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2010 Associated Builders and Contractors - Excellence in Construction

6000 Technology Drive Category: Special Contracting Mechanical: Commercial $2 to $10 Million

Enviromental Systems Corporation Huntsville, AL


2010 Associated Builders and Contractors - Excellence in Construction

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

PROJECT DESCRIPTION 6000 Technology Drive is the renovation of a 3-building campus to meet a Solicitation for Offers with mission critical stringent noise criteria and system redundancy while working within the above ceiling space limitations and structural restrictions of the existing buildings.

Enviromental Systems Corporation Huntsville, AL


Enviromental Systems Corporation Huntsville, AL

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

2010 Associated Builders and Contractors - Excellence in Construction

Chiller yard before construction. It was necessary to keep as compact as possible to not extend beyond the end of the building due to existing utilities nor to impose on the existing parking and drive through area.

PHOTO 1


Enviromental Systems Corporation Huntsville, AL

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

2010 Associated Builders and Contractors - Excellence in Construction

The photo after demolition shows the limited above ceiling space. This specific space is the same area where the Mission Critical photo was taken.

PHOTO 2


Enviromental Systems Corporation Huntsville, AL

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

2010 Associated Builders and Contractors - Excellence in Construction

Chilled Beam piping. This is an in progress piping photo but note the final piping installation will look similar with no insulation on the “chilled� tertiary water piping. The chilled beams are protected during construction by covering finished face with corrugated cardboard. The chilled beams are supported and positioned with adjustable slip cable/ locking device, a product called gripple.

PHOTO 3


Enviromental Systems Corporation Huntsville, AL

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

2010 Associated Builders and Contractors - Excellence in Construction

The chilled yard piping in progress shows the compact design and work necessary to fit in designated space and to be accessible for operation and maintenance. Compact inline pumps are used for primary and secondary chilled water and primary hot water pumps.

PHOTO 4


Enviromental Systems Corporation Huntsville, AL

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

2010 Associated Builders and Contractors - Excellence in Construction

This photo demonstrates the ceiling congestion encountered from duct, lights, and sprinkler piping. Not seen in the photo are hydronic pipes intersecting this corridor. Bundled miles of communication cabling will eventually lay above light fixtures.

PHOTO 5


Enviromental Systems Corporation Huntsville, AL

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

2010 Associated Builders and Contractors - Excellence in Construction

(the “after� of Photo 2) Mission critical. The customers final product with the attractive finished chilled beam installation within the ceiling grid.

PHOTO 6


Enviromental Systems Corporation Huntsville, AL

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

2010 Associated Builders and Contractors - Excellence in Construction

The chilled yard photo shows the distribution of chilled water from three (3) 70 ton chillers, hot water harvested from the same chillers, tertiary chilled water return, boiler (at rear blocked by last chiller), chilled water and hot water pumps, air separators, expansion tanks, system fill points and finally the seven (7) variable frequency drive enclosures for pumps.

PHOTO 7


2010 Associated Builders and Contractors - Excellence in Construction

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

CONTRACTED SCOPE Due to Government Client Confidentiality and National Security Concerns, need-to-know/sensitive information will be excluded from our submission. Environmental Systems Corporation (ESC) was the mechanical design/build contractor for the Renovation of 6000 Technology Drive, which is a campus of 3 buildings in the Cummings Research Park East. The project was in response to a Solicitation for Offers (SFO) published by the United States Army Corps of Engineers for the government tenant. As a member of the design team, Environmental Systems Corporation worked with other design professionals to provide the Crown Group with a cost effective renovation. Buildings 1 & 2 demanded a thorough review and evaluation of all existing mechanical systems and equipment. The review allowed ESC to utilize much of the existing HVAC equipment before moving forward with the new design. Since the tenant requirements described several areas as “mission critical”, Building 3 required a comprehensive review and strict adherence to the SFO which lead to the complete demolition of the existing mechanical system and a totally new innovative design solution.

Building 1: Complete Mechanical Engineering and Construction

•Installed additional RTU dedicated to the UPS Area •Installed new HVAC split system serving new main electrical room •Re-zoned to meet requirements of the new floor plan and occupancy •Installed new web based open protocol Building Automation System

Building 3: Complete Mechanical Engineering and Construction, Certified Commissioning

•Demo. and removed complete HVAC system •Installed new active chilled beam system •Installed new chiller plant with integrated heat recovery system •Installed primary, secondary, tertiary piping system with over two miles of piping •Installed fully redundant cooling system for 13 mission critical areas •Installed of new system for a mission critical data center including full redundant capacity and control •New web based open protocol Building Automation System with integration of Lon and BACnet networks

Type of Construction

•Demo. and removed existing HVAC ductwork and systems not being reused •Installed new ductwork •Refurbished and relocated five existing HVAC units •Re-zoned with a VVT (Variable Volume and Temperature) system •Installed three new HVAC systems to meet tenant requirement. Two of the systems included energy recovery ventilators. •Installed new web based open protocol Building Automation System

Renovation and Rehabilitation

Building 2: Complete Mechanical Engineering and Construction

Merit Shop Participation 100%

•Demo. and removed existing HVAC ductwork and systems not being reused. •Installed new ductwork •Refurbished and relocated two existing HVAC units

Size of the Project 88,480 square feet

Contracted Amount $2,787,892

Length of Construction Project

March 10, 2009 - April 15, 2010 Design - March 10, 2009 – July 10, 2009 Construction - June 25, 2009 – April 15, 2010

Percentage of Self-Performed Work 100%

ABC Members – North Alabama Chapter Ram Tool & Supply Company Mayer Electric Supply Company Service Steel, Inc. Madison Mobile Storage

Enviromental Systems Corporation Huntsville, AL


2010 Associated Builders and Contractors - Excellence in Construction

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

PROJECT NARRATIVE Please note that the need-to-know limitation of information regarding this project has restricted our ability to share some information. While some facts may seem unimportant, they are indeed classified as sensitive information, or need-to-know information. Due to Government Client Confidentiality and National Security Concerns these types of information will be excluded when writing our narrative for our submission. Environmental Systems Corporation (ESC) was contacted by The Crown Group in March of 2009 and asked to participate in a team effort to provide a response to a Solicitation for Offers (SFO) published by the United States Army Corps of Engineers. The Crown Group chose 6000 Technology Drive, which is a campus of 3 buildings in the Cummings Research Park East for the proposed renovation. With Building 3 having been built in 1965 and Buildings 1 & 2 in 1987 the spaces were in need of renovation to meet the recent space requirement needs of the SFO. As part of the design team, Environmental Systems Corporation worked with the other design professionals to provide the Crown Group with a cost effective renovation for the property. The buildings required a thorough review and evaluation of all of the existing mechanical systems and equipment. By coordinating the SFO requirements and the facility review ESC was able to utilize much of the existing HVAC equipment on Buildings 1 & 2 before proceeding with a new design. One of the first challenges that ESC had to overcome was the requirement to submit a fully qualified proposal with design concept and firm pricing (excluding changes caused by the tenant) in less than six weeks. The design for Building 1 required the demolition of the existing HVAC ductwork, the control system, and the HVAC systems that were not being reused. The engineering division designed a new duct system, three new HVAC systems, two of which included energy recovery ventilators, and a new web based open protocol Building Automation System to meet the new tenant requirements. Five of the existing HVAC units were completely refurbished and relocated as part of the new mechanical design. Building 2 required the same approach: the demolition of ductwork, controls, and HVAC systems that were not being reused in the new design. ESC designed a new duct system, refurbished and relocated two existing HVAC units, added an additional roof top unit dedicated to the UPS area, installed a new HVAC split system serving the new main electrical room, re-zoned the

Enviromental Systems Corporation Huntsville, AL

14


2010 Associated Builders and Contractors - Excellence in Construction

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

PROJECT NARRATIVE facility to meet the requirements of the new floor plan and occupancy as well as engineered a new web based open protocol Building Automation System. Buildings 1 & 2 presented their own challenges but not the design challenges presented by Building 3. This building required an entire HVAC system replacement to meet the SFO. There were three primary factors which contributed to the search for a new and innovative approach: the stringent noise criteria of NC 25 in a number of critical areas, a lack of physical space for the installation of more conventional systems, and the requirements for full N+1 redundancy which could not have been accomplished with conventional systems given the space limitations. Paul Smith, P.E. and Vice-President of Engineering attended seminars and academic/continuing education courses over several years where the technology of radiant cooling had been presented. This approach has been used in Europe and the northern United States but when it came to the south the fundamental issues of heat and humidity had to be dealt with and were generally considered to be outside the realm of workable for these systems. The ASHRAE (American Society of Heating, Refridgeration, and Air-Conditioning Engineers) headquarters in Atlanta had investigated and ultimately abandoned the approach for their new facility because of a fear of being able to adequately deal with the humidity inherent to the deep south. The University of the South in Sewanee, Tennessee, had also looked at the option for one of their buildings, but because of it not having a strong history in the region was abandoned for the project. ESC considered the reasoning against the system type, but because of the SFO’s stringent requirements and the physical lack of space in the facility, decided that chilled beams were the strongest candidate for this project and decided to move forward. We felt that since ESC had control of the design, installation, controls, and ultimately maintenance of the beams that many of the fears others had expressed could be addressed and contained. Russell Grimes, President of ESC , Paul Smith, Vice President of Engineering, and Stephen Grimes, Vice-President of Operations began researching the radiant cooling approach and how it could be implemented in our application. They found the Fläkt Woods Company who was having wide spread success with their product in the chilled beam application. Through discussions with our SEMCO (who sell the Flakt Woods product in the US under the SEMCO brand) representative, a trip was arranged. In April of 2009, Mr. Grimes

Enviromental Systems Corporation Huntsville, AL

15


2010 Associated Builders and Contractors - Excellence in Construction

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

PROJECT NARRATIVE and Mr. Smith visited what SEMCO considered to be an IQIC chilled beam system showcase facility in South Carolina. Both men found the trip helpful and informative and they came away with additional ideas for insuring the proper installation and operation of a chilled beam system. The active chilled beam is basically an induction terminal with chilled water coils supplied with medium temperature chilled water and cold primary air. For chilled beam technology to be successful in the Huntsville area, it was imperative that the chilled beam water supply be above the building interior dew-point. Without this the entire chilled beam system would collect condensate and ultimately “rain� in the facility. This control was accomplished by using the water from the circulation of the return water from other cooling processes in the facility. In addition to assisting in controlling the temperature of the chilled water, it also gave the benefit of allowing warmer water being returned to the chillers. This results in chillers that operate at higher efficiency levels. Because the beams are induction terminals, the chilled beam requires less primary air than a traditional air terminal device. The reuse of chilled water, the reduced fan horsepower in terms of air handlers, and the enhanced chiller efficiency allowed the system higher energy efficiencies. By using chilled beams which have no moving parts, the system offered resolutions for the major issues of noise, space, and redundancy. The majority of the air movement from a chilled beam is a result of induction, not mechanical action. This helped to meet the noise criteria. With no moving parts, all of the redundancy issues could be resolved at the use of primary air handler units at the chilled water level. Two air handler units, each specially designed for low dew-point operation and capable of handling the mission critical cooling capacities, were used meeting the project requirement for redundancy.

Enviromental Systems Corporation Huntsville, AL

16


2010 Associated Builders and Contractors - Excellence in Construction

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

PROJECT SAFETY

ESC Safety Organizational Chart

President of Environmental Systems corporation Russell Grimes

Vice President of Operations Stephen Grimes

Project Managers Russell Grimes - Stephen Grimes

Project Superintendent Gary Parton

Kelly Rolen

Robins & Morton Safety Officer

Jeff Morrison

ESC Safety Officer

Brian Youngblood

Workers First Safety Inspector

Enviromental Systems Corporation Huntsville, AL


2010 Associated Builders and Contractors - Excellence in Construction

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

PROJECT SAFETY Company Health and Safety Policy Manual Safety Programs used specific to this project

Daily Pre-Task Planning Documented pre-task planning was conducted by the project superintendent at the beginning of each shift to review and analyze any potential safety hazards; fall exposures, electrical exposures etc.

Weekly Safety Inspections In conjunction with the project superintendent, the esc safety officer visited the site weekly to verify compliance with all ESC Safety programs.

Compliance with all General Contractor Safety Requirements ESC provided full cooperation with Robin & Morton on all requested safety documentation

Additional Training The ESC Safety Officer Jeff Morrison along with three other key field personnel have completed the 30 hour OSHA Certification Program for Construction Safety.

Site Specific Manual Due to ESC’s full implementation of the Company Health and Safety Policy Program, no additional special safety and health programs were needed. Our compliance and enforcement of all of our written policies resulted in no injuries on this project. Additionally our President, Russell Grimes serves as a Trustee for Workers First Comp Fund the Self-Insurance Comp Fund for the State of Alabama, so ESC is dedicated to Job Safety.

Enviromental Systems Corporation Huntsville, AL


2010 Associated Builders and Contractors - Excellence in Construction

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

PROJECT SAFETY Toolbox safety meetings are documented and held weekly with all employees in both English and Spanish

Enviromental Systems Corporation Huntsville, AL


2010 Associated Builders and Contractors - Excellence in Construction

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

PROJECT SAFETY Weekly safety meeting topics from March 10, 2009 through April 15, 2010

March

23 30

Everybody’s A Safety Inspector Working Safely with Corrosives and Solvents Rigging Roofing Hazards

April

6 13 20 27

Anger Management on the Jobsite Eye Protection AEGCP Spills and Disposal of Chemicals

May

4 11 18 25

Pneumatic Tools Ladder Safety – One Step at a Time Lacerations, Contusions, and Abrasions You Are the Sharpest Tool in the Box

1 8 15 22 29

June is National Safety Month Preventing Forklift Accidents Don’t Play the Fool Is There Danger in the Air? How Noisy is a Construction Site?

6 13 20 27 3 10 17 24 31

June

July

August

9 16

September 7

14 21 28

October

5 12 19 26

Fire Prevention Week Scaffolds and Fall Protection What Are Crane Inspectors Looking For? Heart Attack

November 2

Job Safety Analysis Working in the Cold Don’t Let Gravity Take You Down Rebar and MSDs

December 7

14 21 28

Evacuation Plan Respiratory Protection Motor Vehicle Safety Care and Maintenance of Tools

January

4 11 18 25

OSHA’s Top Ten for 2009 Ergonomics: The Right Tool Fits Right Portable Heaters on the Jobsite Watch Your Step When the Jobsite is Icy

February

First Aid for Heat-Related Illnesses Aerial Lifts and Platforms Storing Chemicals Safely Storm Watch

1 The Dirt on Earth-Moving Equipment 8 PPE 15 Welding Operations 22 Struck-by and Caught-In-Between Accidents

March

Work Zone Safety Watch Your Back Housekeeping on the Jobsite Safety Punch List Chemical and Thermal Burns

1 8 15 22 29

Easy Rules for Hand Tools General Housekeeping Confined Spaces Working Alone Hanging Steel

April

5 12

Work Zone Safety Awareness Solvents

Emergency Preparedness Live Circuits Can Kill You First Responders Lockout/Tagout

9 16 23

Enviromental Systems Corporation Huntsville, AL


2010 Associated Builders and Contractors - Excellence in Construction

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

PROJECT SAFETY As part of Enviromental Systems Safety Program we have inspections conducted by our insuring representative to document compliance with all on site safety requirements.

Enviromental Systems Corporation Huntsville, AL


2010 Associated Builders and Contractors - Excellence in Construction

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

PROJECT SAFETY Letter Provided to Robins & Morton by our Project superintendent, Gary Parton verifying training, and eligibility and screening of all ESC employees participating in the construction of 600 Technology Drive.

Enviromental Systems Corporation Huntsville, AL


2010 Associated Builders and Contractors - Excellence in Construction

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

PROJECT SAFETY Company Health and Safety Policy Manual - Drug and Alcohol Policy

Alabama Roofing, Sheet Metal, Heating, & Air Conditioning Contractors' Association Self Insurance Fund Environmental Systems Corporation 4114 Environmental Circle Huntsville, Alabama 35805 (256)882-1122

DRUG AND ALCOHOL POLICY The Company has a vital interest in maintaining a safe and effective working environment for its employees, a working environment as free from the use of illegal and non-prescription drugs and alcohol and unauthorized use of prescription drugs as reasonably possible. Employees with drug and alcohol abuse problems make up only a small fraction of the workforce, and the Company regrets any inconvenience that may be causes to other employees by the problems of a few. But being under the influence of drugs or alcohol on the job poses serious safety and health risks, not only to the user but also to all who come in contact with the user. The benefits to be derived from reducing the number of accidents and the greater safety of all the employees make up for any inconvenience. The Company asks for your full cooperation in implementing this policy. Rules 1.

Possession, Etc.: The distribution, sale, purchase, use, or possession of intoxicants, including alcohol, non-prescribed narcotics, marijuana and other hallucinogenic drugs, or other nonprescribed controlled substances while on Company property or during work hours is prohibited.

2.

Possession, Etc. of Equipment: The distribution, sale, purchase, use or possession of equipment, products and materials which are used, intended for use, or designed for use with non-prescribed controlled substances while on Company property or during work hours is prohibited.

3.

Use of Illegal Drugs: Reporting to or being at work or being on Company property with a measurable quantity of illegal intoxicants, non-prescribed narcotics, hallucinogenic drugs, or other non-prescribed controlled substances in blood, urine, saliva, or breath is prohibited.

4.

Use of Alcohol: Reporting to or being at work or being on Company property while possessing, drinking or being impaired or intoxicated by alcohol is prohibited. While having any alcohol in a person's system is prohibited, a Breath Alcohol Concentration (BrAC) of .04 will be accepted as presumptive evidence of intoxication. Additionally, mandated employees (employees subject to provisions of 49 C.F.R. Part 40 and the Omnibus Transportation Employee Testing Act of 1991) with a BrAC of .02-.039 will be placed out-of-service for a period of no less than 24 hours. Evidential breath testing devices (EBT's) on the National Traffic Highway Safety Administration Conforming Products list will normally be used to determine BrAC.

5.

Use of Lawful Drugs: Reporting to or being at work or being on Company property with a measurable quantity of prescribed narcotics or over-the-counter drugs in blood, urine, saliva, or breath or use of prescribed or over-the-counter drugs where in the opinion of the Company such use prevents the employee from performing the duties of his or her job or poses a risk to the safety of the employee, other persons or property is prohibited. If the Company is of the opinion that the employee poses a risk to safety, the employee may be required to take a leave of absence or other appropriate action as determined by management. The Company's Medical Review Officer (MRO) may be consulted regarding any question of fitness for duty.

Enviromental Systems Corporation Huntsville, AL


2010 Associated Builders and Contractors - Excellence in Construction

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

PROJECT SAFETY Company Health and Safety Policy Manual - Lockout/Tagout Program

mechanical engineering & contracting / commissioning / building automation

Lockout/Tagout Program TABLE OF CONTENTS I. PURPOSE II. SCOPE III. PROGRAM COMPLIANCE IV. DEFINITIONS V. RESPONSIBILITY VI NORMAL PRODUCTION OPERATIONS VII. MINOR SERVICING TASKS VIII. PREPARATION FOR LOCKOUT/TAGOUT IX LOCKOUT/TAGOUT PROCEDURES X. RESTORING MACHINES/EQUIPMENT TO NORMAL OPERATIONS XI. GROUP LOCKOUT/TAGOUT PROCEDURES XII. SHIFT OR PERSONNEL CHANGES XIII. OUTSIDE SERVICE OR CONTRACTORS XIV. PERIODIC INSPECTIONS APPENDIX A (LOCKOUT/TAGOUT TRAINING PROGRAM OUTLINE) APPENDIX B (MACHINE/EQUIPMENT LOCKOUT PROCEDURES FORM)

Lockout/Tagout Program

Revised 7/21/03

3 3 3 3 4 4 5 5 5 6 7 7 8 8 9 12

© 1998 Excellence Alliance, Inc. – Page 2

Enviromental Systems Corporation Huntsville, AL


2010 Associated Builders and Contractors - Excellence in Construction

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

PROJECT SAFETY Company Health and Safety Policy Manual - Hazard Program

Enviromental Systems Corporation Huntsville, AL


2010 Associated Builders and Contractors - Excellence in Construction

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

REFERENCES

Enviromental Systems Corporation Huntsville, AL


2010 Associated Builders and Contractors - Excellence in Construction

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

REFERENCES

Enviromental Systems Corporation Huntsville, AL


2010 Associated Builders and Contractors - Excellence in Construction

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

REFERENCES

Enviromental Systems Corporation Huntsville, AL


2010 Associated Builders and Contractors - Excellence in Construction

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

SUPPLEMENTAL MATERIALS

Enviromental Systems Corporation Huntsville, AL


2010 Associated Builders and Contractors - Excellence in Construction

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

SUPPLEMENTAL MATERIALS

Enviromental Systems Corporation Huntsville, AL


2010 Associated Builders and Contractors - Excellence in Construction

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

SUPPLEMENTAL MATERIALS

Enviromental Systems Corporation Huntsville, AL


2010 Associated Builders and Contractors - Excellence in Construction

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

SUPPLEMENTAL MATERIALS

Please note that the need-to-know limitation of information regarding this project has restricted our ability to share some information. While some facts may seem unimportant, they are indeed classified as sensitive information, or need-to-know information. Due to Government Client Confidentiality and National Security Concerns these types of information will be excluded from our submission.

Enviromental Systems Corporation Huntsville, AL


2010 Associated Builders and Contractors - Excellence in Construction

Category: Special Contracting Mechanical: Commercial $2 to $10 Million

AQC CONTRACTOR

Enviromental Systems Corporation Huntsville, AL



ESC construction