column individually. Fabrication and erection took place at the same time that the next gridline was detailed back at the office. “The shop guys worked over the weekends to get 600+ connections fabricated and shipped to the jobsite, where 10 team members practically lived in an empty 18,000 sq. ft. warehouse to execute the project,” recalled Victor García, CEO. In all, the project comprised a total of 327 60-foot beams, each weighing 6,039 lbs., and 64 columns ranging from 3,000 to 6,800 lbs. each.
Embracing technology, rewarding workmanship “We decided from the very start [of the company] to be a paperless operation and maximize the efficiency of all our activities,” said García. “Top-of-the-line software such as Tekla PowerFab and Tekla Structures allows us to generate 3D pre-construction models to cover every aspect of the project and obtain accurate takeoffs from the beginning. This makes it feasible to offer competitive pricing.” He adds: “Our digital system enables clear communication between our field crew management team and shop, which is essential to the smooth execution of large, complex projects and achievement of a Flawless product. Our technology gives us an advantage against our competitors as we are already at least two weeks ahead on the detailing process once a project is awarded.” Using this software played a significant role in the company’s ability to meet the challenges of this project. “We owe a huge debt of respect to Tekla, which made it possible to generate highly accurate models and bring the whole system together to get this project back on track. It was amazing how well everything flowed. Ultimately, we got the fabrication done in under six weeks and erection completed in three months,” said García. The expertise and dedication of the team were the other key factors contributing to the successful completion of the job. “Roque Acosta, project manager, and Mack Segell, the foreman on site, and Dwayne Guynn, the in-shop foreman all made it possible to execute this project in a safe and timely manner. Our safety consultant, Bryan McClure from Trivent Safety Consulting, helped our team work safely with 100 percent tie-off and other solid safety policies,” credits García. García began Flawless Steel Welding during the recession, when steady employment as an ironworker was hard to find. He took on small welding jobs to establish a solid reputation and build name recognition. His team’s consistently exceptional performance has created opportunities to work for larger contractors. FSW has grown from employing a couple of welders to more than 30 employees. In the near future, the company will be moving into a 35,000 sq. ft shop roughly twice the size of their current location, enabling FSW to add heavy fabrication equipment and improve efficiency. Flawless Steel Welding operates with a ‘mission mindset,’ encouraging employees to strive for excellence both personally and as a team. FSW invests in every new employee (affectionately called “Agoges” after the Spartan tradition of educating and training young warriors) with job-specific, state-of-the-art training, including attending NCCER’s three-year apprenticeship program. The training program helps shape new recruits into skilled, knowledgeable, and competent workers able to meet the rigorous standards set by OSHA and NCCER. “Our people are the backbone of our success. As a company, we are known for the highest possible standard of quality, and as individuals, we take pride in our work. We believe our employees perform 36 | THE STEEL ERECTORS ASSOCIATION OF AMERICA
"We were impressed with the erector's willingness to field fabricate the beam ends to accommodate the revised connection design, in order to expedite the project." — Judge’s Comment regarding Flawless Steel Welding LLC on Corbin Park Garage
better because they are happy at work,” said García. “In our company name, we are reminded continually of the standard we’ve set, both for our company and our team to be flawless. Our employees are not just collecting Friday’s paycheck, they are committed to individual and professional success. We serve our community by creating jobs, teaching integrity, and giving our team members an opportunity to learn a respected, rewarding trade. In return, they demonstrate the professional attitude, impeccable craftsmanship, quality products, and on-time schedules that our clients seek and expect.”
■■Gem of a Building Reflects Careful Coordination Derr & Gruenewald, Brighton, Colo., was awarded Class II (over $500K to $1 million) Project of the Year for their work on the Prism building, a low-rise office tower infill project in downtown Denver. The nine-story, 101,118 sq. ft. structure features a jewel-like glass curtain with five diagonal folds. The angled planes of the “crinkle” wall provide expansive views from inside the building and give the exterior the appearance of a multi-faceted, light-reflecting prism. The successful completion of the building also reflects the erector’s coordination with designers, fabricators, other trades, and nearby tenants. After some earlier projects were scrapped during the economic downturn of the 2000s, Shea Properties was looking to create an iconic, one-of-a-kind boutique office building that would stand out against a backdrop of high-rise towers. The building also complements a newly opened 28-story luxury apartment building, The Quincy, which Shea built on the block. A thorough constructability analysis by Derr & Gruenewald (DGC) revealed that the project required nearly 300 moment welds. Described as a remarkable amount of welding, DGC estimated it would take a team of 20 ironworkers nearly two months to complete all of the welding. DGC worked with the fabricator and design team to determine what could be done in the shop, and what would have to be done in the field, and ultimately came up with combination of shop welds and bolted connections that reduced the number of welds from 300 to 100. The solution significantly cut down the duration of the project, which was completed in just three months. “Getting involved early allowed us to come together and collaborate, to influence the design and make it more erector-friendly. It’s something we try to do on every job,” said Mike Waters, Safety Director. The Prism’s south-facing “crinkle” wall included geometries that