14

To keep pace with fierce competi-tion, Boston-based J.C. Cannistraro has found creative ways to lever-age building information modeling (BIM) solutions from Technical Sales International (TSI) to the fullest poten-tial and, in turn, push savings and productivity to new levels. The com-bination of CAD-Mech and JOB-Site Solutions software with the Trimble Total Station from TSI produces con-struction-ready models that enable

W H A T ’ S I N S I D E

11

J.C. Cannistraro Improves Jobsite Productivity Using TSI BIM Solutions

SMART SOLUTIONSH e l p i n g c o n t r a c t o r s s a v e m o n e y a n d e n h a n c e p r o d u c t i v i t y S

UM

ME

R

20

11

Victaulic Helps 4 J’s Plumbing, Fresh Meadow Mechanical, and KSW Complete the 9/11 Memorialfor 10-Year Anniversary OpeningTo keep the National September 11 Memorial on track to open on the 10th anniversary of the 2001 terrorist attacks, contractors 4 J’s Plumbing & Heating Corp., Fresh Meadow Mechanical Corp., and KSW, Inc., turned to Victaulic. For two enormous reflecting pools with waterfalls of an unprecedented size—and an incredibly tight timeframe—4 J’s Plumbing and Fresh Meadow Mechanical needed a reliable piping solution they could install quickly. KSW not only faced

time constraints but also space constraints that prohibited them from using a welded solution for a heating and cooling system to keep the bronze name plaques at mod-erate temperature year-round.

Victaulic was the piping system of choice to meet the compressed construction schedule, reduce total installation costs, accommodate expansion and contrac-tion, ease future system maintenance, and

New York-based contractors 4 J’s Plumbing, Fresh Meadow Mechanical, and KSW did their part to keep the National September 11 Memorial project on track by using Victaulic piping and couplings to meet the com-pressed construction schedule and reduce total installation costs.

Cannistraro crews use data from the TSI CAD-Mech software to identify each hanger, then rolling racks with several hundred hangers are sent out to the field and rolled to the appropri-ate section of the building. Cannistraro saves time and money by installing entire floors of hangers before a piece of pre-fab pipe is brought on the job.

3

North, Anvil Score Big Savings on Super Bowl Project .............. 3

D.V. Brown Teams with Johnson Controls to Cut Energy Costs ...... 8

Shinn Increases Productivity with Miller Electric, Get the Point ... 10

Kirk Williams and Grinnell Cut Costs on Air Force Base ............ 14

TJ Dyer Cuts Labor Costs by 20 Percent with Aquatherm ......... 15

continued on page 6

Small Effort in the Office Translates to Big Savings Onsite

continued on page 4

Time-Saving Tools Are In Demand

This issue of Smart Solutions demonstrates the continuing demand for products and services that save time and trim labor costs to meet ever-tightening deadlines.

Time is MoneyHigh-profile projects can have especially demanding schedules.In this issue, see how Kirk Williams Company relied on Grinnell to complete the new Wright-Patterson Air Force Base Human Performance Wing. New York-based 4 J’s Plumbing, Fresh Meadow Mechanical, and KSW kept the National September 11 Memorial project on track by using Victaulic

products, while Anvil’s Gruvlok products allowed North Mechanical to keep the new Indianapolis JW Marriott on schedule—in time for the 2012 Super Bowl.

Read why Smith & Oby and Coleman Spohn prefer Viega’s time-saving products and how the easy-to-install Quad Close Trap Seal device by Jay R. Smith Mfg. Co. helped Olson Plumbing keep its Colorado College renovation project on schedule. By choosing Metraflex Metraloop expansion joints, Edwards Engineering estimates saving over 1,200 man-hours in renovating Chicago’s Kluczynski Federal Building. Learn why Mesa Mechanical picked the Josam Push-Fit Stainless Steel Drainage System for a project at Las Vegas’ Bellagio.

Find out how TJ Dyer kept costs down by using Aquatherm’s Climatherm® piping for a Cincinnati senior living community’s heating system. And, learn how Shinn Mechanical saves significant labor hours with the Miller Electric Mfg. Co.’s PipeWorx‘ Welding System.

Meanwhile, our partners at CNA remind us that an ounce of prevention is worth a pound of cure. They provide 10 simple tips to prevent equipment theft.

Taking Advantage of Tech Cost-conscious contractors are also seeking ways to leverage new technology to stay com-petitive. In this issue, get tips from J.C. Cannistraro on using building information modeling solutions from Technical Sales International to push savings and productivity to new levels. Learn how Shinn Mechanical uses Get The Point’s Total Station Solution software and equipment to transmit accurate layout information rapidly to field crews. Read about Action Electrical & Mechanical Contractors’ success in streamlining accounting processes and more with the Digio document management solution by Jonas Software.

Performance Pays OffEnergy efficiency is no longer a bonus in building construction—it’s the new norm. Learn how J.E. Shekell is using AirAdvice/BuildingAdvice Energy Audits to identify areas for improvements and help clients make the case for undertaking energy-efficient renovations. Also read how D.V. Brown & Associates not only kept installation costs down for a school renovation project but also helped the school meet energy-efficiency requirements by using Johnson Controls products.

Planning for SuccessFor more smart solutions, join us for the 2011 Mid-Year Conference—Navigating the Recovery: Strategies for Success—in Indianapolis September 12–14. The educational ses-sions will help you transition your company from survival mode to success. For more infor-mation, visit www.mcaa.org/education.

Bill BartleyChairman

SMART SOLUTIONSHelping contractors save money and enhance productivity

Smart Solutions showcases new tech-

nologies and promotes cost-saving and

productivity-enhancing applications

available from members of MCAA’s

Manufacturer/Supplier Council. Smart

Solutions is published biannually for

contractor members of MCAA and its

subsidiaries.

All information in this newsletter was

supplied by members of MCAA’s

Manufacturer/Supplier Council. MCAA

is not responsible for any claims made

regarding products or services mentioned.

Cynthia Buffington

Senior Executive Director

Jan Letow

Director, Membership

Adrienne Breedlove

Director, Publications

Dana Trevas

Consultant

1385 Piccard Drive

Rockville, MD 20850-4340

301-869-5800

Fax 301-869-3520

e-mail cbuffington@mcaa.org

www.mcaa.org

S M A R T S O L U T I O N S S U M M E R 2 0 1 13

To complete a new JW Marriott hotel in Indianapolis, North Mechanical Contracting chose Anvil’s Gruvlok product to provide the kind of perfor-mance and value required to keep the project on time and within budget. The $450-million hotel and conven-tion center project was smack in the center of Indianapolis’ crowded down-town area and had to be completed a full year ahead of the 2012 Super Bowl there. Complicating matters further, North also had to provide services to other Marriott hotels within the same complex that would open a year before the mar-quee JW Marriott property, compressing North’s time-frame considerably.

“We have a 30-plus-year track record installing grooved piping systems,” said Rod Foley, proj-ect manager for North Mechanical. “We knew that grooved would save us time and labor costs, two things very important on this job,” so North selected Anvil’s Gruvlok products.

2012 Super Bowl Brings Need for New LodgingsWhen Indianapolis won the bid for the 2012 Super Bowl, the city realized it likely didn’t have enough hotel rooms to accommo-date the more than 100,000 people expected to come to town for the big game. The city selected Marriott Corporation to build a 1,005-room, luxury JW Marriott property near Lucas Oil Field, home of the Indianapolis Colts

and site of the 2012 Super Bowl. The glass curtain wall project broke ground in May 2008.

North provided plumbing and mechanical systems for the conven-tion center, as well as full infra-structure HVAC and plumbing for the existing buildings and the new hotel in the complex. While weld pipe was included in the original bid, North wanted to use as much

time- and labor-saving grooved piping as possible to help meet the tight timeframe. “Everything North needed was available in the Gruvlok line,” said Kyle Crawford, Anvil Mechanical Specialist. Gruvlok products used by North Mechanical in the Marriott project included 3´́ –12´́ couplings and fittings and Anvil pipe supports, both clevis-type and roller hangers.

Ready for Some Football!The project was com-pleted in December 2010. “Anvil kept everything moving,” said Foley. “They provided a value product that worked as promised and was deliv-ered to meet our product schedule. We plan on using Anvil products on our upcoming Indianapolis Veterans Administration hospital chiller replace-ment project.”

Now, Indianapolis has another luxury hotel prop-erty to welcome guests for the Super Bowl in 2012.

Greg Fuller, president of North Mechanical and an MCAA Board Member, will discuss how his company successfully uses integrated project delivery—a collabor-ative process involving all the participants early in devel-opment—on September 13 at MCAA’s 2011 Mid-Year Conference in Indianapolis, IN (visit www.mcaa.org/education for more details). For more information about Anvil, visit www.anvilintl.com.

North Mechanical and Anvil Score Big in Super Bowl Project KickoffPartners Tackle Space, Time Constraints Together with Grooved Piping Solution

North Mechanical Contracting chose Anvil’s Gruvlok product to stay on time and within budget for a new luxury JW Marriott hotel and convention center in Indianapolis (shown here under construction)—which is now ready to welcome more than 100,000 people when Super Bowl 2012 kicks off.

S M A R T S O L U T I O N S S U M M E R 2 0 1 14

eliminate confined space safety con-cerns. “Victaulic was definitely a prob-lem solver,” said KSW Chief Executive Officer Floyd Warkol. “This was an absolute perfect application.”

A Memorial for AmericaThe National September 11 Memorial & Museum will honor the nearly 3,000 people who lost their lives in the ter-rorist attacks of September 11, 2001, and the World Trade Center bombing on February 26, 1993. The memorial consists of two reflecting pools, each approximately one acre in size, sunken 30 feet into the footprints of the north and south towers of the World Trade Center. Featuring the largest manmade waterfalls in the country, each pool contains about 560,000 gallons of water, and every minute, 24,000 gal-lons of water ringlets cascade over the edges of each fountain. The pools are set within an eight-acre plaza studded with oak trees. The mechanical rooms housing the pumps for the waterfalls are located directly beneath the pools, approximately 50 feet below plaza level. The name plaques are bronze parapets surrounding the twin pools that are inscribed with the names of the victims.

The memorial will open in a dedica-tion ceremony for victims’ families on September 11, 2011—the 10-year anni-versary of the attacks. It opens to the general public by reservation a day later on September 12. (Online reservations for free visitor passes can be made at www.911memorial.org.)

Tight Deadline Gets Tighter4 J’s Associates, LLC, a joint venture of 4 J’s Plumbing and Fresh Meadow Mechanical, both based in New York, began the piping and equipment instal-lation for the fountains in March 2010. In June, the target completion date for the north pool was moved to ensure that the pool would be filled and the pumps operating in time for a November 2010

demonstration. The team of contractors faced a tight schedule, one in which everything had to be done right the first time. Meanwhile, New-York based KSW handled the installation of a heat-ing and cooling system for the name plaques, as well as the chiller plant.

Victaulic grooved mechanical piping solutions were selected to join much of the piping for the seven different types of mechanical systems on each pool, including the stainless steel waterfall systems and filtration systems, stainless steel sump and galvanized ejector lines, and ductile iron plaza drainage system, as well as the name plaque heating and cooling system.

Faster and Easier InstallationsCompleting the project on time was a primary concern of the Port Authority. “I assured them it wouldn’t be a prob-lem,” Daniel Justus, president of 4 J’s Plumbing, recalled. “They asked if we’ve ever done a fountain project this large, and I said I don’t think anyone has done a fountain project this large. But it’s a doable project for us, just larger pumps and bigger pipe and fittings.”

Victaulic grooved mechanical piping is faster and easier to install than other pipe-joining methods because the gasket and coupling housing are simply posi-tioned on the grooved pipe ends and the bolts and nuts tightened with standard hand tools.

For the 24´́ and 16´́ waterfall piping, Victaulic Advanced Groove System (AGS) couplings were selected. AGS couplings feature enhanced pressure ratings and are the only couplings on the market that feature a two-piece housing design up to 60´́ in diameter for increased installation speed and ease of assembly.

On the memorial project, Victaulic QuickVic® installation-ready cou-plings further reduced installation time. The couplings do not require disassembly prior to installation, so plumbers could simply “stab” the cou-plings onto the grooved pipe ends and tighten the bolts. Victaulic couplings featuring installation-ready technology are up to 10 times faster than welding and six times faster than flanging to install.

VICTAULICcontinued from page 1

4 J’s Plumbing and Fresh Meadow Mechanical chose easy-to-install Victaulic couplings to meet the tight deadline for the National September 11 Memorial reflecting pools, which are approximately one acre in size and sunken 30 feet into the footprints of the north and south towers of the World Trade Center.

S M A R T S O L U T I O N S S U M M E R 2 0 1 15

“The use of Victaulic couplings and fittings accelerated the installation process tremendously,” said Michael Russo, chief operating officer of Fresh Meadow Mechanical. “It’s a much easier system to install.”

In addition to speeding the construc-tion, Justus and Russo credit the couplings with reducing costs. “It’s definitely going to cost more money to weld a pipe than to groove it and use the couplings,” Justus said. Not only would welding have been more expensive, it also would have been extremely difficult given the time and space constraints. “Welding all the pipe onsite would have been impos-sible,” Russo stated. “There’s between 3,000 and 4,000 couplings. If all those connections had been welded, we’d still be welding.”

To further reduce installation time, as well as organize and coordinate deliv-ery of the piping, a majority of the larger pipe was fabricated offsite and delivered to the jobsite for connection. This approach allowed for relocation of some labor to a controlled envi-ronment, minimizing the amount of material handling onsite while also saving space. In the cramped quarters of the pump rooms—particularly the south pump room, which is about half the size of the north—there wasn’t much room in which to work. KSW’s Warkol explained, “The mechanical rooms are shared space. There were different companies working under different contracts for different enti-ties all at the same time. The orches-tration of the various contracts and the various trades by the Port Authority is an unbelievable feat.”

Couplings Accommodate Last-Minute Changes, System MaintenanceThe speed of installation also proved to be advantageous when last-minute design changes were handed down. “We had several design changes throughout the job, some small, some

large,” Justus explained. Victaulic grooved piping systems provide easy access for system alteration, as well as maintenance and expansion, because a coupling creates a union at every joint. To access the system, a worker unscrews two bolts and removes the coupling housing and gasket—no torch, saw, or welding machine is nec-essary.

“With grooved pipe, if you have to take something apart, you take off the coupling and you extend it or alter it; it’s easy to work with. If you have welded pipe, you have to cut into the pipe and you have to weld another fit-ting. Doing that in the field versus the grooved system—it’s night and day,” Justus said.

The serviceability of the Victaulic grooved system also simplifies system maintenance. Given the nature of the application and the chemical treatment of the water, periodic inspections will be conducted to detect microbiologi-cal growth within the piping. “The access capabilities of the Victaulic connections [allows maintenance per-sonnel to] take systems out of service, open up the piping, and do a visual internal inspection very easily,” Russo explained.

Accommodation of thermal movement was also a requirement. The design of a Victaulic flexible grooved pip-ing system accommodates expansion and contraction by permitting linear movement and deflection of the pipe within the coupling, thus minimizing the need for costly expansion joints or large expansion loops, which would have been nearly impossible given the space constraints.

Safe Installation in a Confined SpaceWhile 4 J’s Plumbing and Fresh Meadow Mechanical installed piping for the reflecting pools, KSW was installing piping for the bronze name plaques, which required a heating and

cooling system to keep the plaques cool in the summer and warm in the winter. The system, including 4´́ steel mains and 3/4´́ copper branches, was to be installed in a 4-foot-tall crawl space below the parapets. Because welding in such a location would have introduced confined space concerns, Victaulic couplings were selected to join the mains.

Proud To Be Part of HistoryThe speed of installation of the Victaulic grooved piping system was a considerable factor in complet-ing the project on time. The 4 J’s Associates team was able to turn over the north pool to the Port Authority on November 3, 2010, and installation of the piping systems for the south pool was substantially completed by January 2011, more than three months ahead of schedule. “Victaulic was a key player in being able to meet the required timelines for the project,” Russo stated.

“The Port Authority and the founda-tion were really happy with what we did,” Justus said proudly. “They praised us for our workmanship and for completing the job in the time-frame we did.”

As proud as each of the firms were to finish ahead of schedule, the symbolic nature of the project resonated even more. “Being a part of the rebirth of the World Trade Center area was a remarkable experience. It meant a lot to us as a contractor in the New York metropolitan area and our employees to be involved in the project,” Russo reflected.

Warkol added, “It’s exciting to be a part of what’s taking place down there. It’s a major piece of American history.”

For more information about Victaulic products, visit www.victaulic.com. To learn more about the 9/11 Memorial, visit www.911memorial.org.

S M A R T S O L U T I O N S S U M M E R 2 0 1 1�

off-site pre-fabrication and efficient installation processes.

As Joe Mierzejewski, Cannistraro’s project manager and coordination department manager, commented, “We are always attempting to find ways to become more efficient and save labor costs, and the CAD-Mech and JOB-Site Solutions software and Trimble hardware from TSI is the perfect ave-nue for that.”

Pre-Fabrication Ensures Quality, ProductivityBringing the bulk of the work to Cannistraro’s pre-fabrication facility ensures that every component is pre-engineered, thereby improving mate-rials management and overall project flow. Cannistraro’s “Fab Lab” has the capacity to design and pre-fabri-cate piping components for the most complicated mechanical systems. The company has pre-fabrication and storage facilities for the plumbing and fire protection trades, as well as a 40,000-square-foot HVAC shop complete with overhead cranes, a plasma cutter, and automatic welding machines.

“We can take months off of a schedule because we do three or four months of work upfront, before we’re on the job,” said Mierzejewski.

Without pre-fab capabilities, contrac-tors deliver piping pieces to jobsites—which then remain in a pile, taking up precious floor space. The subsequent, on-site, “stick-built” method results in lower productivity, longer installa-tion schedules, and greater waste and debris. Weather, too, becomes a for-midable factor—shutting down work-sites, damaging materials, and making work uncomfortably cold, hot, or wet for construction workers. Measuring, cutting, fitting, and assembling in the field is tiresome, time-consuming,

wasteful, and potentially dangerous—and those fac-tors all drive up costs.

Minimizing Layout LaborCannistraro has also found opportunities for savings and efficiency in the installation of hangers and sleeves. Once the components are assem-bled, time and labor costs can accrue during on-site installation of sleeves and hangers. “The Boston mar-ket and job conditions don’t always allow us to sleeve ahead of time. Coring after a deck has been poured has become the common practice in this area,” said Mierzejewski. Through the use of TSI JOB-Site Solutions software and Trimble Total Station, the labor required to layout points is signifi-cantly reduced. Typically, the employ-ees doing the layout have to attach the wireless controller (the Nomad) to a rod with a 360-degree prism mounted on top and walk around the site to shoot the points.

Making More Intelligent ModelsTo solve the problem of uncon-structable 3D models received from designers, Cannistraro now uses TSI’s CAD-Mech software for creating intel-ligent models for fabrication. “Using TSI’s BIM software, our foremen work directly with our modelers to produce pre-fabrication documents known as ‘spool sheets.’ These documents are downloaded to the shop floor, where our licensed mechanics create piping assemblies that are ready for delivery and installation,” said Mierzejewski. The entire process is driven by geom-etry in the model provided by TSI’s CAD-Mech software.

Furthermore, the model allows Cannistraro to produce stock lists auto-matically for estimating and change management. CAD-Mech generates detailed reports for shipping, purchas-ing, and fabrication; with the auto-

spooling feature, detailers can create fabrication drawings with an automatic bill of material generation for each ISO drawing. Building owners and con-struction managers can then view cost implications for project planning and make decisions within the context of the model.

Additionally, by using TSI’s BIM soft-ware, Cannistraro can take advantage of barcoding to track equipment and piping assemblies from pre-fabrication to installation.

From Fabrication to Installation—Bang It and Hang It“Before we purchased the CAD-Mech and JOB-Site Solutions software and Trimble hardware from TSI, the installer would be armed with a coor-dinated 2D drawing, a tape measure, a hammer drill, inserts, a lift, band saw, cords, and the associated hanger stock,” said Mierzejewski. Using the Trimble Total Station in conjunction with TSI’s CAD-Mech and JOB-Site Solutions BIM software makes sleeves, coring, and hanger layout safer, more efficient, and less expensive.

With the ability to extrapolate intel-ligence out of the CAD-Mech soft-ware, the Cannistraro crews can now individually number each hanger and run a report showing the rod size,

TSIcontinued from page 1

Extrapolating information from TSI’s CAD-Mech software, the Cannistraro crews can individually number each hanger, then send it to the appropriate section of the building, saving labor time onsite.

S M A R T S O L U T I O N S S U M M E R 2 0 1 1�

length, and various other pieces of information. That number corre-sponds to the concrete inserts and the physical drawing. Rolling racks with several hundred hangers are sent out to the field and rolled to the appro-priate section of the building. Entire floors of hangers are installed before a piece of pre-fab pipe is brought on the job.

Before this innovation, the installer would lay out hangers off a 2D draw-ing and control lines. If not done perfectly, pre-fab may be slightly off and need to be altered, or some hangers might need to be moved. With the combination of TSI’s CAD-Mech software producing the pre-fabbed hangers and piping, the JOB-Site Solutions software extract-ing accurate hanger locations, and the Trimble hardware’s offering overwhelming accuracy and ease of use in the field, Cannistraro estimates saving approximately 70 percent in material and labor per hanger installed, with substantially more pre-cision. Upon realizing those astonish-ing numbers, the Cannistraro team

started coming up with new ways to use these innovations.

Taking it a Step FurtherCannistraro has invested in a mobile coring rig that increases the num-ber of holes drilled per day. While the Trimble unit has saved time and greatly improved accuracy of laying out core holes, Cannistraro has taken the idea one step further by integrating the Trimble with the mobile rig. By mounting the prism and Nomad (hand-held controller) directly to the mobile rig, the rig can layout the hole and core it. Reducing a two-man job (layout and coring) to a one-man job has cut labor costs even further.

Setting a LEAN Standard for EfficiencyCannistraro’s basic processes now constitute a LEAN construc-tion standard. They create small “batches” of work broken down into four basic tasks (generate pre-fab sheets, generate pre-fab hangers, install Bang-Its, install hangers) that can be repeated with efficiency, accuracy, and speed.

The need for one or two installers to carry around tools and stock for several tasks has been eliminated. The job is reduced to a single man, a rolling cart full of numbered hangers, and a lift. Each task is completed with minimal tools and minimal stock. More impor-tantly, Cannistraro is less dependent on other trades to complete work. “Anytime a step can be eliminated or improved, it’s a worthwhile venture,” said Mierzejewski.

These efficiencies are achieved as a result of information included in Cannistraro’s 3D drawings produced with CAD-Mech. A small amount of additional effort in the office has trans-lated to significant savings in the pre-fab shop and on the jobsite. Further, savings are realized in less wear-and-tear on small power tools, reduced rental time of a lift, and, most importantly, the elimina-tion of potential eye injuries and back strain from overhead drilling.

3D BIM Provides Competitive AdvantageWith TSI BIM Solutions, Cannistraro’s plans become multi-dimensional construction models that show the whole project in a 3D, ani-mated view where the team can see every fitting, hanger, and support—as well as dimensional, material, cost, and labor data—before a job is installed. “It’s a great tool that helps us do our job better and gives J.C. Cannistraro that competitive advan-tage,” Mierzejewski concluded.

Mike Cannistraro, vice president of engineering at J.C. Cannistraro, will explain how his company has used the BIM process to create fabrication and preassembly effi-ciencies that greatly improve labor productivity and provide a competi-tive advantage on September 13 at MCAA’s 2011 Mid-Year Conference in Indianapolis, IN (visit www.mcaa.org/education for more details). For more information about TSI, visit www.technicalsalesinternational.com.

Opportunities to Improve Efficiency and Savings with BIM

• Automatic intelligent hanger and sleeve generation

• Piping spools and pipe pre-fabrication

• Hanger pre-fabrication

• Reduced field labor for hanger inserts and sleeves

• Increased productivity of hanger installation because of exact measurements

and pre-fabricated hangers

• Reduced rework of pipe fabrication because of exact location of hangers and

sleeves

• Reduced field manpower as a result of pipe prefabrication

• Reduced safety costs with less field labor

• Increased LEAN construction by using just-in-time delivery

• More green building adherence because of fewer materials and less waste at

the jobsite

S M A R T S O L U T I O N S S U M M E R 2 0 1 18

By using Johnson Controls products for the renovation of five schools in Dunkirk, NY, D.V. Brown & Associates, Inc. (DVB) not only keeps installation costs down but also helps the school meet energy-efficiency requirements that will result in energy savings. Dunkirk City School District is in the second phase of a two-phase renovation project that began in July 2010. Responsibility for making $3 mil-lion in mechanical equipment upgrades to four elementary schools and the district’s middle school rests with DVB, headquartered in Tonawanda, NY.

“We are replacing and upgrading equip-ment that is at least 20 years old,” said Don Brown, DVB president and CEO and a member of MCAA’s Board of

Directors. “The project engineer pro-vided us with options for new equip-ment that will meet the specifications for the project. Based on our previous experience and the reliability of their products, we opted to go with products from Johnson Controls and the York® brand of Johnson Controls.”

The HVAC systems upgrades include indoor and outdoor Solution™ air-handling units, blower coils, Series 10 packaged rooftop units, unit ventilators, hot water coils and hot water unit heat-ers, FW Series fan-coil units, condens-ing units, and a YLAA air-cooled scroll chiller. All of the equipment meets or exceeds the energy efficiency require-ments for the buildings. School districts like Dunkirk are facing limited funding

and tight budgets, so administrators are looking to save money by improving the efficiency of their buildings and reduc-ing their energy consumption.

Factory Packaging Ensures Quality, Saves Time and HeadachesBut just as important to the school dis-trict and DVB is the fact that much of the equipment features factory-packaged controls from Johnson Controls.

“We both benefit,” Brown explained. “As the installer, we know we are get-ting equipment with controls that have been consistently installed in a controlled environment, ensuring quality and saving time.” In fact, technicians in the factory have easy access to all segments of the equipment, making precise installation and wiring easy and efficient.

“By the time the equipment arrives at the jobsite, it is already tested and integrated with the control system, sav-ing us time and limiting or eliminating many of the headaches associated with startup,” Brown continued. “Johnson Controls has a reputation for equipment that is very well laid out and very ser-viceable. All the key components and controls are very well thought out, mak-ing installation easy and an efficient use of our time.”

With air-handling units, factory mounting maintains leakage perfor-mance. Factory wiring is “plug-and-play”—that is, the equipment is ready to go once it’s installed. Sensor probes are pre-engineered to determine the best mounting location, ensuring accurate and reliable readings. Each mounted and wired device is tested at the factory, and each unit includes factory-generated control diagrams.

Ease of Installation of Johnson Controls/York Products Helps D.V. Brown & Associates Keep School Renovations On Time, On BudgetEnergy-Efficient Products and Digital Controls Will Help School District Cut Energy Costs

D.V. Brown & Associates selected rooftop units and other Johnson Controls products for a school renovation project in Dunkirk, NY, because they are reliable, easy to install, and help the school meet energy-efficiency requirements.

S M A R T S O L U T I O N S S U M M E R 2 0 1 1�

As a result, installation of the equip-ment requires less time.

Factory packaging “makes our job easier and less costly,” said Brown. “But lower installation costs also benefit the school district, and the time savings we real-ize with these controls helps to keep the construction schedule on budget and on time. This is especially important to school districts, where accomplishing work over the summer, between the end of the school year and prior to the start of the new year in September, is critical.”

Metasys System Allow Wireless Access, Customizable ReportsIn addition to the benefits offered by digital controls applied to the mechani-cal equipment, the school system will also appreciate the advantages of hav-ing wireless controls on network-based equipment. The Metasys® building man-agement system from Johnson Controls integrates building technologies and automates and manages systems in a

single building or multiple buildings. Information on system performance and status can be accessed from any web-based device. The Metasys Ready Access Portal delivers information on standard web browsers (including Apple® iPhone® and iPod® touch plat-forms), enabling facility managers to monitor building systems and facility usage and respond quickly to changes or operating challenges, no matter where they are.

In addition, Metasys provides easily customizable reports that help school districts optimize operation of all the facilities on the network even as it helps to ensure redundancy and reduce life-cycle costs going forward. Improved graphics make it easy to use, which can result in better cost management and improved system performance.

The school district can also anticipate improved comfort as a result of new controls and equipment upgrades, con-

tributing to an environment that is more conducive to learning. At the same time, school district efficiency goals are achievable, thanks to the improved energy performance of the new equip-ment and controls.

“The use of Johnson Controls equip-ment, with its factory-packaged con-trols and wireless field bus system, is a win-win for all concerned,” Brown concluded. “As the mechanical contrac-tor, we’re enjoying all the advantages of a simpler, less time-consuming installa-tion process while feeling confident in the reliability and quality of the equip-ment we’re installing. Meanwhile, the school district is realizing efficiency improvements that will result in energy savings and control flexibility that will ensure improved performance and a more comfortable, productive envi-ronment for students and staff.”

For more information, visit www.johnsoncontrols.com.

Ten Tips for Preventing Equipment TheftWith the price of used equipment at an all-time high, the current uncertain economic conditions, and the inherent vulnerability of jobsites and yards, CNA encourages you to implement strategies to protect against jobsite burglaries, vandalism, and equipment theft. The following tips can help:

• Do not leave machines on unfenced properties or jobsites. When possible, temporarily move machines to fenced yards or locate a secure lot near the jobsite, such as a car dealership.

• Disable machines that have to be left on jobsites. Disconnect batteries; pull fuses, relays, or ignition circuits; and remove tires.• Do not leave machines or materials on trailers. Equipment on trailers is much easier to steal.• Randomly check jobsites during off-hours. Give designated employees a list of what machines, tools, and materials should be

at each jobsite, so that missing property is not overlooked.• Do not leave hand tools or small equipment at jobsites. Lock boxes should be secured with additional locks, chains, etc.• Advise jobsite security guards if any activity is expected. Thieves are often familiar with the work site and may even have cre-

dentials that allow them to be on the site or to move equipment. Be sure security guards have a contact number so that they can alert you about suspicious activity.

• Let employees know that management will be making spot checks of jobsites. Let the grapevine work to your advantage.• Create an accurate list of all important equipment, with serial numbers. The list will help aid in the potential recovery of any

stolen equipment.• Mark all tools with the company name and address. Make it as large and as permanent as possible.• Register your equipment on the National Equipment Register today: www.ner.net.

It’s always a good time to prevent theft.

For more information on CNA’s insurance solutions, please visit www.cna.com/construction.

S M A R T S O L U T I O N S S U M M E R 2 0 1 110

While Shinn Mechanical, Inc. of Kent, WA, has already increased its MIG weld quality to the point where opera-tors can’t remember their last rejected weld, its welders also complete joints three to four times faster than shops that rely solely on stick and TIG tech-nology by using the new PipeWorx™ Welding System, a pipe-specific mul-tiprocess welding system from Miller Electric Mfg. Co.

PipeWorx features the Pro-Pulse™ pulsed MIG and RMD™ (Regulated Metal Deposition) processes, as well as stick, TIG, and flux-cored pro-cesses that have been optimized spe-cifically for pipe fabrication. It also provides traditional MIG processes. Switching between processes requires pushing one button. Because operators do not need to manually switch polar-ity, cables, or hoses, they are more productive, and a potential source of errors is eliminated.

Same Quality, Three to Four Times FasterWhile some code requirements and weld procedure specifications require TIG or stick welding or both, Shinn Mechanical has worked with its cus-tomers to qualify as many applications as possible for the RMD and Pro-Pulse. For example, welding 4´́ - and 6´́ -diameter pipe generally requires two passes. “We would run an RMD root with a Pro-Pulse cap,” said Steve Sayers, a pipefitter/welder with UA Local 32 who has worked at Shinn Mechanical since 2005. “We go to Pro-Pulse on every size that requires more than two passes whenever codes and procedures allow.”

Sayers continued, “It would be a minimum of double, if not three times, faster to put in an RMD root

as opposed to a standard TIG or stick weld. With the Pro-Pulse capabilities, because of how much metal you can put down with still having an x-ray-quality weld, your production times [are] three to four times faster [with] the same quality of work you could [do] with a TIG or stick procedure. We haven’t had a wire [welding] reject in well over a year.”

With Miller Electric Mfg.Co’s PipeWorx Welding

System, “Your production times [are] three to four

times faster [with] the same quality of work you could [do] with a TIG or stick

procedure. We haven’t had a wire [welding] reject in

well over a year.”—Steve Sayers, Shinn Mechanical

Miller engineers have confirmed Sayers’ estimates for RMD. While productivity rates vary depending on joint configuration, diameter, sched-ule, material, etc., general travel speeds for root pass welding are as follows:

• TIG: 2–4 inches per minute (ipm)• Stick: 5–8 ipm• RMD: 6–12 ipm

On average, the RMD process creates a root pass weld with a 1/8´́ - to 1/4´́ -throat. In many instances, the amount of root pass metal deposited can sup-port the heat input requirements of a

pulsed MIG fill pass. In many applica-tions, Shinn Mechanical eliminates the traditional hot pass, which can save 10–15 minutes of time on 12´́ -diam-eter, Schedule 40 pipe.

Multipurpose Machine Saves MoneyOn any given day, pipefitter/welders need TIG, stick, flux-cored, MIG, and pulsed MIG welding capabilities. A traditional pipe shop would equip its welding areas with a TIG/stick welder and perhaps a multiprocess welder, which typically doesn’t have a high-frequency start function.

“With the PipeWorx, you have the ability to have a high-frequency start, which is huge when you’re doing quality work,” said Sayers. “Now you don’t have a scratch start, which always takes a chance of leav-ing a tungsten inclusion. [PipeWorx] keeps us from having to buy an additional welding machine just to have the high-frequency capabilities in the start, which is a huge money savings.”

The PipeWorx’s push-button process change capabilities also provide a significant savings. In a matter of sec-onds, operators can switch between:

• DC TIG, with Lift-Arc‘ starts or high frequency for non-contact arc starts;

• stick, with arc performance opti-mized for E6010 or E7018 elec-trodes in pipe applications;

• flux-cored;• conventional MIG; or • RMD or Pro-Pulse processes.

To illustrate, “Let’s say I just did a Pro-Pulse cap and then wanted to switch back to a TIG start,” said Sayers. “It can

Shinn Mechanical Increases Pipe Fabrication Quality and Productivity with PipeWorx Welding System

S M A R T S O L U T I O N S S U M M E R 2 0 1 111

take me a minute to grab my torch, my foot pedal, set it up, and I’m ready to go within a minute’s time between change-overs. And the only reason it takes that long is because my TIG torch and foot pedal are all wrapped up. In order to change between the TIG setup and the wire setup, it takes all of two seconds. Just walk right over to the machine, pull the trigger on either one of the guns and I’m right back into the MIG position.”

With all other multiprocess welding systems, process changeover takes 5–10 minutes. Operators usually need to change the welding lead (TIG torch to stick electrode holder to wire feeder, etc.) as well as swap the work lead because different processes require different polarities. In pipe fabrication

shops, MIG, stick, and flux-cored pro-cesses use reverse polarity (DCEP), whereas TIG welding uses straight polarity (DCEN).

Pipefitter/welders typically change processes an average of eight times per day, which adds up to a total of 40–80 minutes of changeover time. Using a conservative overhead rate of $60/hour, changeover costs of old welding systems quickly add up:

• $40–$80 per day per operator• $200–$400 per week• $10,000–$20,000 per year

By eliminating unproductive process changeover time to “all of two sec-onds,” coupled with faster welding

speeds, Shinn Mechanical pipefitter/welders can easily achieve their daily goal of 200 weld inches (i.e., complet-ing 20 joints on 10´́ -diameter pipe).

Pre-Programming Settings Saves TimeAs noted earlier, Shinn Mechanical works to qualify many procedures for the RMD and Pro-Pulse pro-cesses. To facilitate quick change-over between these processes, Sayers uses a dual wire feeder that stores four welding programs on each side. He uses the right side to put in the root pass.

“I’ve got my RMD setting, MIG set-tings for different applications, and then I’ve also got a pulsed setting for

Because Miller Electric Mfg. Co.’s PipeWorx Welding System allows operators to switch quickly between multiple types of weld processes, Shinn Mechanical not only saves labor time, but also avoids “having to buy an additional welding machine just to have the high-frequency capabilities in the start, which is a huge money savings,” observed Steve Sayers of Shinn Mechanical.

S M A R T S O L U T I O N S S U M M E R 2 0 1 112

certain applications,” said Sayers. “I can put a bead into anything with any of those four settings. Then I just switch over to my left side gun, and that’s where my Pro-Pulse side is for my fill and my caps. I can generally, off of those four programs, run any-where from 2´́ , Schedule 40 pipe all the way up to as large a pipe as there is” just by adjusting wire feed speed.

To switch between programs, Sayers uses the trigger select function, which eliminates the need to return to the feeder’s control panel to switch between passes.

Arcs Designed for Pipe WeldingUnlike other multiprocess welding systems, the PipeWorx features arc characteristics specifically designed for pipe welding. For example, the arc characteristics, metal transfer, wet out, and puddle control of Pro-Pulse and RMD produce optimum results in the joints and welding positions typical of pipe welding.

“You can get out of position a little easier, and it seems to hold a puddle better,” observed Sayers. “RMD also leaves less wagon tracks in your weld in the side walls of the pipe. When you’re doing high-quality work, you don’t have to grind out nearly as much of your base metal to get down to clean metal again [before] your sec-ond pass.”

Sayers estimated that RMD reduces grinding time by 30 percent compared with conventional short-circuit MIG. On 12”-diameter pipe or larger, RMD can save five minutes or more of grinding time per joint, which helps Sayers accomplish his daily goal of 200 weld inches per day.

Sayers also noted that RMD “looks closer to TIG-like. It lays down flat-ter than short-circuit welding does. It doesn’t seem to fall in as much. It tends to hug the sides of the walls of the pipe to where it does have the

tendency of laying flatter, maybe … a little wider and get really good pen-etration. It doesn’t seem to drop in nearly as easily as short arc does. That way, you don’t have excessive pen-etration on your root pass.”

RMD Is a Quick StudyHistorically, pipe fabricators refused to adopt conventional MIG processes, or they limited use to non-critical applications. Fabricators felt that consistently producing code-quality welds with no or little rework required a high degree of skill and significant training. Miller designed RMD so that novice welders could learn it in a mat-ter of days, and experienced welders could learn it in hours.

“The fabrication timeyou save is just

unbelievable. I couldn’t imagine trying to do it

any other way.”—Steve Sayers, Shinn Mechanical

“RMD runs extremely smooth,” said Sayers. “It’s easy to tell when you do have a problem because it will be noticeable. The machine will let you know to stop because the arc will have a crackle sound that’s not familiar. When it’s running consis-tently, it always has the same sound; it doesn’t change.” Further, “if it cre-ates a little bit of a keyhole, you just slow down, and it seems to fill itself right back in.”

One of the biggest challenges in pipe welding occurs when two sec-tions of pipe are misaligned, known as a “high-low” situation. Sayers stated that if the misalignment is within 1/8´́, RMD “generally has no problem picking up both of those edges and doing a good tie-in [so] you don’t have to try to go back and

grind or try to make a repair. [It] doesn’t thin out your walls too much to where when you try to put your secondary pass in it doesn’t want to blow through.”

RMD provides these benefits because it precisely and consistently controls metal transfer. Uniform droplet depo-sition produces a stable and more controllable weld puddle (as opposed to the “explosion” of traditional short-circuit transfer). RMD enables consistent tie-in to the sidewall, com-pensates for high-low misalignment, easily bridges gaps of up to 3/16´́ , and creates more consistent root reinforce-ment on the inside of the pipe.

Consistent, High-Quality ResultsShinn Mechanical has had nearly two years of experience with the RMD and Pro-Pulse processes and one year with the PipeWorx Welding System. In that time, the PipeWorx Welding System has paid for itself many times over. This new welding technology consistently produces x-ray quality results in critical applications for root, fill, and cap welding. Add in productivity-enhancing features, such as quick process changeover, trigger select, and welding speeds that help accomplish a daily goal of 200 weld inches, and pip-efitter/welders such as Steve Sayers say there’s no way they would go back to older welding technology.

“With the PipeWorx setup that we’ve got and all of the things that we’ve brought in with our [new] shop, it’s unbelievably fast,” said Sayers. “The fabrication time you save is just unbe-lievable. I couldn’t imagine trying to do it any other way.”

Thanks to Shinn Mechanical for dem-onstrating its Articulated Weld Boom for participants at MCAA’s Pre-Fab Seminar in Seattle, WA, May 4–6, 2011. The Articulating Weld Boom won the company the 2008 E. Robert Kent Award for Management Innovation. For more information about PipeWorx, visit www.millerwelds.com.

S M A R T S O L U T I O N S S U M M E R 2 0 1 113

Using Get The Point’s Total Station Solution software and equipment, Shinn Mechanical laid out and installed pipe hangers and sleeves efficiently and accurately for a parking garage and rental car office facility for SeaTac International Airport. Shinn recognized a significant labor savings compared with the original installation estimate, overcoming many of the time-consum-ing challenges of conventional layout and point positioning.

Parking Garage Poses ChallengesShinn Mechanical installed mechani-cal piping on five levels of garage and office/tenant space. The parking garage was constructed using post-tension slabs, requiring precisely located inserts for hangers. Post-installed concrete anchors were not permissible. Furthermore, the roof structure over the tenant lease space on the top floor was made up of steel beams with limited capacity. Hanger

locations had to be detailed and coordi-nated among the trades to place attach-ments accurately to the structure while ensuring that maximum-rated loads for the beams were not exceeded.

Through the coordination process, Shinn Mechanical located every hanger for all hydronic piping within the 3D AutoCAD model. The question then became how best to transmit the infor-mation to the field crews for layout. Traditional, dimensioned shop drawings were considered, but this process would have been labor-intensive and ineffi-cient given the congestion of trades and the fact that there were few flat surfaces for layout. The structure incorporated compound slopes throughout the garage, as the slab was broken up into grid sec-tions with differing grades in multiple directions. A conventional layout on the floor would have been extremely time-consuming.

The benefits of Get The Point’s Total Station Solution software and equip-ment were immediately apparent. Shinn had little time to spare; the detailer familiarized himself with the software and quickly produced the point lists for input into the Total Station. The learning curve for the detailer and field crew was minimal, and Shinn soon had hanger attachment points installed—ahead of schedule.

One-Touch Positioning Speeds Layout TimeTrying to shoot a laser to the ceil-ing presented a problem, but with Get The Point’s patent-pending GTP X-Y Positioner, Shinn was able to identify the points on the ceiling and on the ground. The basic concept of the tool is to get within a foot or so of the desired point, and then operate the tool with the touch of a finger, instead of picking up the prism pole, moving, leveling, and

repeating until a “0,0” read-out is achieved. This approach allowed Shinn to speed up lay-out time even further.

The project also involved exten-sive seismic bracing require-ments, which were placed using the Get The Point Total Station Solution. With the inputs from Shinn’s 3D AutoCAD model, the system precisely located all of these components, elimi-nating conflicts between the bracing/cables and other trades. Thanks to the successful instal-lation and significant labor sav-ings, Shinn Mechanical intends to put the Get The Point system to use on many more projects in the future.

For more information, visit www.gogtp.com.

Get The Point Software and System Allow Shinn Mechanicalto Speed Up Piping Installation

Shinn Mechanical saved labor costs and time by using Get The Point’s Total Station Solution software and equipment to transmit layout information to field crews installing pipe hangers and sleeves in a parking garage and rental car office facility for SeaTac International Airport.

S M A R T S O L U T I O N S S U M M E R 2 0 1 114

By using Grinnell Grooved Products for a new research, education, and consulting facility at Wright-Patterson Air Force Base, the Kirk Williams Company completed an aggressive 24-month project on time with reduced labor costs. The Columbus-based Kirk Williams included Grinnell Mechanical Products, a premium brand of Tyco International, in their bid for the HVAC and plumbing systems in the new Human Performance Wing, a 680,000-square-foot complex in Dayton, OH.

Because Kirk Williams had worked with Grinnell products previously, they knew that Grinnell Products’ unique grooved couplings and fittings design and top-notch Grinnell Mechanical Services (GMS) team would be assets on this demanding project. “We chose Grinnell Products for the grooved piping systems in part because they were able to draft the mechanical equipment rooms for us, enabling our drafting department to focus on the core areas of the building and keep up with the aggressive MEP coordi-nation schedule,” said Rich Null of Kirk Williams Company.

Located in the northeastern corner of the base, this massive complex includes the newly established 711 Human Performance Wing, as well as the Navy’s Aerospace Medical Research Laboratory and the Air Force’s Physiological Training Unit. Upon completion in late 2010, it became the first human-centric war-fare wing to consolidate research, education, and consultation under a single organization. According to Mark Yates, chief of the U.S. Army Corps of Engineers Louisville

Kirk Williams Company Selects Grinnell Grooved Products and Services to Cut Installation Costs on Air Force Base Expansion

Kirk Williams Company relied on Grinnell Grooved Products and the Grinnell Mechanical Services team to meet the aggressive timeline and cut labor costs dramatically for the new Human Performance Wing at Wright-Patterson Air Force Base.

continued on page 18

S M A R T S O L U T I O N S S U M M E R 2 0 1 115

With copper prices at an all-time high and jobsite copper thefts in the news, Cincinnati-based Thomas J. Dyer Company (TJ Dyer) quickly embraced the alternative polypro-pylene-random (PP-R) piping by Aquatherm for the heating system of a new senior living commu-nity—The Kenwood by Senior Star. With its fusion welding process, light weight, and imperviousness to cold, Aquatherm’s Climatherm® pipe sys-tem allowed TJ Dyer to realize 20–25 percent savings in labor costs over copper piping.

Located on the bluffs of the Ohio River Valley in Northeast Cincinnati, The Kenwood includes a 15-story tower and one three-story residential building. Climatherm was used on the high-rise’s hot water lines feed-ing Trane heat exchangers, from four-inch down to 3/4-inch. Chris Kleinholz, TJ Dyer foreman, appreci-ated that Climatherm did not require constant on-site security during the installation (as copper would have) and offered other benefits.

Innovative System Is Safer to Install, More Durable Than CopperAquatherm’s PP-R pipe systems have been proven in over 70 countries for nearly four decades. TJ Dyer’s major plan and spec projects manager, Jim Ramsey, was most impressed with the product’s longevity and the Aquatherm warranty.

A key to Aquatherm’s success is the fusion welding process that connects the pipe. The fusion process cre-ates seamless connections that last a lifetime when properly executed,

eliminating the need for toxic materi-als, glues and resins, and open flames in piping installations. The PP-R pipe and desired fitting are simply inserted onto an Aquatherm weld-ing device and heated for a specified time (typically only seconds), then joined together. Once fused, pipes and fittings have the same physical properties, eliminating systematic weaknesses.

Additionally, a faser-composite layer in the pipe reduces linear expansion of the pipe by 75 per-cent compared with other plastics, ensuring that it hangs rigidly even when subjected to high operating temperatures (up to 200° F). Fully recyclable, Climatherm is designed

specifically for HVAC and industrial applications.

20–25 Percent Labor Savings“We hit a cold spell during installa-tion, and we didn’t have to stop once,” Kleinholz recalled. “With copper, water in the lines would have frozen, but it didn’t with Aquatherm.”

Kleinholz added that his crew typi-cally realized labor savings of 20–25 percent versus copper, because there is no cleaning and fluxing of the pipe and because Climatherm is lightweight rel-ative to metal. TJ Dyer installer Dexter Campbell—a 30-year industry vet-eran—added that while there is a learn-ing curve involved with the Aquatherm

TJ Dyer Cuts Labor Costs by 20 Percent with Aquatherm’sInnovative Pipe SystemDurable Alternative to Copper, PVC, Allows for Faster, Easier Installation

TJ Dyer saved labor costs by using Aquatherm’s Climatherm piping for the heating system of The Kenwood by Senior Star senior living community in Cincinnati. Climatherm installation involves a fusion weld system that is similar to open-flame welding but faster and safer, while the plastic is lighter than copper and impervious to cold.

continued on page 18

S M A R T S O L U T I O N S S U M M E R 2 0 1 11�

Using BuildingAdvice, J.E. Shekell, Inc., of Evansville, IN, helped a non-profit human services provider cut its energy expenses in half, stay in line with state building code require-ments, and qualify for energy rebates. Contractors like J.E. Shekell know it’s not enough to promise energy savings over time by replacing out-dated systems with new, more effi-cient ones; those new systems must demonstrate significant savings—quickly—and meet strict standards to qualify for utility rebates. Through a BuildingAdvice Energy Audit and subsequent improvements, J.E. Shekell helped the Evansville ARC (EARC), a nonprofit adult disability rehabilitation and child daycare facil-ity, realize dramatic savings.

Desperately Seeking SavingsEARC has had a commercial main-tenance agreement with J.E. Shekell for 25 years. Last year, as EARC felt the recession’s effects in decreased fundraising, the executive director aggressively sought savings oppor-tunities to offset the bottom line. Also in 2010, J.E. Shekell formed its energy services division. President Kevin Shekell saw that offering energy benchmarks, assessments, and measurement services under energy service agreements was the key to finding a new facet of the 33-year old business. The BuildingAdvice suite of products has been part of J.E. Shekell’s energy services division since the beginning.

EARC’s 36-year-old building was ripe for improvement. The original, pneumatic control system was anti-quated and outdated. The facility needed a control system to combat indoor comfort issues, such as wide temperature swings and temperature

variances between spaces. State codes require such care facilities to maintain certain conditions, and the facility would be in danger of temporary closure or, in an extreme case, losing its license, if EARC could not maintain conditions within an acceptable range. The leader-ship’s top priority was to quantify what savings they could achieve with equipment upgrades: upgrades they knew they needed, but were not sure they could afford.

The BuildingAdviceEnergy Audit report

showed that improvements proposed by J.E. Shekell to EARC’s facility could

decrease the annual energy expenditure of $82,000

by over $50,000 inunder a year.

J.E. Shekell Engineer Aaron Derr conducted a BuildingAdvice Energy Audit, which benchmarked the build-ing at an Energy Star score of 26 (on a scale of 1–100, where 100 is most efficient) and shared the results with the EARC Board of Directors. He then proposed $200,000 in HVAC project work, which included the installation of Verify, AirAdvice’s comprehensive measurement and veri-fication tool providing real-time build-ing performance metrics and giving building managers intelligence needed to reduce building energy waste. Derr used Verify to establish baseline usage and measure in real time the effect of

the project work: replacement of dual duct constant volume (CV) boxes with new dual duct VAV boxes, replace-ment of pneumatic controls with a direct digital control (DDC) system, and installation of variable frequency drives (VFDs) on the supply and return fans in the main air handler and also on the cooling tower fan. The new control system incorporated the required logic to sequence all of the system’s equipment together. An addi-tional $10,000 would go to a lighting retrofit.

Rapid Return on InvestmentThe return on investment, or payback period, on the proposed $210,000 worth of upgrades was predicted to be less than two years with rebates and grants. The building’s annual energy expenditure was $82,000. The BuildingAdvice Energy Audit report showed that improvements proposed by J.E. Shekell could decrease that cost by over $50,000 in under a year: an estimated $45,899 per year on electric and $5,095 on gas.

Naturally, there was a lot of skepti-cism on the part of the client. The potential savings were so large, they really didn’t believe they could save that much. As Derr said, “I didn’t believe the numbers myself at first. Being new to BuildingAdvice, I’d not had an opportunity to field-test their system and verify their results against real-time data. But our manual and model calculations were showing that they could.”

BuildingAdvice ReportSecures GrantEARC began securing funding for the upgrades. Based largely on data con-tained in the BuildingAdvice Energy Audit report, the Indiana Office of

J.E. Shekell Uses BuildingAdvice to Slash Energy Bills in HalfEnergy Audit Results Help Evansville ARC Win Block Grant, Earn Utility Rebates

S M A R T S O L U T I O N S S U M M E R 2 0 1 11�

Energy Development awarded EARC a block grant in April of 2010 total-ing $100,000. “All of the predicted energy dollars saved came from the BuildingAdvice report,” Derr said. Led by HVAC & Design/Build Project Manager Mark Unfried, J.E. Shekell completed installation of equipment and control systems in November 2010. By reviewing the measurement and verification data from Verify reports, Derr saw usage decreases and trends showing improvement immediately.

The building’s new control system is, to an extent, pre-programmed by the manufacturer, but Derr uses Verify to check its work. For example, controls had been programmed to set back the system on evenings and weekends, but by checking against baseline measurements at the outset of labor, reports helped to show that the air handler was running at low speed constantly instead of shutting off when it could. By monitoring these reports daily, Derr has been able to work with the control professionals to optimize the programming.

Instant ResultsIn the month following equipment installation, EARC saved 36 percent in electrical energy and decreased its bill by $2,065 compared with the previous year’s bill for the same month. What looked good on the surface became great after the air handler was reprogrammed. Energy savings then totaled over 50 percent less in each of the next two months compared with previous usage, drop-ping a total of $5,852. EARC is on target to achieve the 50-percent energy savings projected—even with current demand charges based on last summer’s peak usage. EARC will see additional savings once the high demands from the old system are out-side of the 12-month utility demand reference window. Derr and EARC continue to fine-tune the system to squeeze out every bit of savings.

In early 2011, EARC received rebates totaling over $20,000 from their local utility , which uses a third party to verify proposed sav-ings before awarding rebates. The third-party consultants didn’t believe the numbers coming out of

BuildingAdvice either and requested supporting documentation for all of the proposed savings and the calcu-lations behind them. Derr worked closely with the AirAdvice support team members to “back out,” or expose, all of the BuildingAdvice calculations into a spreadsheet of data more commonly produced by energy engineers, showing all the calculations manually. The BuildingAdvice support team pro-vided that level of detail and worked directly with the utility consultants to answer all of their questions.

In comparison with prior utility bills, the building’s energy usage has dropped radically. Last year’s lowest monthly winter demand was 112 kilowatts, whereas the build-ing has averaged 50 kilowatts in demand since the project work was completed. The company has saved $7,917 in electric bills over the last three-month period as compared with a year ago.

For more information about BuildingAdvice, visit www.airadvice.com/solutions.

Left: BuildingAdvice measures Evansville EARC’s energy consumption against compa-rable buildings’ usage and provides a metric on targeted energy efficiency. The detailed data allowed J.E. Shekell to increase EARC’s energy savings even more after the first month by optimizing the programming.

Below: The BuildingAdvice report paints a picture that resonates with customers. These graphs of the carbon dioxide sensors show whether a building is reaching ASHRAE stan-dards and whether there is room to economize its performance through energy improvements.

S M A R T S O L U T I O N S S U M M E R 2 0 1 118

District’s contracting division, the project represented “the largest single military construction contract award in the Louisville District’s history.”

GMS Provides Roadmap to Increased ProductivityThe GMS team and Kirk Williams worked together to develop a stream-lined division of labor. GMS pro-vided the roadmap for Kirk Williams, which then oversaw fabrication and installation. Jointly, they were responsible for the design of the facility’s hydronic hot-water system, air conditioning system, and over-all plumbing system. GMS created a 3D map that outlined the needed materials and specified every detail, enabling the pipes to be fabricated in a controlled environment, labeled, tagged, and shipped directly to the site. Grinnell Products’ process elim-inates all of the guesswork, because each piece is identified and matched so the on-site contractor knows exactly where each piece fits.

The enormous facility was designed to house numerous laboratories with

highly technical and secure equip-ment. The unique needs of these labs drove the infrastructure design. For example, bulkheads and other structural elements could not impede the laboratory equipment. Numerous design changes were made on site. And because the Department of Defense had placed a strict two-year timeframe on the construction, with costly penalties for missing mile-stone deadlines, construction had to move forward even before final designs were completed. “We had five different new construction or remodel facilities for this project all being constructed simultaneously. With a local vendor’s help, Grinnell Products was able to keep us sup-plied with everything we needed at each location on time. There was no wasted effort in sorting materials in order to get it to the right facility,” said Null.

“This was a large-scale project that was completed in record time,” said Michael Bedzyk, senior product manager for Grinnell Mechanical Products. “Because of the pace and strict guidelines, design changes were being made all along the way. Everyone at Grinnell Products

believes strongly in partnership and that shows in our on-site management. We were onsite at least twice a week for the length of the project. This ensured that deadlines were met and that the design and installation pro-cesses were seamless.”

Grooved Products Dramatically Reduced Labor CostsBy using grooved products instead of soldering or welding, labor costs were dramatically reduced. At the outset of this project, more than 40 plumbers and pipefitters were onsite at all times. In the last 12 months of construction, that number was cut in half. “We are proud of how our team performed on this project,” said J.K. Williams, owner of Kirk Williams. “To successfully complete a job of this magnitude under design, build and fast-track conditions is a testament to our organization and our partners on the project and at Grinnell Mechanical Products. We look forward to working with allof the parties involved again inthe future.”

For more information, visit www.grinnell.com.

heat fusion weld, “I’ve never been a fan of any plastic, but with this fusion, it’s more like welding, and you can see the bead of the connection.”

Campbell continued, “It takes a little more planning, and we did a lot more prefabbing with it than we would have with copper, but I would use it again. It works really well. PVC might be easier, but it’s not nearly as reliable.”

The piping installation moved quickly, with not a single leak reported throughout the entire project. Additionally, the lighter weight of the PP-R compared with copper in four-inch lines was a huge labor-saver. “It was a lot easier working with the three- and four-inch polypropylene on ladders than it would have been with copper or welded pipe,” Kleinholz said.

The Climatherm pipe was insulated in plenums to meet codes, but because it has a natural R-value of 1, no additional insulation was necessary, offering addi-tional material and labor savings.

The heating system has now been operating for nearly a year. All reports on the heating system pip-ing have been positive, and the key players on the job were most impressed with Aquatherm. So while the residents likely have no idea that an innovative piping product helps deliver their comfort, the people who worked on and operate the heating system know better.

For more information, visit www.aquathermpipe.com.

GRINNELLcontinued from page 14

AQUATHERMcontinued from page 15

S M A R T S O L U T I O N S S U M M E R 2 0 1 11�

Mesa Mechanical, Inc. chose Josam Company’s Push-Fit Stainless Steel Drainage System to address corrosion in the drainage systems at the famous Las Vegas Bellagio Hotel and Casino. The ease of installation helped Mesa Mechanical stay within budget, and as the spectacular fountains at the Bellagio continue to flow properly, so does the water through the drainage system that flows behind the scenes.

“I am pleased to report that the han-dling and installation of this system far exceeded our expectations and thus allowed the actual labor costs to fall within the confines of a limited budget, a crucial component to preserving a competitive edge in today’s market,” said David C. Fata, executive vice presi-dent of Mesa Mechanical.

The stunning shooting fountains in front of the Bellagio have become an icon of

beauty associated not only with this world-famous resort but with all of Las Vegas. While such spectacular displays of water draw the attention of millions of guests, the possible effects of a failing drainage system could produce similar gusts of water with much different results.

The Bellagio VIP Players Area, which sits above the account-ing offices of the casino, is an important area of the casino that cannot afford any catastrophes. Although the piping system in the VIP Players Area was only installed approximately 10 years ago, facility management personnel noticed that the system was beginning to expe-rience serious corrosion issues. The casino made a decision to replace the drainage system with the Josam Push-Fit system.

Having been in business for 16 years in the Las Vegas area, Mesa Mechanical has witnessed similar corrosion issues with various casinos. Fata was impressed by the unique features of the Josam Push-Fit system, including the ease of installation thanks to the Push-Fit con-nection, the minimal cuts and waste because of the eight different standard pipe lengths, and the ease of handling the lightweight stainless steel. Mesa Mechanical’s winning bid on the Bellagio project estimated that installa-tion time using the Josam system would be half that of a cast iron no-hub system.

As with all shipments, the Josam Push-Fit product arrived at the jobsite with each piece of pipe individually wrapped and crated to avoid any damage in ship-ment. The installation included pipe and fittings sized from 2´́ to 4´́.

“Our company has worked with vari-ous piping systems in the past, and the Josam Push-Fit system was one of the easiest to install that we have ever worked with,” said Fata. “Cutting the

Mesa Mechanical Bets on Josam Push-Fit Drainage Systemto Avoid Corrosion in Casino Ease of Installation Keeps Project Within Budget

Thanks in part to the Josam Push-Fit products installed by Mesa Mechanical, the drainage system in the VIP Players Area at the Bellagio Hotel and Casino is flowing as fluently as the spectacular fountains outside.

The Josam Push-Fit Stainless Steel Drainage System “was one of the easiest to install that we have ever worked with,” said Mesa Mechanical Executive Vice President David C. Fata, and it kept the company’s labor costs within budget for a drainage system replacement project at Las Vegas’ Bellagio Hotel and Casino.

continued on page 22

S M A R T S O L U T I O N S S U M M E R 2 0 1 120

Action Electrical & Mechanical Contractors found that the Digio document management solution by Jonas helped them streamline their billing and collection processes, better identify cost overruns, and improve information exchange. Going digital also minimized the need for paper storage and recycling, saving Action additional time and money. Digio filled a need that the Smyrna, GA-based company had identified many years ago but put off until the right solution was available.

“Converting to Jonas and Digio has prompted us to reevaluate our processes and how we manage our business, which has made us more efficient. And that’s a very good thing in this economy,” said Action’s Chief Operating Officer, William Redding. “By using Jonas, we now have four or five people handling the volume of work that used to be done by seven or eight employees.”

Buried in PaperworkLike most construction companies, Action was buried in paperwork. From job files and invoices to material receiv-ing tickets and work orders, every activ-ity was managed on paper—and storage space for the company’s paper archives was running out. As Action’s leaders looked toward the future, they knew that their current recycling program wasn’t enough. Adopting greener busi-ness processes that reduced paper would be important for increasing efficiency, staying competitive, and supporting the environment.

Years ago, Redding looked for a stand-alone document management system that would integrate with the company’s

accounting software. But the options were limited. “The price on the first doc-ument management system we looked at blew us out of the water,” he recalled. “It had a starting price of $50,000, and there was no guarantee that it would work with our current accounting program.”

Action decided to table their document management search and turn their atten-tion to another pressing need: replacing their multiple legacy software systems with a single, integrated solution that would handle both accounting and service management. Surprisingly, this new technology initiative would eventu-ally solve Action’s paper problem.

One Solution Paves the Way for AnotherIn 2008, after evaluating nearly a dozen different construction management sys-tems, Action purchased Jonas Software.

With Jonas, the company was able to integrate core accounting func-tions—including job costing, multi-union payroll, purchasing, inventory, and equipment management—with service management and dispatching.

At the time, Jonas was preparing to unveil Digio, a full-featured docu-ment management system for storing, organizing, managing, and sharing documents electronically. “When we found out that Jonas was developing a document management system,” Redding said, “we were thrilled.”

Action jumped at the chance to use Digio, which fully integrates with Jonas and Microsoft Office. In July 2009, Action began their quest to reduce paper by using Digio to cre-ate digital archives for completed work orders that included all related

information, such as the service ticket, materials used, and customer invoice. “Once a work order is billed, every-thing ‘prints’ to Digio automatically,” Redding explained. This approach streamlines Action’s collection process by eliminating the need to retrieve paper records from multiple departments when answering customer questions or mak-ing collection phone calls.

After successfully using Digio with work orders, Action migrated many other paper-based processes to Digio, includ-ing accounts payable (AP), accounts receivable (AR), and project close-out.

Digio Saves Time, Improves ProcessesDigio has improved the company’s col-lection process and inter-department workflow. It also saves time associated

With Digio by Jonas, Action Electrical & Mechanical Contractors Improves Office Efficiency Digital Solution Means Instant Information Access and Less Paper

With the Digio document management system from Jonas Software, Action Electrical & Mechanical Contractors moved from paper to digital accounting processing, eliminating the need to print, retrieve, and store paper records from multiple departments.

continued on page 22

S M A R T S O L U T I O N S S U M M E R 2 0 1 121

Eager for an alternative to the nearly impossible task of installing 1,900 guides in the renovation of an occu-pied building, Edwards Engineering found the “perfect solution” by using Metraflex Metraloop expansion joints to simplify installation and reduce labor costs. By using Metraloop joints, Edwards needed only a fraction of the guides, saving over 1,200 man-hours in labor and minimizing the interruption to the people working in the building.

Edwards Engineering of Elk Grove Village, IL, began the renovation of the John C. Kluczynski Federal Building in Chicago in July 2010. Approximately $11 million in funds from the American Recovery and Reinvestment Act was bud-geted to replace the 36-year-old building’s mechanical equipment and riser pipes as part of an overall upgrade to meet new federal guidelines for energy consump-tion. The 45-story steel-frame Kluczynski Building contains 1,200,000 square feet of space and is one of a three-building com-plex that also includes a U.S. Post Office and the Everett McKinley Dirksen United States Courthouse.

Minimizing Disruption in an Occupied Building“One of the major challenges to upgrading the mechanical system and risers is doing it while the building is occupied,” explained Michael Johnson, Edwards executive vice president. “The system needs to be installed with the least amount of flame and using instal-lation methods that produce as little odor as possible, minimizing disruption to work spaces.

“There are 44 risers in three tiers, for a total of 132 risers in the building,” he continued, “and all the copper ris-ers needed compensators to accom-modate over three inches of calculated

expansion. This meant thousands of guides would be welded to the build-ing frame, which was in direct conflict with minimizing odor and flame.” The drawings called for 264 bellows com-pensators, two compensators per riser. Per manufacturers’ recommendations, over 1,900 guides would be required to complete the installation.

With the building occupied and the work of federal employees to continue with minimal interruption, finding loca-tions to install all these guides was next to impossible. Risers were not always close enough to structural steel to eas-ily install guides in proper locations. Edwards revisited the drawings to find alternatives to the compensators and guides originally specified. “We needed to determine a much better solution, since welding thousands of guides was really not feasible,” explained Johnson.

“We found the Metraloop expansion loop would easily handle the three-inch movement, plus require significantly fewer guides,” said Johnson. “The Metraloop installation requires only one Metraloop per riser and two guides per Metraloop, for a total of only 264 guides—a fraction of the number of guides previously required.

“The ability of the Metraloop joint to absorb non-linear expansion also assisted in the installation of the piping risers,” he continued. “In addition, the dramatic reduction in the number of guides that needed to be installed meant less interrup-tion where people were working and significantly less labor required to weld all those guides onto the build-ing steel.” Edwards Engineering estimated a savings of 9–12 hours of

Edwards Engineering Saves 1,200 Man-Hours in Federal Building Retrofit with Metraflex Metraloop Expansion Joints

continued on page 22

By switching to Metraflex Metraloop expansion joints instead of a combination of guides and traditional compensators, Edwards Engineering used a fraction of the number of guides and half the number of move-ment compensators, saving over 1,200 man-hours in the renovation of Chicago’s Kluczynski Federal Building.

S M A R T S O L U T I O N S S U M M E R 2 0 1 122

pipe was achieved with ease, and mak-ing a joint was easily accomplished by lubricating the joint and pushing the spigot and socket together. The installation of the product supported every pre-sales statement that Josam Company made. We experienced virtu-ally no waste and zero leaks the first time that we tested the system. The Josam Push-Fit product is definitely a good solution to the corrosion prob-

lems that the casinos are experiencing, and I have every intention of using this product again.”

The Josam Push-Fit system is available in sizes 1-1/2´́ through 8´́ and includes a full range of pipes, fittings, and hang-ing accessories. Push-Fit gaskets are supplied standard as EPDM, and FPM is available as an option. The products meet or exceed the performance require-ments of ASME A112.3.1-2007, and most products are IAPMO listed under File #6780. The Josam 316L stainless

steel Push-Fit pipe system is ideal for areas requiring corrosion resistance and where a high level of hygiene is impor-tant. Commercial kitchens, food service, and food processing applications benefit from the low total cost of ownership of the Josam pipe system. In addition, the product will maintain a consistent appearance, which is especially impor-tant for exposed drain pipes inside or outside the building.

For more information on the Josam Push-Fit System, visit www.JOSAM.com.

with filing and retrieving documents, searching for misfiled paperwork, and getting information to remote job sites. “We have a fairly large field office that’s two hours away,” Redding explained. “The project team used to call the main office to request documents like AP invoices. With Digio, that information is now at their fingertips.”

Action’s shrinking paper job files demonstrate the time and paper sav-ings associated with electronic docu-ment management. “Although it was very time-consuming, we used to put duplicate copies of purchase orders, AP invoices, and AR invoices in each job file,” Redding said. “Now our project

managers can run a quick query in Digio and access this information in moments.”

Action also uses Digio to ensure that they don’t overpay on material invoices. For example, signed receiving tickets are scanned and filed by job number for easy reference and reconciliation when invoices come in, so catching mistakes like quantity errors on vendor invoices has never been easier. Spotting potential job cost overruns is easier, too. “If job numbers look a little off,” said Redding, “all the information we need to investi-gate is in Digio.”

Improved customer service is another benefit Action has realized with Digio. “When a customer calls with a docu-ment request,” Redding stated, “we

don’t have to say, ‘Let me get back to you.’ Instead, we can pull the docu-ment up in seconds and e-mail it to them while they’re still on the phone.”

Moving Toward a Paperless FutureLooking forward, Action plans to encour-age their project managers to use the full power of paperless job files. “Digio is such a great tool, and Jonas is continually improving it to keep up with new technol-ogy,” Redding said. Action is planning to further streamline their service operations by adding Jonas Mobile to their solution. “Our customers are impressed that we use technology to deliver information to them faster. I’m excited by the future possibili-ties with Jonas.”

For more information, visit www.jonassoftware.com.

labor per riser times 132 risers, or approximately 1,200+ man-hours.

The flexible Metraloop expan-sion joint has virtually no anchor loads and requires minimal guiding. Because they are capable of 360-degree movement, Metraloops help compensate for building settlement, thermal expansion, and contraction, protecting the integrity of a piping system during a seismic event.

Rapid Response KeepsProject on TrackOnce Edwards determined Metraloops were the best option to reduce impact in the buildings retrofit, they worked with Metraflex to confirm their calcula-tions and expedite the first shipment of Metraloops to the worksite. “We needed to install 2´́– 4´́ Metraloop joints and needed to start the installations as soon as possible once we determined the existing drawing specification could not easily be accommodated,” explained Johnson. “Metraflex was able to ship the first 24 Metraloops within four days.”

As the multi-phase mechanical retrofit continues and more risers have been replaced, the Metraloop expansion joints continue to simplify installation and reduce labor costs. “This was really the perfect solution to our problem,” stated Johnson. “If we had to install all those guides, it would have required a lot of dis-ruption and a lot of time. The Metraloop joints have removed the complexity and streamlined the riser installations.”

For more information, visit www.metraflex.com/metraloop, or contact Metraflex at info@metraflex.com or 800-631-4347.

JOSAMcontinued from page 19

JONAScontinued from page 20

METRAFLExcontinued from page 21

S M A R T S O L U T I O N S S U M M E R 2 0 1 123

Because school construction projects are often strictly controlled by deadline dates, Olson Plumbing chose the new Quad Close Trap Seal device by Jay R. Smith Mfg. Co. for the Worner Center renovation project at Colorado College in Colorado Springs. The Quad Close is easy to install and to retrofit with exist-ing drains, so Olson Plumbing knew the product would save them time and help them meet their deadline.

Kirk Nelson, project manager for Olson Plumbing, has experience with trap seal devices. “We have to be finished soon, and we like to use products that help us with our time. Installing trap seals are nothing new to us, but we like using Smith products,” said Nelson. “So, when we found out that they had a new trap seal product, we wanted to try it.”

The Worner Center is a 19,000-square-foot facility that serves as a central hub for campus activities at Colorado College and includes offices, a food court, a coffeehouse, and much more. The renovation project focused on a kitchen area and four mechanical rooms. It required dozens of 2´́ and 3´́ floor drains and sanitary floor sinks (that were also Smith products). A Quad Close Trap Seal Device was used in every drain installed in the project. The fact that the Quad Close device func-tions as a trap seal allows it be used in tandem with trap primer connections to provide additional trap seal protection. The Quad Close is designed to be installed in the drain body outlet, inside the throat of the strainer, or inside the pipe. It is made to handle a wide range of pipe and internal body diameters. It will fit inside 2´́ , 3´́ , and 4´́ PVC and cast iron pipe. The 3 1/2” model is made to fit inside a strainer throat with an inside diameter of 3 1/2.´́ The Quad Close

can also be used in retrofitting existing drains. It is made from a chemically resistant elastomeric material that pre-vents substances such as beer and soda from sticking to the surface of the device.

The Quad Close creates a watertight seal and will stay open when water is flowing into the floor drain and will close when the water stops flowing. When closed, the Quad Close prevents the emission of sewer gas, minimizes the evaporation of water in the trap, and helps prevent backup into a build-ing. The Quad Close meets or surpasses many of the ASSE 1072 requirements.

Standard trap primer connections on floor drains with infrequent use can sometimes allow the trap seal water to evaporate, which can cause sewer gases to escape into the room. The Quad

Close can be used to complement floor drains that have been specified with a trap primer connection to prevent this problem. The specially formulated elas-tomeric material is thicker and more durable than other trap seals, which makes it less vulnerable to UV, chemi-cals, cuts and tears.

Nelson is fully aware of the impor-tance of workmanship and pricing is in today’s commercial construction mar-ket. “We really want to give our cus-tomers the best work we can for their money. The market has changed, so it is up to us to use new products that allow us to remain profitable and still produce quality work,” he said.

For more information on the Quad Close Trap Seal Device, visit www.jrsmith.com.

Jay R. Smith Mfg. Co. Helps Olson Plumbing Meet Tight DeadlineEase of Installation Makes New Quad Close Trap Seal a Good Fit for Campus Construction Site

Olson Plumbing chose the easy-to-install Quad Close Trap Seal Device by Jay R. Smith Mfg. Co. to help save them time and money in renovating Colorado College’s Worner Center.

S M A R T S O L U T I O N S S U M M E R 2 0 1 124

MCAA Past President Lonnie Coleman’s company, Coleman Spohn Corporation, is so confident that Viega products save them money on labor and installation, they built those savings into their bid to provide Viega ProPress® and Viega ProRadiant® systems in the University Hospitals (UH) Ahuja Medical Center in Beachwood, OH, working in partner-ship with fellow Ohio contractors Smith & Oby. “Viega ProPress saved us a lot of money, which we offered to the owner,” said Dave Kause, vice president of operations at Coleman Spohn. “That’s the incentive we used—the financial sav-ings, the ease of installation, and meeting their schedule.”

Together, the two contractors installed Viega ProPress in sizes 1/2´́ –1´́ , as well as Viega ProRadiant S-no-Ice® snow melting system, throughout the medi-cal center. “We use Viega products on numerous projects,” Kause said. “It’s our intent to continue using it. And that’s based on our past experiences.”

High-Tech Medical Center Meets Northern Ohio’s NeedsThe UH Ahuja Medical Center is the most technologically advanced hospital in Ohio. Named for UH Board Chairman Monte Ahuja and his family, who donated $30 million in support of UH’s Vision 2010 strategic initiative, the facility occupies 370,000 square feet situated on 53 acres.

The eco-friendly medical center already has 144 beds, but it plans to expand to offer 600 beds throughout three phases. With seven floors of inpatient, outpa-tient, and emergency services, as well as a medical office building, UH Ahuja Medical Center is designed to meet the medical needs of Cleveland and the greater community of northeastern Ohio.

Viega Saves Time, LaborBecause installing Viega ProPress saves

time and labor costs, Coleman Spohn offers that time and labor savings cost back to the property owner. “In many cases,” Kause said, “we offer the owner incentives to go from a traditional solder to a Viega ProPress application because of the ease of it. We’re so familiar with the product. It’s just easier for our people in the field.”

Mike Brandt, executive vice president and chief operating officer of Smith & Oby and an MCAA Board member, expressed similar feelings about the time and labor savings that Viega ProPress provides compared with soldering. “It was more of a cost savings on labor,” Brandt said. “Plus, in the future, it’s easier to add on to the system on a Viega ProPress system than a solder type. If you have to cut into a tee, it’s not as hard to do. And you don’t need a hot work permit.”

Smith & Oby and Coleman Spohn installed Viega ProPress throughout the UH Ahuja Medical Center. They also installed a Viega ProRadiant S-no-Ice snow melting system in the hospital

helicopter pad, parking lots, building entrances, and sidewalks. Viega Technical Services helped with the design of the snow melt system as well as the location and quantity of the manifolds.

“The Viega engineers worked with us on the design,” Brandt said. “They came out and gave us their training on the tool. It worked out well. They got us the answers we needed. They were very helpful.”

Both Brandt and Kause commented on the reliability of the Viega sales force, specifically their relationship with Viega District Manager Josh Dimacchia. “We get great service locally,” Kause said. “All our project managers prefer to deal with Josh and use Viega products.”

“I think Viega ProPress is a great prod-uct,” Brandt said. “It’s a much better installation than the old fashioned solder joint way.”

For more information, visit www.viega.net.

Viega Systems Save Smith & Oby, Coleman Spohn Money,Time on Medical Center Installation

Smith & Oby and Coleman Spohn installed Viega ProPress and Viega ProRadiant systems in the University Hospitals (UH) Ahuja Medical Center in Beachwood, OH, because Viega products save them money on labor and installation.