THINK GREAT!

The Safety IssueIN THIS ISSUE:

Beyond EMR: Consigli’s Safety Culture

Ask the Experts: Safety in Numbers with

the Della-Giustinas

The Safety IssueIN THIS ISSUE:

Beyond EMR: Consigli’s Safety Culture

Ask the Experts: Safety in Numbers with

the Della-Giustinas

CONNECTING OUR PEOPLE AND OUR ACCOMPLISHMENTS

FALL/WINTER 2014

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The holidays are already upon us. Spending time

with family and friends is what it’s all about, so

it’s only fitting that this edition of The Arch is

devoted to safety. Our company had a

terrific year by any measure, particularly

with a reduction in jobsite injuries.

Something to boast about at the dinner

table with your family, for sure.

But why all the fuss about working

safely, all the time? If less people are

getting hurt, why are we always

pushing this safety thing? We all

know that one injury is too many, and

that’s why we’ve had a renewed focus

on getting better. The road to “zero”

injuries is a journey, not a destination,

so we’ve looked at making our approach

to safety much more comprehensive.

That’s why we developed S.A.F.E. SM

Introduced this summer, S.A.F.E. – Staying

Accident-Free Every Day is built on a strong

safety program foundation that we wanted

to make stronger. We have seen some

significant improvements and we’ve only

just begun.

One specific aspect that is garnering the most

attention is Humanization. If we can embrace

the philosophy that injuries affect us beyond

the jobsite – that we have family and friends

counting on us – it can make a difference. Let’s

put a face on injuries, and who gets affected by

them. So when you’re celebrating the holidays

this season, let’s remember what we should all be

thankful for. The others at the table will be glad

you did.

Anthony and I want to thank you for the great

work done this year. We, too, are thankful that

you’re with us at our table.

Matthew Consigli

A MESSAGE FROM MATTHEW

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ONE MISSION: S.A.F.E.SM

Consigli’s Safety and Health Program has one mission:

Ensuring our teams return home from work safely each day—healthy, whole and uninjured—is our S.A.F.E. program’s objective. At Consigli, “S.A.F.E.” literally means “Staying Accident-Free, Every day.”

The vision of the Consigli Safety and Health program is represented by a single word—ZERO! For us, “ZERO” reflects our position that no accident is acceptable, and each accident is preventable. With the S.A.F.E. mission driving our vision of “ZERO,” we are leading the way to the safest jobsites in the construction industry.

And, with industry statistics showing that the best safety practices reap both the rewards of safe work environments, as well as financial and schedule benefits, zero gets you an awful lot these days.

Recent industry reports on safety management programs show the big picture of these results. In 2013, a McGraw Hill Construction industry survey showed many companies seeing benefits, including:

• 71 percent reported lower injury rates

• 51 percent reported increases in project return-on-investment

• 3 percent reported faster project schedules

• 39 percent reported decrease in project budget

• 66 percent reported both greater ability to contract new work and better project quality

To learn more about how our safety management is continually improving on our sites around the Northeast, please read on in this issue of the Arch for highlights of our evolving culture of safety. ■

A Message from Matthew

One Mission: S.A.F.E.SM

FEATURES

Beyond EMR: The Evolution of Consigli’s Safety Culture

Landmark Restoration: Creating a Culture of Safety in the Sky

Ask the Experts: Safety in Numbers The Della-Giustinas, Three Generations of Safety Management

NEWS

Technology UpdateInnovations in Safety

Self-Perform Spotlight Keeping Our Self-Perform Teams Safe: The 101 on Silica

New York Spotlight Pace University’s Campus Expansion

Boston Spotlight Ipsen Biomeasure’s Fit-Out Scores Big with Lean Construction Management

Consigli Honors Best Places to Work 2014

2014 Safety T-Shirt Design Winners Announced!

Employee Spotlight New Employee Safety Ride Impressions

Winter Clothing Safety Reminders

Sorry for our oversight! The following list of masons, who worked on the Wat Nawamintarara-chutis Thai Temple, were mistakenly omitted from the “Once in a Lifetime Project” article published in The Arch, Summer 2014 issue: Rich Glidden, Stanley Boratyn, Kevin Baroni, David Serra.

FALL/WINTER 2014 TABLE OF CONTENTS

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4

3

7

8

10

11

12

13

14

14

15

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CelebrateSeasonthe

You’re Invited to

We welcome you and a guest to celebrate the season with us at the

Consigli Christmas Party

Union Station2 Washington Square, Worcester, MA

Saturday, December 13th • 6 PM – 11 PM

Your invitation is in the mail!RSVP to Lili Schiffman at 508.458.0339 by December 5th.

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S.A.F.E.: The Sum of Many Parts

That each construction site needs to be a safe construc-tion site seems an obvious and simple idea, doesn’t it? And yet, creating a construction company’s safety culture that truly results in everyone going home in one piece each day isn’t simple, it takes a lot of doing.

And that’s what we’re doing: a lot.

While our safety program, before its recent evolution, has always promoted strong safety practices and helped the firm maintain an EMR of .70, there was still room for improvement. Under the guidance of Consigli’s Safety Director Dan Della-Giustina, we have integrated a number of the industry’s newest best practices for safe sites.

Humanizing Safety — “Protect the ones you love

by protecting yourself”

The result? Consigli’s newly evolved Safety Program “S.A.F.E.—Staying Accident-Free Every day,” launched this summer. Our S.A.F.E. program has six features.

Dan Della-Giustina, Consigli’s Director of Safety, recently highlighted one of the main industry shifts guiding our new program, “The biggest change I’ve seen in the field is the humanistic approach to our construction workers, treating them as the human beings they are, as opposed to a simple labor commodity. I think once

the industry realizes that when you treat people like human beings, and treat them with respect and give them a decent place to work, they’ll naturally be more produc-tive and you’ll see fewer accidents.”

As Dan explained, a central change in construction safety today—and one that is at the heart of our new safety program—is truly about heart and home. This is the direct and regular reminder to all that staying safe is our individual and shared responsibility, so that families can count on us coming home safely.

To keep this most basic idea fresh on site, we have begun an on-site poster pro-gram. With messages like “Your biggest fans are waiting for you at home,” “My favorite people in the world are counting on me to make it home safely tonight,” and “Tomorrow with your family is the reward for safety today,” we are work-ing to keep safety present in everyone’s thoughts, in the rush of each day.

BEYOND EMR: THE EVOLUTION OF CONSIGLI’S SAFETY CULTURE

BEYOND EMR: THE EVOLUTION OF CONSIGLI’S SAFETY CULTURE

Leadership: Empowering Team Members

A company’s culture is as strong as it is deep. The implementation of our safety program begins with the commitment of our senior management team to safety and the empowerment of each project team member to place a site’s safe environment above all else. We are seeing this take shape as team members step forward to implement safety incen-tive programs and embody leadership in the field—like our Cambridge MITIMCO team’s successful encouragement of subcontractors to participate in our Jobsite Gym program.

Mike Haseltine, Consigli’s Vice President for Field Operations noted that “The biggest difference between our new approach to safety and our old approach is, we want to impact people’s long term attitude toward safety, rather than focusing on their short term actions. We want people to understand how important their safety is to them, to their families and to their co-workers, and encourage them to think about the safest way to accomplish tasks.”

Training: Integrating Subcontractors into Our Safety Culture

Integrating the subcontractor workforce into the Consigli safety culture, through project-specific incentive programs and customized 10-hour training programs, assists in mitigating subcontractor risk.

An example of an incentive program that has worked well was developed and man-aged by Ron Perry, Project Manager for our Smith College Cutter and Ziskind

student residence renovations. Subcon-tractors that had a two-week stretch without any “unsafe” ratings in the weekly safety audit, were awarded either a Consigli high visibility t-shirt or sweatshirt.

Jobsite Gym: Stretching Bodies and Minds

Today all our project teams begin each day on site warming up with our Jobsite Gym program, to help eliminate musculoskeletal injuries. The introduction of “stretch and flex” programs to the construction industry is an example of one of the newer best practices that we are implementing.

A recent article in Risk + Insurance discussed the emergence of “stretch and flex” regimens, noting that over the last eight years, many of the largest national general contractors have adopted these types of programs.

And for good reason: industry statistics show that when construction crews participate—even if it takes a little

5

time to warm up to the idea of on-site warm-ups—there is a marked reduction in injuries from strain and stiffness. In a report by insurance industry underwriter, Zurich Services Corporation, on their experience with more than 100 companies implementing workplace stretching programs from 2007 to 2009, they saw an overall 61 percent reduction in strain/sprain frequency and a 30 percent reduction in strain/sprain severity. Jobsite Gyms work.

When “Nothing Hits the Ground,” Jobsites Are Safer

We are also bringing the Lean-inspired policy of “Nothing Hits the Ground” to our jobsites. This requires that all construc-tion materials, when delivered to the site, be on racks, pallets or a wheeled conveyance of some type. Like our Jobsite Gym program, this approach improves project safety in a number of ways, from a cleaner, more organized site, to easier access of materials.

Our work for Ipsen Bioscience, Inc. in Cambridge this year—one of our Lean management beta test projects—incorpo-rated this approach with great success, as well as integrating the Lean use of pre-fabrication for the M/E/P system racks. Superintendent Tom Smith explained that when the pre-fabricated racks were delivered to the site, they were then placed on wheeled supports, making their installation dramatically quick and easy.

Technology + Leading Indicators of Safety

Using Predictive Solutions, our safety au-diting mechanism allows us to anticipate and avoid jobsite incidents, by identifying and analyzing leading indicator data.

Jonathan Thomas, Director of Safety Management Solutions for the National Safety Council, reports in a recent issue of NSC’s Safety + Health that a main defining concept of leading indicators is that they are measurements of safety events or be-haviors that precede incidents and have a predictive quality. The core components of our safety program, from senior manage-ment’s role in empowering whole teams to place safety above all else, to safety training and “stretch and flex” programs, all have emerged as leading indicators for the safest sites and the safest teams.

This is our path forward: through our integration of “S.A.F.E.,” we will continue to track and adapt our safety program, to continue to keep it tuned to what really works—and what allows everyone to go home safely, each day. ■

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Safety at Consigli

By the Numbers

OSHA-trained hours by Consigli staff

Full-time Consigli safety team members—

above industry average for safety staff

Our “Experience Modification Rate”

(EMR)

Above industry average for EMR

Subcontractor firms we have provided safety training for

over past five years

5,572

8

.70

30%

75Jobsite work stations and wheeled pipe racks illustrate the “Nothing Hits the Ground” policy in action on the Ipsen job.

Building Raving Fans“With the help of Consigli, Safway

was able to produce a fall protection plan which enabled Safway erectors

to stay 100 percent tied off without over complicating methods, therefore increas-ing productivity. Working together as a team, Safway and Consigli personnel

created a safety culture on site in which guys felt the need to work safe and to

look out for one another’s safety as well. With this kind of attitude toward safety, it was easy for Safway crew members to

‘buy into’ the site-specific safety plan and the high-profile nature of the project. We

look forward to working with Consigli and ensuring the safety culture remains

through the completion of the job.”

Russell Riopelle, Safway Scaffolding

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Since 2004, we have completed significant restoration, upgrades and maintenance for Maine’s State House,

a landmark building listed on the National Register of Historic Places. However, this is the first full replacement of the 100-year old copper dome and restoration of the “Lady of Wisdom” sculpture, located on top of the dome, since their installation in 1909-1910. Our work also includes restoration of the cupola and complete painting of the exterior above the roofline.

Driving Innovation

The dome’s unique steel structural system and framing were analyzed by Becker Structural Engineering, a year in advance of dome construction, so that we could create a 3D model staging plan to be subsequently engineered to eliminate interior shoring. As a result, all workers access staging from the outside of the building on scaffolding which encases the entire dome. This was particularly important given the building was fully occupied throughout the renovation.

Delivering Quality

The following safety measures ensured that the team would deliver quality to the client:

• The Governor’s parking lot was the only place to locate a crane near the build-ing, so all crane activity was performed between 4:00 a.m. and 7:15 a.m.

• Installing weight load limit signage on the staging let workers know where and how much material could be stored.

• The existing paint and gilding materials contained lead, so we installed a wash/safety station at the base of the staging for worker use.

• We also conducted safety tours for the Augusta Fire Department. ■

LANDMARK RESTORATION

Creating a Culture of Safety in the SkyWorking 200 feet in the air on elaborate staging, carpenters, coppersmiths and engineers are making highly visible changes to the exterior of Maine’s State House dome in Augusta.

State House Dome

By the Numbers

7,000 = square feet of copper replaced on the dome

100 = years the repairs to the roof will last

50 = years the new LED lights installed in the statue’s torch will last

30 = years it will take for the copper to oxidize and change to a green patina

13 = number of feet high the re-gilded statue stands

Before either our Safety Director, Dan Della-Giustina, or son, Daniel Jr., Assistant Safety Manager, began their careers in construction safety management and joined Consigli, Daniel E. Della-Giusti-na—father to Dan, grandfather to Daniel and former Chairman of West Virginia University’s Department of Safety and Environmental Management— was building the foundation for today’s professional field of safety management. As the author of 19 books on safety and

environmental management, and Chairman of WVU’s program for

17 years, his field leadership is internationally recognized

and includes shaping OSHA’s outreach training programs, expert witness roles in serious

injury cases and consulting on public safety events like Colorado’s tragic

Columbine shooting.

In recent conversations with this multi- generational trio, the three Della-Giustinas talked about their commitment to the field, its early years, recent industry shifts and tomorrow’s trends.

What attracted you each to the field of safety management?

Professor Della-Giustina: My first love: athletics and coaching. I went to Springfield’s American International College on an athletic scholarship—we were New England’s champs. Early on I

was a high school and college coach and later, Director of Health and Transpor-tation with the Pittsfield Public Schools, before getting my Ed. S. degree at Mich-igan State in Safety and Environmental Management and my Ph.D. in Research. I joined WVU’s faculty in the 70’s and began building our department in the Statler College of Engineering. Today, I can say there is nothing better than safety because of what it does. It saves lives.

Dan: One thing that brought me in: the mock-disasters that my father set up at WVU to instruct on disaster preparedness. Everyone in the local EMS community responded, and the mock disasters determined where strengths and weaknesses were. My father and I used to discuss them all the time. And we

talked about the WVU program a lot; that’s how this all began.

Another early influence was learning the average life expectancy for people working in construction was ten years less than the norm. That gave me a lot of motivation to join the industry.

“At one time companies would take anybody and

put them in a safety position, and they usually knew little,

if anything.” —Professor Daniel E. Della-Giustina

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Safety in Numbers: The Della-Giustinas, Three Generations of Safety Management

Maybe it’s the fact

that Consigli is a fourth-

generation, family-led

firm, that helped attract

two staff members with

their own lineage in a

“family business.”

ASK THE EXPERTS

Daniel Jr.: My degree is in criminal justice—which is a little funny because on the job sites we joke about that, since construction safety in the past has been thought about as enforcement. This is one of the things I’ve learned from my Dad, that safety is about management, not enforcement. My interest really began over the summers during college, when I worked as a laborer for Consigli. I began to really like the feel of construction and the industry.

Have you influenced each other?

Dan: Oh, yes, my father has influenced me in many ways—his dedication to the safety profession, for one, but even more, I learned what hard work is all about, through him. That’s probably the most im-portant life lesson. As a child of Italian immigrants—first genera-tion—he grew up in the south end of Springfield, Massachusetts. At twelve, he was in the streets shining shoes, peddling papers. He’s carried that work ethic with him all of his life, and he’s instilled that in me.

Professor Della-Giustina: Have I been influenced by Dan? Oh, yes. I use examples from his work out in the field—the students really love that. It really is fantastic, it’s a great field. And I’m glad Dan does this work, and now my grandson is involved and you can’t beat that. We’re in this for generations.

Daniel Jr.: My grandfather has taught me about a strong work ethic, too. And, my Dad, well, all I know about safety, I know from him. And I’ve learned a lot from him about what you don’t learn in the field, the insurance side, what you need to learn about safety investigations, those aspects.

What has been a core challenge?

Professor Della-Giustina: Well, our pro-gram is part of the College of Engineering at WVU, and folks here don’t like to hear it when I tell them it’s people themselves that create most safety problems. We like to think if employees are properly trained, we won’t have any problems. But the research shows that 85-90 percent of all incidents are due to human behavior.

Five percent have an engineering aspect—like leaving the machine guard on—and about one percent deals with environment. So, if you’re a CEO, where are you going to put your money?

Twenty years ago I consulted with the Iowa Beef Corporation, the largest beef producers in the world. I didn’t realize it, but the CEO of Iowa Beef was there and when I presented about the fact that safety programs need to connect with people—that 85-90% human-factor—he jumped up and said “That’s what I want our program to be about!”

What has evolved most?

Dan: When I started in 1980, safety was literally a separate field of management, and wasn’t integrated into an organi-zation’s overall business structure. Now, safety is integrated into just about every industry, construction and everything else. Companies know a comprehensive safety and health program saves money, because incidents are expensive. Before that it was, “Well, he’s the safety guy, that’s his issue.”

Another change—a lot of tech school and engineering program graduates now have OSHA 10- and 30- hour training under their belts when they leave school. You never saw that before.

Professor Della-Giustina: Yes, ditto what Dan said. This integration and profession-alism is vital because at one time compa-nies would take anybody and put them in a safety position, and they usually knew

little, if anything. In contrast, today we have almost 2,200 graduates of our Masters in Safety and Environmental Management program. When our students graduate from our program they have five or six offers to choose be-tween—things have changed that much.

We’re strictly a Masters/Ph.D. program, and there’s not an industry out there—whether it’s construction or manufactur-ing or so many others—where we don’t have our graduates working, because it’s cost effective.

Do you “talk shop”?

Dan: Yes, every week—my father and I have long conversations, usually every Sunday. Because my father works as an expert wit-ness on serious injury cases, often we’ll discuss those injuries, what’s applicable on the regulatory side, the training side, the behavioral side.

Professor Della-Giustina: Yes! I tell people, my son is in the field, and he knows more than I do, because he’s working hands-on, on the jobs. I’ve watched him give accreditations and

national conferences, and he’s excellent. He can go in and discuss problems with OSHA, and they know he knows more about it than they do. It’s great to have someone follow you in that direction.

What are the trends?

Dan: The biggest trend is the humanistic approach to our construction workers, treating them like the true human beings they are, as opposed to a labor commodi-ty. I think once the industry realizes when you treat people like people, with respect, they’re going to be more productive, and there’ll be fewer accidents.

Professor Della-Giustina: Industry and government know how valuable safety is now. Dan and I are in the National Safety Council, and almost 20,000 people attend these days. What they’re talking about now—the humanizing of safety management—this is the approach we’ve implemented at West Virginia for 25 years. Industry needs to reinforce this, and stay focused.

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(cont. on pg. 11)

Just two of Professor Della-Giustina’s nineteen safety field text books.

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drones

INN

OVAT

ION

S IN

SAF

ETY

Drone Flights Offer New Perspective of Jobsites

Using a drone to fly over and capture video of our active jobsites gives us a completely new and different perspective on jobsite safety. It’s much easier to look at the “big picture” of the overall site and review issues like access and laydown areas in a clearer manner. The video footage from our drone flights have provided us with a valuable record of weekly progress as well, giving us the ability to look back at our project performance and look for ways that we can improve what we’ve done.

Innovation Submissions Address Safety

We’ve had a great response to our Innovation Incentive Program and are implementing some of the suggestions related to safety:

1. Installing removable ladders on flatbeds for better/safer access. This is a great idea borrowed from one of our subcontractors.

2. Clearly identifying visitors on Consigli sites with a different color hard hat is a simple but effective idea that brings another level of attention to detail on our jobsites.

Logistics Models Improvements

Over the summer, we had a BIM intern create new 3D content in logistics models, including: fall protection; temporary guards; overhead protection for pedestri-ans; more accurate cranes (with swing radii) etc. The level of detail in our logistics models continues to go up, and we’re focused on making these as realistic as possible with the input from field staff.

Pre-Fab Lab

In October, we kicked off our M/E/P pre-fabrication efforts for Milford Regional Medical Center at our temporary location in the Ambulance Building next door to the Granite Building. Some of the benefits of pre-fabrication that lead to improved safety are: minimizing overhead work, having an optimum working height at bench level and having a climate-controlled environment.

Procore Launched

As Procore is rolled out as our new PM platform, it will include a “Safety Walk” component. We currently have a draft version running on one project and will be refining it to be ready to go for everyone before the end of the year. ■

TECHNOLOGY UPDATE

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What is it?

While there are many jobsite dangers, silica dust can be one of the most dangerous. Silica is found in concrete, rock and many other typical building materials, such as brick, tile and other fibrous cement products, to name a few. The dust can be created when these products are cut or drilled, releasing fine particles of silica in the air.

What are the effects?

When inhaled, the dust can cause silicosis, a non-treatable disease. Initial exposure will cause irritation of the eyes, nose and throat, like most other dusts. However, when silica dust is inhaled over long periods of time, even at relatively low concentrations, it can cause damage to lung tissue. After being removed from exposure, the disease will continue to progress, with symptoms appearing 10-20 years after exposure.

How do we prevent exposure?

To work safely and prevent the creation and inhalation of silica on the jobsite, Consigli’s Safety Program includes the following steps to protect our self-perform crews:

1. Use tools that are fitted with a water attachment to suppress dust

2. Use a water spray as dust suppression when performing demolition, grinding, cutting or drilling into any materials that contain silica

3. Have a Certified Industrial Hygienist conduct an exposure assessment on any of the tasks mentioned above to determine if an exposure to silica exists above the OSHA permissible exposure limits

4. Attach point of operation dust extraction devices (attached to High Efficiency Particulate Air vacuum

systems) to any tools or equipment that produce potential silica-containing dust

5. Conduct HEPA vacuuming and wet sweeping of project areas to remove settled dust

6. If necessary, and only as a last resort should engineering controls not work, provide respirators with HEPA filtration

7. Display posters and signs warning of the presence of silica on site

While there is no medical treatment for silicosis, Consigli’s Safety Program out-lines a clear plan for occupational disease hazard protection from silica dust. To read more about our Safety Program, you can find it on the Gateway at http://gateway.consigli.com/departments/FieldOps/Safety/default.aspx. ■

SELF-PERFORM SPOTLIGHTWhat wisdom do you have for those entering the field?

Professor Della-Giustina: I use Dan’s career as a model. I describe how he has moved in the field, starting with Aetna in cost control, joining the National Society of Safety Engineers, the National Safety Council, directing Consigli’s program. I tell students, “You can do this, too.” I show them you have to be energetic, and you can’t expect to work 8-5. You’ve got to work weekends, you’ve got to work nights, and you’ve got to talk to people.

Dan: Remember, people like to teach. Talk to the people in the field. Ask a lot of ques-tions. I learned by talking to the supers, the project foreman. Ask about means and methods. And respect the people out there, they know a lot more than you do.

Daniel Jr.: You need to have a passion for it. Whether you’re a super, a safety manag-er, a carpenter; it’s a demanding field and people put in a lot of effort: you need to be dedicated and passionate.

Growing the family biz?

And now, if all this makes you wonder if there are others in the D-G family business—the answer is yes. Dan’s niece, Daniella Della-Giustina, an astrophysicist at the University of Arizona, recently determined the safest way for space travel to Mars, protected from the sun’s radiation. The safety solution—travel protected by the shadow of orbiting comets; safety in space, the final frontier? ■

The Della-GiustinasBy the Numbers:

The Della-Giustina family’s combined years in the field of safety management

Age that Daniel Jr. was when he first walked a job site with his father, Dan

Safety management text books written by Professor Della-Giustina

(cont. from pg. 9)

Keeping our Self-Perform Teams Safe: The 101 on Silica

91.5

319

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Pace University’s Campus Expansion: Where Innovation Meets Safety + SavingsLike a carefully orchestrated theater production, the construction of Pace University’s $100M Master Plan for the Westchester County campus in Pleasantville, the first dramatic scenes are underway. On center stage—the new Central Residential Halls are rising up; on stage left—new Environmental Center facilities have taken shape; while on stage right, the transformation of the existing Kessel Student Center is almost complete. This multi-phased, 15-building master plan implementation project, led by KCCM’s Project Executive Mark Zych, is requiring the best innovative thinking to keep the many moving parts synchronized, and the campus as a whole, a safe site for crews, students and staff.

“Building off-site ensures better construction quality management and safety

conditions, as well as reducing on-site disruption and

material storage needs.” —The Modular Building Institute

Modular Design Meets Residential Suites Design

The construction of two, new four- story residence halls is at the center of this first phase of this master plan implementation. Along with a third hall to be built in a future phase, they will add a total of 1,000 new beds to the campus and create a new, cohesive core around a traditional “Campus Green.” What is less traditional—and providing our partners at Pace great cost savings, site safety and schedule benefits—is the manner in which sections of this new student housing is being built, through the use of pre-fabricated, modular bedroom suites.

The Fab in Pre-Fab

The Modular Building Institute defines modular construction as “a process in which building components are constructed off-site, under controlled plant conditions, using the same materials and building codes, but in about half the time as when built on-site. Building off-site ensures better construction quality management and safety conditions, as well as reducing on-site disruption and material storage needs.” Our work at Pace is benefiting from all these advantages.

The use of pre-fabrication was not originally part of the approach by project architect EYP. During KCCM’s in-depth pre-construction planning, we successfully encouraged EYP to consider adopting a hybrid modular design approach, knowing it could bring many benefits, while not hindering the design goals. This approach combined the use of modularly built bedroom components, with traditional on-site building methods for the customized construction of the halls’ common areas and shared spaces, like foyers, lobbies, cafés, and social and meeting rooms.

The Right Connections

The team dedicated valuable pre- construction planning to make the most of schedule and cost advantages by using pre-fabricated modular building

components. Because the accurate coordination of the mechanical, electri-cal and plumbing (M/E/P) systems in the pre-fabricated suites to the systems in the buildings’ public spaces is crucial, the team is using a building information model (BIM) to plan seamless connections.

One advantage of modular, pre-fabricated suites is that the team has been able to plan overall coordination by focusing on a prototypical suite, identifying where it connects to the building systems that run

above the hallway ceilings. Through the model we are confirming

the dimensions and space requirements for the

M/E/P systems.

Andy Deschenes, Director of Consigli’s Project Services, likened this connection of each suite’s duct work from either side of the central corridors, into the compact ceiling spaces above the corridors, as a “zipping up.” Andy explained, “In effect, our pre-construction model is helping us determine how we build a giant duct-work ‘zipper’ that will integrate the systems from the suites on both sides of each hall. Once we have the dimensions confirmed in our prototype, this will help us be highly efficient in the field.”

All of this carefully planned modular construction at Pace is saving time, creating a safer building environment, and ensuring a high quality of construction. Win, win, win! ■

NEW YORK SPOTLIGHT

A suite view: A BIM cut-away of Pace’s modular residential units

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A New Zero Sum Game: Ipsen Biomeasure’s Fit-Out Scores Big with Lean Construction Management

Our work for Ipsen in Cambridge’s Kendall Square—the fit-out of a new 48,000-square-foot research and develop-ment center completed this summer— was one of this year’s several “beta test” Lean projects, with big, winning results.

The big winners: project safety, project quality, project schedule and our client, a new Raving Fan.

The results: zero lost time accidents, and a Pull-Planning process that allowed us to re-sequence the project as the design was developed and meet the owner’s requirements for delivering the building.

This fast track biotech project—notable for its complex M/E/P systems, vivarium and research laboratories—mobilized in November of last year, and received the project’s certificate of occupancy July 1, 2014. Led by PX Brian Hamilton, PM Erick Lacy, APM Janice Narowski, PE Mike Byron, Supers Tom Smith and Kyle Griffin, M/E/P Manager Ed Dubois and M/E/P Coordinator Jose Ayala, the team created a safe site without any lost time accidents, through the combined implementation of the “Nothing Hits the Ground” materials- handling strategy, Just-in-Time deliveries, and pre-fabrication of the project’s M/E/P racks. These three Lean approaches added up in a powerful way.

With a large percentage of injuries related to materials handling, the safety benefits alone of the “Nothing Hits the Ground”

strategy make it a valuable tool; when used in tandem with the strategic scheduling of Just-in-Time deliveries and pre-fabrication, its benefits multiply.

Over the project’s six months, materials were kept off the ground in a number of ways: drywall on drywall carts; the heavy equipment was kept on pallets, ready to be moved when needed. Pre-fabricated pipe racks arrived on site just-in-time for their installation, and moved into place on wheeled racks.

Project Super Tom Smith readily credited our strong sub team in supporting our Lean efforts. “We had A-list subs— TG Gallagher and Sullivan & McLaughlin.”

Tom noted that electrical sub SullyMac’s use of pre-fabrication extended to pre-measured, pre-labeled, pre-cut lengths of wire, ready to go on mini-spools, stacked neatly on pallets. This pre-construction preparation saved time during installation, as well as keeping the site clear of wire scraps.

When asked, “What were the most valuable Lean techniques?” PM Erick Lacy summed it up, “Pull-planning and the follow-up daily subcontractor meetings coordinated activities for maximum efficiency and identified opportunities for schedule improvement.” ■

BOSTON SPOTLIGHT

Lean Construction 101

Nothing Hits the Ground

This Lean approach requires that all contractors on site use rolling carts, racks, dollies and pallet jacks for mate-rials and equipment. This simple policy has several Lean benefits: 1) ensuring that materials can be safely and quickly moved around site, 2) helping prevent many of the strains, sprains and repeti-tive motion injuries associated with materials handling, 3) creating cleaner, more efficient sites.

Pull-Planning

Pull-Planning is a technique for outlin-ing and meeting scheduling deadlines. Techniques involve using sticky notes to mark essential elements of work, working backwards from the end-date.

Continual Improvement

Lessons for Next Time• To accurately forecast and implement

the commissioning phase, involve the commissioning agent, owner, design team and subs from the project’s start to allow time for planning and design reviews

• From project’s start, explore every opportunity to innovatively implement pre-fabrication

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What better way to promote jobsite safety than to be reminded by our children?Consigli’s annual Safety T-Shirt design contest, open to children of Consigli employees under the age of 12, is judged by the Safety Committee.

The first prize design is emblazoned on the backs of the new Consigli Safety T-shirts and handed out at the October Safety Meeting.

1st Place Winner Kayleigh T., age 6 Bobbi Cenedella’s niece

All participants received a Toys ‘R’ Us gift certificate. Congratulations to the winners, and thank you to all who participated!

Recognition for our Projects

Engineering News RecordNew England Best Project Awards

• 225 Binney Street

• Wat Nawamintararachutis Thai Temple and Meditation Center (NMR)

Maine PreservationHistoric Preservation Honor Award for Restoration

• Maine State House Dome

Recognition for our Practices

Boston Business Journal’s Largest General Contractors in Massachusetts.

ENR’s Top 100 Contractors in the nation

ENR’s Top 100 Green Contractors in the nation

Preservation MassachusettsPaul E. Tsongas Award for Commitment to Historic Preservation

CONSIGLI HONORS

Consigli Named “Top Places to Work”

2014 Safety T-Shirt Design Winner!

2nd Place Winner Charley Drew, age 8Todd Drew’s daughter

This year, Consigli was ranked in the Best Places to Work lists for Connecticut (#1), Maine (#15) and Massachusetts (#16).

“We are so proud and

humbled to be recognized

by The Boston Globe, Mainebiz and The Hartford Business Journal,

as well as by our employees for being a great place to work. These

rankings are a reflection of the culture you have created, and are

a testament to the success we’ve enjoyed by empowering our

people. Thank you.” Matthew & Anthony Consigli

#2#77#29

SAVE THE DATE!

Consilgi Annual MeetingMarch 21, 2015More information to come!

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Garrett Johnson Project Engineer

What impressed you the most about your safety ride?

A: Although the construction site was incredibly fast-paced and potentially extremely dangerous, measures were in place (and monitored) which allowed the site to function as a safe environment. When walking the site, I realized that workers were aware of potential dan-gers and knew the appropriate steps to eliminate these dangers. And, if a worker was not conforming to the correct safety measures, the safety manager would notify the worker. The system in place seemed very effective.

What did you learn about site safety that surprised you?

A: I was most surprised by the thorough-ness of site safety. The amount of safety paperwork alone was impressive, not to mention the safety walk checklist and report, and required safety protocols. After the safety ride, I had a much better understanding of how a construction site can still be a safe place to work.

How is Consigli’s approach to project safety different from what you expected or have experienced at other construction companies?

A: I expected that there were a few major issues that the safety manager

was looking out for. After seeing the safety walk checklist, I realized there are hundreds of different observations that the safety manager makes on a safety walk. I thought the safety walk checklist on the iPad was a really intuitive way to keep track of safe and unsafe conditions because observations are recorded in real time as they are seen on the site. ■

Stuart Kibbee Project Executive

What impressed you the most about your safety ride?

A: The fact that every new hire, no matter the position or role within the company, participates in the safety ride.

What did you learn about site safety that surprised you?

A: After being in the business for close to 30 years, it amazes me that the workers

still have a hard time understanding the importance of having a strong safety program. It is truly in their best interest.

How is Consigli’s approach to project safety different from what you expected or have experienced at other construction companies?

A: Consigli’s approach is very sound. One difference I noticed on the safety walk from my last company was the use of the iPad and software to complete a safety inspection in real time while we were on

the walk. If this information is used appropriately, it can be a very effective, proactive management tool. ■

EMPLOYEE SPOTLIGHT: New Employee Safety Ride Impressions

This season, remember the following safety tips when dressing for cold and wet weather:

First, NEVER wear cotton in the winter. When cotton gets wet, it wicks heat away from your body causing your core temperature to drop quickly, possibly causing hypothermia—which can be deadly.

Symptoms of hypothermia begin gradually and include confused thinking, which can prevent self-awareness and lead to risk-taking behavior.

Wool and synthetics, such as polypropyl-ene, are superior materials for holding in heat and providing insulating properties when wet. Remember to dress in layers you can shed to reduce sweating.

When working in cold weather, always allow for more time indoors to keep warm. And, once the weather drops below freezing, make sure to cover any exposed body parts to prevent dangerous frostbite, which can occur quickly. ■

WINTER CLOTHING SAFETY REMINDERS