bring visitors to our county in numbers we’ve never seen,” Montgomery County Commission Chairman Elton Dean said in a statement on the project’s website. “This is the type of forward thinking, quality of life project that will grow Montgomery’s population by enticing millennials to move here and stay here.

“Not only will it improve the lives of citizens, but it will attract new tourists and give existing visitors a reason to stay one more night, which equates to an increase in tax revenue for the community,” he said. “It will generate additional revenue, create opportunities for new and existing small and minority businesses, and add another world-class attraction to our destination.” 

Official: State On ‘Sound Footing’ With Prison Construction Plan An Alabama finance official said recently that the state is on “sound footing” moving forward with an ambitious prison construction plan that will see some $1.3 billion spent building modern corrections facilities.

Bill Poole, the state’s finance director, appeared on Alabama Public Television’s (APT) Capitol Journal program May 6 where he said the recent signing of a contract to build the first of at least two new prisons is a sign that the state is on solid legal ground.

His response came in the wake of protests from Democrats and social justice organizations over the Alabama Legislature’s decision to distribute $400 million from its first round of American Rescue Plan Act (ARPA) funds to put toward the prison plan, arguing that pandemic relief money should not be spent on projects not related to the pandemic.

However, the state contended that the segment of ARPA intended to make up for “lost revenue” during the pandemic allows for shoring up general government services, Montgomery’s Alabama Daily News report-

ed May 9.

“We felt like we were on solid legal grounds in every aspect relative to the ARPA funds or else we would not have proceeded in that regard,” Poole said. “We had legal opinions, we checked with the variety of resources that we needed to check with, and so we felt like we were on very sound ground.”

During his appearance on the ABT program, Poole said the U.S. Department of Treasury recently released its final guidance on the use of ARPA funds, which did not contradict the state’s understanding.

“Unless Congress or the Treasury Department changes the rules, then with the rules as they were prescribed and are prescribed, we believe we are on sound footing,” he explained.

The Daily News reported that in April, Alabama signed a $623 million contract with Montgomery-based Cadell Construction Co. to build the first of the new prisons, a specialized men’s facility in Elmore County designed to house 4,000 inmates. The state’s Department of

Corrections has described the prison as one that will be equipped with modern mental health facilities and include job training capabilities.

Construction contracts related to a second Alabama prison, to be built in Escambia County near the Holman Correctional Facility, have not been released.

three new facilities from private developers, according to the Montgomery news source.

That plan fell apart in early 2021, but Caddell and Harbert had been vetted and put in the groundwork to quickly move on prison construction, Alabama lawmakers said last fall.

Gov. Ivey Approved Building Funds Last Fall In a special session, the Legislature and Gov. Kay Ivey approved the borrowing of up to $785 million and the use of $400 million in state ARPA monies for prison construction.

The newspaper said the legislation also called for “design-build contracts,” in which a single entity performs both the design and construction under a single agreement. In the more standard design-bid-build, designers and contractors are hired separately.

Caddell and B.L. Harbert International, a contractor headquartered in Birmingham, were both part of the teams expected to build prisons under Ivey’s earlier plan to lease

Elmore Facility Designed as ‘Specialized Prison’ Poole said he was pleased with how the process is currently moving forward.

“The Elmore prison is the specialized prison, so it will have enhanced health care, mental health, and educational and workforce training aspects,” he said.

He added that the Elmore facility, north of Alabama’s capital city, is the larger, more complex, and most expensive of the two anticipated projects.

“I’m pleased we reached a final agreement with the general contractor,” Poole said. “I think it is a fair deal in terms of the state’s interest and look forward to starting that project.” 

Construction Equipment Guide • Alabama State Supplement • www.constructionequipmentguide.com • June 1, 2022 • Page 3

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Mobile, AL 251-633-4020

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Page 4 • June 1, 2022 • www.constructionequipmentguide.com • Alabama State Supplement • Construction Equipment Guide

Port of Mobile photo

The Mobile ship channel is currently undergoing a $367 million deepening and widening program to bring in larger vessels. American Shipper noted that the project is scheduled to be completed by the end of 2025.

Feds Award Port of Mobile $300M for Infrastructure Upgrades Due to more than $300 million in federal funding, the Alabama State Port Authority is set to improve infrastructure and intermodal access at the state’s only deep-water shipping facility.

The Port of Mobile will receive $265 million from the 2022 FY $1.5 trillion federal spending bill, which the U.S. Senate passed March 11; President Biden added his signature to the bill four days later.

Alabama Sen. Richard Shelby described the funds as “great news for our Gulf Coast.”

“South Alabama stands to benefit immensely from these investments,” Shelby said in a statement. “Mobile has a lot of potential, and this funding will improve upon its existing infrastructure to transform our coast and the entire state.”

American Shipping reported that the federal spending package had the following provisions for the Port of Mobile: • A total of $132.7 million for improvements to the facility, including the design and construction of docks, wharves, and piers, as well as for land acquisition and site development.

• $67.3 million for freight and intermodal rail infrastructure improvements at the Port of Mobile and the

Montgomery inland intermodal transfer facility.

• Another $65 million to support dredging of the Mobile port and multiple inland and intracoastal waterways throughout the state of Alabama.

In addition, the U.S. Department of Transportation (DOT) recently awarded a $38 million grant to the Alabama State Port Authority to improve access between ship berths and an intermodal rail facility at the Port of Mobile.

Part of that grant will be used to fund construction of a connector bridge between the APM Terminals container facility at the port and an off-dock intermodal rail yard and a logistics park. Another part of the grant will fund site development and related infrastructure for added distribution and warehousing at the port.

Federal Funds Add to Mobile Port’s Prosperity Business is indeed booming at Alabama’s only oceangoing shipping facility.

The Mobile ship channel is currently undergoing a $367 million deepening and widening program to bring in larger vessels. American Shipper noted that the project is scheduled

to be completed by the end of 2025.

“The port is progressing nicely on the channel modernization program, and we just closed out calendar year 2021 with unprecedented growth at our container intermodal facilities,” John C. Driscoll, CEO of Alabama State Port Authority, said in a statement.

The figures bear out Driscoll’s statement.

Containerized cargo volumes at the Mobile facility in 2021 increased 19 percent year-over-year, while refrigerated containers in 2021 posted a whopping 50 percent increase in volume compared to 2020.

The Port of Mobile handled 47,768 20-ft. equivalent units just this past January, a 17.5 percent year-over-year increase.

Mobile’s Intermodal Container Transfer Facility also saw a massive 167.9 percent year-over-year increase in volume during January, handling 2,579 TEUs. Top commodities that pass through the Gulf Coast port include heavy lift and oversized cargo, coal, aluminum, iron, steel, copper, lumber, veneers, roll and cut paper, cement and chemicals. 

Work Is Under Way On Site of Novelis’ New Aluminum Mill MILL from page 1

The new Alabama facility also will be the most sophisticated and sustainable of its kind, according to BCEDA, and will produce an initial 600 kilotonnes of finished aluminum goods capacity per year, though Fisher said he anticipates expanding that output.

“With this massive investment and largescale hiring plans, Novelis will launch a

high-tech aluminum mill that will generate significant economic impacts throughout the region for generations,” Alabama Gov. Kay Ivey said in a statement. “Novelis is a worldclass company, and we know that it has selected a prime location in ‘Sweet Home Alabama,’ and specifically Baldwin County, as home for its growth plans.”

Salaries at the Baldwin County plant are expected to average $65,000 annually.

Novelis also is unveiling plans to develop an Advanced Manufacturing and Leadership Training Center in Daphne, Ala., BCEDA announced. The leadership center will be built at the Daphne Innovation + Science Complex along Ala. Route 181.

“Baldwin County’s accelerated growth and forward-thinking leadership has made it possible to attract Novelis, a world-class

company, to our community,” shared Lee Lawson, president and CEO of the BCEDA. “The economic and generational impact this investment will have on Baldwin County will help further diversify and grow our economy for years to come.”

The South Alabama Mega Site in Baldwin County is located in the southwestern part of the state, 35 mi. northeast of Mobile, near the Gulf Coast. 

Construction Equipment Guide • Alabama State Supplement • www.constructionequipmentguide.com • June 1, 2022 • Page 5

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Construction Equipment Guide • Alabama State Supplement • www.constructionequipmentguide.com • June 1, 2022 • Page 7

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Page 8 • June 1, 2022 • www.constructionequipmentguide.com • Alabama State Supplement • Construction Equipment Guide

Tower, Emergency Room Expansion Under Way On Hospital HOSPITAL from page 1 Cullman Regional said, “The active ED was not meeting our According to the hospital’s website, during the final current community needs.”

The space needed for the additional beds was an unused months of 2020 and into 2021, Cullman Regional’s critical care unit reached a capacity of 200 percent. That means there courtyard. The retaining wall and utility relocations were were twice as many patients as beds available. This was completed before construction of the main building could reportedly the highest capacity of any ICU in the United begin.

“Doubling the size of the critical care unit requires an States.

The ED project began in February 2021 and should be addition to the main hospital building that will extend from the fourth floor all the way to the ground floor,” said Morris. complete this summer.

“We’re proud of the progress in the ED and are looking “Infrastructure, such as electrical, plumbing, mechanical and forward to celebrating the completed project this summer,” said Malone.

The new ED will feature a larger, more modern patient lobby and increase capacity by 80 percent.

“Providing positive patient experiences and quality healthcare are priorities for the hospital. A new and larger ED lobby and additional treatment areas will help us do both.”

The tower expansion construction began in January 2022 and is expected to be finished in late 2023.

“It’s imperative that North Alabama healthcare systems like Cullman Regional invest in facilities, technology and talent to meet the future healthcare needs of our rapidly growing region,” said Cullman Regional CEO James Clements. “We’re thankful for a visionary Healthcare Authority Board that believes in our hospital, and for our partners in progress — Doster Construction and TRO.” TRO Jung Brannen Architects was selected to carry out the hospital’s vision for the new construction, while Birmingham-based Doster Construction serves as the general contractor.

The project includes previously completed renovations As for the condition of the site before work began, Bobby to existing spaces, which created five additional beds, Morris, director of plant operations and construction of for a total of 30 new beds.

The project will extend the west bed tower by 84 ft., which will enable the hospital to add 13 new critical care and 12 medical/surgical patient rooms.

data must all be expanded.”

Eliminating the possibility for moisture intrusion is the biggest challenge for crews because the facility is maintaining operations that coincide with construction.

Currently, interior finishes are being performed in the ED, while cast-in-place stair tower, foundation and structural steel matters are being addressed as work continues on the four-story structure.

ED Phase 1- 2B work has been completed, as have fourstory site work and site retaining wall construction.

The four-story tower work has involved drilled pier foundations, structural steel, brick exterior, the cast-in-place retaining wall and five-story cast in place stair tower.

Noise control has not been an issue for crews; however, when expanding and constructing medical facilities, water intrusion and dust/debris control where new construction ties into an existing space remain chief concerns.

Morris said the elements also can cause problems.

“Weather is always a concern when starting an addition from the ground up. We build in a certain amount of rain days, based off the past rain percentages for those months.

Any additional rain days that may actually be experienced would add to the overall schedule of the project.”

Doster Construction senior project manager Jacob Odom said that a 130-ft. ballasted tower crane is being used on the project and is considered crucial in setting steel, constructing the retaining wall and completing the five-story stair tower.

It’s also needed for flying air handling units to the second floor, setting materials on elevated levels as they are constructed and working on elevated concrete pours. The crane allows for the safest and quickest method to complete vertical construction activities. see HOSPITAL page 10

In north central Alabama, construction continues on a four-story tower and expanded emergency department at Cullman Regional Hospital.

Construction Equipment Guide • Alabama State Supplement • www.constructionequipmentguide.com • June 1, 2022 • Page 9

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Hoar Tops Out On Science, Engineering Complex at UAB Hoar Construction announced the topping out of Phase I of the new Science and Engineering Complex at the University of Alabama at Birmingham (UAB), signifying the building reaching its highest point.

The $76 million development represents Phase I of a three-part project that aims to consolidate all of the basic science undergraduate and graduate studies in one complex.

Construction of Phase 1 began in February 2021 and is expected to wrap up in spring 2023.

The 138,842 sq.-ft. facility is located on 14th Street South between University Boulevard and 10th Avenue South. The first phase of the concrete structure consists of four levels that will house biology, chemistry and physics labs and classrooms alongside faculty and staff offices. It also will feature specialized labs including an optics lab and cold growth environment rooms. Collaboration spaces will be designed to allow students across different disciplines and levels of education to mingle and work together in a cohesive learning environment.

Throughout construction, Hoar has successfully worked through challenges related to the procurement and pricing of materials as pandemic effects continue to cause delays within the industry. Hoar utilized Building Information Modeling (BIM) and prefabrication strategies during the preconstruction phase, saving valuable time and money for the installation of electrical and plumbing components.

Computerized 3D models of the building enabled the team to determine any defects in the design, the amount of materials needed and placement of items to avoid schedule delays. Prefabrication was used by trade partners to build out

Hoar Construction announced the topping out of Phase I of the new Science and Engineering Complex at the University of Alabama at Birmingham (UAB), signifying the building reaching its highest point.

select components of the project off site, including electrical panels and steel and plumbing systems.

“We are proud to continue our relationship with UAB through the construction of its new Science and Engineering Complex, which will play an integral role in unifying students and faculty while establishing the university as one of the region’s premier science research institutions,” said Chris Ryals, superintendent of the project.

“Hoar is dedicated to expanding its reach into all sectors of higher education, and we are pleased to play a part in the

university’s next chapter of growth in our home base of Birmingham. We look forward to completion next year as we partner with UAB on turning this longstanding vision into reality.”

This project continues a lengthy relationship between Hoar and UAB, as the firm has previously completed several significant developments for the university including the construction of a new residence hall, Blazer Hall, and renovation of Heritage Hall. Hoar also served as general contractor of the construction of the Abroms-Engel Institute for the Visual Arts as well as the Shelby Biomedical Research Building.

Additional project partners include Goodwyn, Mills & Cawood (lead architect); Lord Aeck Sargent (LAS) (lab and research spaces consultant); MBA Engineers (structural engineers); Schoel Engineering (civil engineers); Newcomb & Boyd (mechanical engineers); and Hyde Engineering (electrical engineers).

Hoar has established itself as one of America’s leading builders, with a total volume of more than $1 billion in 2021.

Recently completed and currently under-construction educational building projects from Hoar include a 93,000-sq.-ft.

Health Sciences Facility for Tennessee State University in Nashville, Tenn., a 63,900-sq.-ft. Research Center for Abilene Christian University, a 106,000-sq.-ft. Science Teaching Laboratory Building for the University of Houston, and a 54,000-sq.-ft. School of Concrete and Construction Management Building for Middle Tennessee State University.

For more information, visit www.hoar.com. 

Doster Construction Leads Cullman Hospital Project Team HOSPITAL from page 8

Other heavy equipment on the project includes lulls, skid steers, buck hoists, concrete trucks, pump trucks and excavators. Materials include steel, brick, concrete, sheetrock and paint, along roofing materials, windows and doors.

For Doster’s crews, who represent one of the nation’s top healthcare contractors, working on the hospital project is extremely rewarding.

“It’s a privilege to have a hand in constructing a facility that will care for the health and well-being of so many individuals and families,” said Odom.

Malone added, “For Cullman Regional employees, physicians and stakeholders, the expansion projects are exciting and a source of pride. The investment in our hospital is an investment in the community, and that’s very rewarding.

“We hope these projects help our future patients and visitors feel confident about the quality of care they can receive at Cullman Regional.”

Established in 1939, Cullman Regional Medical Center is a fully accredited 145-bed medical center owned and operated by the Healthcare Authority of Cullman County and serves more than 150,000 residents in a six-county service area. The hospital, a Level 3 trauma center, features a medical staff of nearly 200 physicians and specialists, employs nearly 1,000 and delivers close to 1,000 babies each year.

(All photos courtesy of Doster Construction) 

For Doster Construction crews, who represent one of the nation’s top healthcare contractors, working on the hospital project is extremely rewarding.

Construction Equipment Guide • Alabama State Supplement • www.constructionequipmentguide.com • June 1, 2022 • Page 11

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Page 12 • June 1, 2022 • www.constructionequipmentguide.com • Alabama State Supplement • Construction Equipment Guide