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ISSUE 12A

POWER UP EDITION

MARVELS

F E R M I N AT I O N A L ACC E L E R ATO R L A B O R ATO RY

ACCELERATING INTO THE FUTURE by Keith Wiederhold

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Nancy Grossman, Safety Director of Fermi Lab, said she “had never previously worked with so professional of a contractor.”

Bringing together the necessary components for advanced research and testing, the expansion and renovation of the Muon Laboratory and Cryomodule Test Facility at Fermi National Accelerator Laboratory in Batavia, IL presented unique challenges, both above and below grade. Forces of Nature Tasked with constructing a 233’ test tunnel connecting the Muon Laboratory to a new absorber building, Barton Malow worked around the clock to monitor and quickly respond to record rainfall that filled the massive trench during construction. Though the “cut and cover” type of tunnel construction left the site vulnerable to the elements, effective dewatering and storm water management techniques proved effective. Temporary sump pumps and underdrain systems were used to limit flooding and allowed the team to continue work and maintain the largescale excavation. Weighing In Due to the specialized nature of experimental activities being performed by Fermi, excessive weight requirements of materials and equipment played a significant role in scheduling and manpower staffing. Additional Concrete Reinforcement: Heavy equipment planned for placement in the tunnel required additional floor strength. Weighing 2-3 times more than a typical concrete slab, concrete reinforcement of the tunnel’s foundation required the team to allocate additional time - four weeks of dedicated construction vs. approximately four days on a typical project of similar size. Moving Precast Panels: 30,000 lbs. each, and a unique shape, one-of-akind exterior skin precast concrete panels were removed, replaced and repositioned. A special hi-lo truck with a lifting boom was brought in for four solid days of installation. Control MATTERS: Dust and Vibrations With Fermi physicists continuing to work and experiment within the facility on a daily basis, the Barton Malow team took advanced measures to control dust and vibrations that would affect research. To shelter demolition debris from sensitive operational activities, 30’ high areas were tarped off and water sprayed to capture loose matter. Styrofoam was also used as a shock absorber for falling material. Daily communication with the physicists was also facilitated to address and minimize potential disruptions. Elements Unite Identifying and understanding Fermi’s project-specific construction requirements and challenges early in the process allowed the team, which included Hanson Professional Services to tackle issues head-on and maintain the project’s schedule safely. In fact, in September 2011, Barton Malow was recognized by Fermi for achieving a combined 42,405 hours with no “Lost Time Incident” recorded.

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CANYON POWER PLANT

A POWERFUL PROJECT by Kevin Camerson

The Southern California Public Power Authority (SCPPA) and city of Anaheim (City) didn’t have to look far for a construction team to build their Canyon Power Plant. Working about 100 miles south on I-5, Barton Malow was finishing construction on the Otay Mesa Generating Plant in San Diego when we were awarded the Canyon Power Project. The majority of Barton Malow’s Otay Mesa team relocated to Anaheim for the Canyon Power Plant. Turn on the Power The Plant was conceived by PB Power, SCPPA, and the City of Anaheim but engineering, procurement and construction services were Barton Malow’s responsibility. The schedule was tight – the Barton Malow team mobilized on the site in May 2010 and had until November 2011 to achieve substantial completion of the final two units at the Plant. In just nineteen months Barton Malow erected four combustion turbine generators, four generator step up transformers, and four continuous emissions monitor systems. In addition, we also procured and constructed the inlet chilling system and ammonia systems, five gas compressors and associated piping, plant air system, a 20-foot sound wall around the entire facility and the Plant Operations Building.

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Conserving Precious Resources Water conservation was a major goal on the project. During peak usage the turbines could use up to 413,000 gallons of water a day for cooling purposes. Rather than use potable water for cooling the turbines, the City contracted with the Orange County Water District to use reclaimed water from the Orange County Groundwater Replenishment System. The only potable water used on the site is in restrooms, kitchens, drinking fountains, and in some emergency services. Silver Results Use of reclaimed water is one reason portions of the Canyon Power Plant earned LEED Silver certification from the U.S. Green Building Council. Other environmental initiatives included solar panels on plant buildings and a geothermal cooling system at the control building. Using Electricity Wisely The Plant has the capability to provide energy to 150,000 residents in the City of Anaheim during peak hours. SCPPA stated that the project, “Has the power capability to make a difference between forcing customers to turn off their electricity use completely, versus using electricity more wisely during the hot summer months.”

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M c L A R E N P R OTO N T R E AT M E N T C E N T E R

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PROTON POWER by Teresa Miller, AIA, LEED AP

The McLaren Proton Treatment Center addition to the Great Lakes Cancer Institute in Flint will provide the first proton therapy services in the state of Michigan. Proton therapy is a non-invasive, pain free way to treat cancer tumors without damaging surrounding tissues. The center provides treatment for previously untreatable cancer conditions including pediatrics, brain tumors and others. There are only a dozen operational proton treatment centers in the United States. A Hyper-Collaborative Team The design-build joint venture of Barton Malow (Southfield) and The Christman Company (Lansing) was hand-picked by McLaren to perform this project. The design team is SmithGroup (Detroit) and RTKL (Chicago). The prototype nature of the project resulted in intensive design coordination with the equipment vendor, ProTom International and the owner. One of McLaren’s primary goals was to deliver this project as quickly as possible, therefore the project team developed a hyper-collaborative environment to make decisions quickly. From A/E selection, McLaren approved the conceptual design within one month and the project broke ground just four months later. The overall time frame for design and construction is only 18 months. Equipment installation will take another year with the first patient treatment anticipated in December 2012. Fast but Safe In order to meet the schedule several risk-reducing measures were implemented. Design Assist Mechanical/Electrical/Plumbing partners (Limbach, Shaw & Shambaugh) were selected to mitigate schedule concerns and leverage value engineering ideas for cost control, plus 3D BIM coordination has been used for general coordination and phasing. The project team also self-performed earthwork, exterior carpentry and interior work, and equipment installation. Utilizing self-perform labor has played a major role in reducing risk, avoiding cost increases and providing the highest quality installations possible. Beaming The project is nearing completion with the installation of finishes. The accelerator was installed in September and is producing beam as part of the final trials required for FDA approval of the equipment. Temporary radiation shielding is in place to protect on-going work including installing equipment in each of the treatment rooms.

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A R G O N N E N AT I O N A L L A B O R AT O R Y

BIM IN THE RESEARCH WORLD by Brian Gorzynski, AIA, NCARB

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Barton Malow Company and Barton Malow Design are building the $5.8 million Material Engineering Facility (MEF) for Argonne National Laboratory in Chicago. This design/build project is an 11,600 square foot facility that will house the Federal Government’s testing facility for the next generation of lithium ion batteries. BIM Expertise Required Our team’s demonstrated use of building information modeling (BIM) was the leading factor in being selected for this project. More than 50% of the construction budget was for the mechanical system and warning sensors. The heavy mechanical and warning sensor requirements, coupled with the fact the new facility was built inside an occupied and fully functioning existing lab, made it imperative for the project to be designed and modeled in three dimensions. Coordinating Success The first step of the coordination process was to model the existing laboratory that houses the new MEF facility. This allowed the team to determine the construction envelope that was available for the new project, and also determine utility tie in points and develop the shop drawings that would bring those utilities to our site. The entire design team used Autodesk’s REVIT software to design in each of their respective disciplines. Barton Malow AE Services managed the coordination process. Buzzsaw was used for file management and distribution.

The coordination model was assembled and coordinated in Navisworks with clash reports created and posted to Buzzsaw every week per each discipline for the subs to review and fix for the following weeks meeting Virtual Meetings Equal Real Savings The kick-off meeting and coordination meetings were conducted via WebEx between Barton Malow’s Southfield, Michigan office and with subcontractors participating from their various office locations. Barton Malow’s BIM coordinator never met face-toface with the subs or Barton Malow’s Chicago-based project team members. WebEx provided project cost savings by eliminating travel expenses incurred for the BIM coordinator to go to Chicago every week for regular coordination meetings. Virtual meetings also allowed for saved time. The BIM coordinator conducted quick, impromptu meetings with individual subcontractors to discuss and resolve issues between the regularly scheduled coordination meetings. Without the use of BIM technology this project would have been nearly impossible. The owner will now use the BIM data provided by Barton Malow to assemble the as yet undeveloped scientific processes that will reside inside this new the MEF.

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DTE ENERGY COMPANY MONROE POWER PLANT

A POWERFUL RELATIONSHIP Although Barton Malow has served DTE for almost 20 years, our work at the Monroe Power Plant started in 2005.  Our work at the 3,000 megawatt plant has included engineer/ procure/construct (EPC), general contracting and designbuild contracts as well as self-perform civil, concrete, resteel fabrication and mechanical installation services. Reducing Emissions Requires Lots of Concrete Specific projects at the plant have included Flue Gas Desulfurization (FGD) foundations for units 1, 2, 3 and 4. FGD’s help reduce sulfur dioxide, nitrogen oxides, mercury and particulate emissions from coal-fired power plants like the DTE Monroe site. Our current work on site includes the Selective Catalytic Reducer (SCR) unit 2 project, where we’re performing work at and below grade. The work for these environmental upgrade units and adjacent facilities and infrastructure

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by Alan Albert

includes driving H-pile, concrete foundations, sumps, pits and trenches, site utilities, storm and sanitary sewers, underground fire protection, embedded piping and drainage, electrical duct banks and grounding and pipe supports as well as concrete foundation walls and supported slabs, equipment pads and elevated slabs. To date, we’ve placed 70,000 cubic yards of concrete at DTE Monroe. That’s enough to cover 79 football fields with 6 inches of concrete! The Relationship Continues Barton Malow was recently selected as the design-builder for the 33,000 square foot Warehouse B project. We’re providing design and construction services as well as self-performing the excavation, backfill, underground utilities, concrete and interiors. This fast-tracked project marks our most comprehensive contracting approach for DTE to date.

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Over the past 3-1/2 years, Barton Malow’s self-perform labor forces have worked approximately 300,000 man hours on the Monroe site with only one recordable incident.

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P E R S O N N E L

P R O F I L E

TERESA MILLER, AIA, LEED AP-Team Builder

Project Manager, McLaren Proton Treatment Center

Architect, preconstruction and logistics leader, builder, technology guru. These words describe Teresa Miller’s career, an unconventional path focused on personal excellence and unparalleled client service. Teresa is a registered architect with masters degrees in architecture and engineering. She understands construction inside and out, from beginning to end. But her real strength is her ability to bring people together to form hypercollaborative teams where everyone is invested in the success of the project. Said Teresa of the McLaren Proton project, “We knew we had a client who was engaged in the process and excited about their project, and wanted to make sure we carried that enthusiasm and commitment through the design and construction. We formed a great team of contractors, owner’s representatives and a design team who all worked together to find solutions. In the end, everyone felt a sense of pride and ownership at what we had accomplished.”

Building Innovative Solutions www.bartonmalow.com CONTACT

DANA GALVIN, CPSM FOR MORE INFORMATION


Barton Malow Marvels 2012A