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The National Air and Space Museum
STEVEN F. UDVAR-HAZY CENTER
Improving Safety and SustainabilityCraig Dubler
Construction ManagementSenior Thesis Presentation
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
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Presentation Outline
• Project Overview• Analysis I: Steel Sequencing• Analysis II: Simulated Safety Plan• Analysis III: Sustainable Redesign• Conclusions
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
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Presentation Outline
• Project Overview• Analysis I: Steel Sequencing• Analysis II: Simulated Safety Plan• Analysis III: Sustainable Redesign• Conclusions
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
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Project Overview
• Function: Display and preservation of Smithsonian’s collection of
historic aviation and space artifacts
• Size: 470,000 S.F. • Cost: $125,000,000• Delivery Method: Design-Bid-Build• Duration: 30 months
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
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Project Overview
Architectural features:
• Main Exhibition Hangar• Public Amenities• Observation Tower• Space Hangar
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
Main Exhibition Hangar
Space Hangar
Public Amenities IMAXObservation Tower
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Project Overview
• Main Exhibition Hangar– Arched tri-truss design– Hanging mezzanine
walkways– Counter-weighted exhibit
doors– Rubber membrane roof
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
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Project Overview
• Public Amenities including IMAX Theater– Consists of class rooms,
restaurants and retail shop
– Exterior:• Curved glazing• Metal panels• Metallic ceramic tiles
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
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Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
Structural System• Main Hangar
– Arched tri-truss steel system that ties into cast-in-place thrust blocks
– Drilled caisson foundation
• Public Amenities & IMAX Theater– Steel skeleton with slab on metal
deck– Spread footing foundation
• Observation Tower– Steel system encased in concrete– Mat footing foundation
Project Overview
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Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
Facts• 6500 tons of steel • 40,000 cubic yards of concrete • 30,000 cubic yards of excavation • 800,000 sq. feet of roofing • 64,000 linear feet (12 miles) of Walker
duct
Project Overview
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Presentation Outline
• Project Overview• Analysis I: Steel Sequencing• Analysis II: Simulated Safety Plan• Analysis III: Sustainable Redesign• Conclusions
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
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Steel Sequencing
• Main Hangar Steel– 15 percent of total construction cost– Erection process complex and unsafe– Steel fabricated in
Montreal, Quebec– Total erection time
around six months
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
Extra planning required!
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Steel Sequencing
Proposed solution:
• 4D Model of Steel Sequencing– Show steel erection including cranes
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
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Steel Sequencing
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
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Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
Existing Plan: 2D Proposed Plan: 4D
Steel Sequencing
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Steel Sequencing
Advantages of 4D Steel Sequencing
• Allows Smithsonian to easily understand erection process
• Subcontractors aware of where and when steel erection takes place
• Steel erectors develop milestones• Ask question about erection feasibility
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
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Presentation Outline
• Project Overview• Analysis I: Steel Sequencing• Analysis II: Simulated Safety
Plan• Analysis III: Sustainable Redesign• Conclusions
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
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Simulated Safety Plan
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
Jobsite safety extremely important
• Complex size and shape of building• Dangerous activities (e.g. Steel erection)• Contractor Controlled Insurance Plan
(CCIP)• Half of workforce is Hispanic, and
understands little English
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Simulated Safety Plan
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
• Hispanic Workforce– Creates a communication barrier
• Increases site safety hazards• Lowers productivity• Creates conflicts between managers and
workers
– Workers killed has more than doubled in last five years
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Simulated Safety Plan
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
4-D Safety Plan• Safety Plan Model
– Shows where and when activities take place
• Safety Plan Legend– Shows hazards associated with each activity
• Worker and Bystanders
• Specific Job Hazard Analysis– Describes hazards in more detail
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Simulated Safety Plan
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
Steel Erection
Roofing
Fire ProtectionMechanical
Glazing
Painting
Electrical
Metal Studs
Concrete
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Simulated Safety Plan
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
Sample Hazard Analysis(Northwest side of Hangar)
04-08-2002
Fire Protection Contractor•Falling•Welding•Cutting Metal•Heavy lifting•Struck by objectsAlso…•Roofing (struck by objects)•Steel (welding, struck by objects)•Mechanical (cutting metal)
Mechanical
Fire ProtectionRoofing
Steel Erection
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Simulated Safety Plan
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
Feasibility of 4-D Safety Plan• Preconstruction Meetings• Jobsite Orientation• Weekly Safety Meetings (Toolbox
Talks)
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Simulated Safety Plan
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
Key factors for Implementation• Develop in early stage of project
• Be sure model is understood by all workers– Model is useless if workers are not trained
to notice hazards
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Presentation Outline
• Project Overview• Analysis I: Steel Sequencing• Analysis II: Simulated Safety Plan• Analysis III: Sustainable
Redesign• Conclusions
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
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Sustainable Redesign
Mechanical System Redesign • Lower energy cost in Public Amenities
area
Site Redesign• Improved water retention system
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
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Mechanical System Redesign
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
FiltersReturn Air
OutdoorAir
ReheatCoil Cooling
Coil
Supply Fan
SecondReheat Coil
SupplyAir
Mixed Air
Exhaust
Existing AHU A-07
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Mechanical System Redesign
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
FiltersReturn Air
OutdoorAir
ReheatCoil Cooling
Coil
Supply Fan
SecondReheat Coil
SupplyAir
Mixed Air
Exhaust
Proposed AHU A-07
Enthalpy Wheel
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Mechanical System Redesign
Advantages of Enthalpy Wheel• Lower energy costs
– Save around $8,000 per year– Increased indoor air quality (IAQ)
• Low maintenance• Long life expectancy
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
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Site Redesign
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
Main Hangar
Public Amenities
Bituminous Pavement Bituminous Pavement
Water RetentionPond
Water RetentionPonds
Existing Site Water Retention System
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Site Redesign
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
Main Hangar
Public Amenities
Overflow (.5%)
Porous Pavement Porous Pavement
Water RetentionPonds
Proposed Site Water Retention System
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Site Redesign
Advantages of Porous Pavement• Elimination of large water retention
pond– Save approximately $130,000 – Space available for future expansion
• Natural rain-water filtration (pollutant removal)
• Increased skid resistance
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
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Sustainable Redesign
Summary
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
Sustainable Item
Initial Savings After 10 Years
Enthalpy Wheel -$30,000 $50,000*
Porous Pavement $130,000 $100,000**
Total Saved $100,000 $150,000* Including energy saving of $8,000 per year** Including maintenance cost of $3,000 per year
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Presentation Outline
• Project Overview• Analysis I: Steel Sequencing• Analysis II: Simulated Safety Plan• Analysis III: Sustainable Redesign• Conclusions
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
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Conclusions
• 4D Steel Sequencing– Simplifies erection process
• Simulated Safety Plan– Elimination of careless accidents only
if understood by every worker onsite• Sustainable Redesign
– Lower energy costs and increased IAQ– Natural rain-water runoff
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
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Thanks To….
• Hensel Phelps Construction Company– Mike Mattivi, Chad Mease, John Louge, and Dave Webb
• Smithsonian Institution – Lin Ezel
• Penn State AE Faculty– Dr. Messner, Dr. Horman, Dr. Riley, and Dr. Ling
• Family and Friends– Mom, Dad, Kelly, Amy, Jessica, and Gram….
You are truly my inspiration to succeed.
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
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Questions?
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Enthalpy Wheel
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
How it works• Transfers heat and humidity between
the exhaust and supply air • Brings the supply (incoming) air closer
in temperature and humidity to the exhaust air
• Reduces the load on the heating and cooling systems
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Sizing Enthalpy Wheel
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
Taken from Appendix E
Return air flow = 7314 cfm Vmin/Vmax = 0.80Supply air flow = 9200 cfm
Unit effectiveness = 0.825
Using a TE 3-9, the face velocity is 760 FPM, the pressure loss is 0.76 in. wg.
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Enthalpy Wheel - Energy Savings
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
$/kWh
$/therm
Annual Cost savingsCooling costs = $0.1/cfmHeating costs = $1.0/cfm
Total saved = $1.1/cfm of outdoor air
Total OA = 7314 cfm
Total Annual Savings = 7314 cfm * $1.1/cfm
= $8,045 per year
Rate of return = $33,000 / $8,045 = 4.1 Years
Washington D.C
Enthalpy Hrs. Cooling = 9,000Enthalpy Hrs. Heating= 41,000
Heating and Cooling cost*
Cooling = $0.055/kWhHeating = $0.55/therm*gathered from MSN living index
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Porous Pavement
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
Four Layers:•Wearing layer - asphalt with
greater than normal percentage of voids•Transition layer - layer between top wearing layer and the stone reservoir •Stone reservoir - thick layer of aggregate (5ft)•Geotextile – keeps soil out of
stone reservoir
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Porous Pavement - Construction
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia
Subsurface excavated without heavy equipment compacting the bed bottom. Fine grading is done by hand Geotextile is laid. Then clean/washed uniformly graded aggregate is place in the bed as the storage media.
Porous pavement asphalt layer is then placed, the same way as regular, on top of the stone reservoir
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Porous Pavement - Concerns
• Heavy equipment not allowed on porous soil– No staging in future porous pavement areas– Compacts soil and greatly lessens permeability
• Facilities maintained on a regular basis– Leaf Removal– Vacuum Sweeping
• Restricted Snow Removal– Plastic plow blades – does not damage surface– No sand or anti-skid – clogs pores
• Vehicle Restrictions– Passenger Cars and Trucks Only – Rutting may occur
Craig Dubler Steven F. Udvar-Hazy CenterConstruction Management Chantilly, Virginia