Organization: MCAA

Parker Hannifin’s Transair Aluminum Piping Helps Lynch Complete Cleanroom Retrofit in Six Months

To meet a tight deadline, William F. Lynch Co., Inc. recommended Parker Hannifin’s Transair aluminum piping over copper piping, saving installation time, labor, and material costs. By using Transair, Lynch was able to install twice the piping specified in the initial design and still finish the job on time.

Nypro, a plastics injection molding company in Clinton, MA, contracted Lynch, of Worcester, MA, to retrofit an abandoned building so that it could expand and upgrade its health care production facility. As facilities age and building restrictions tighten, retrofitting an older building for modern-day manufacturing can be challenging, especially in the medical industry. In addition, the project timeline allowed just six months for construction.

Seizing an Opportunity

Nypro has been negotiating with a pharmaceutical company to fill the medical delivery devices manufactured by Nypro with the medicine at the time of production, improving efficiency for both parties. However, Nypro’s Clinton facility was too small to handle the expanded scope of work, said Senior Manager of Maintenance & Facilities Mark Butler.

Nypro sought an additional location for its health care division with adequate space for an ISO 8-compliant cleanroom, which has strict regulations regarding airborne particulate cleanliness. The room also required laminar flow—in which air flows in a parallel pattern with no mixing of layers—and HEPA air filters installed in the ceiling, Butler pointed out.

“We keep the particle count down by pressurizing the room, so when you open the door, the minute particles, if any, blow out instead of in,” Butler said. “We’re also very particular about the room’s temperature and humidity.”

The company found a 193,000-squarefoot abandoned building with 58,400 square feet for the cleanroom and another 18,000 square feet for cleanroom expansion. The rest of the building houses support, warehouse/shipping, and offices. Project work included rework of the mechanical systems and the design and installation of a compressed clean dry air (CDA) system. CDA air is critical to Nypro’s manufacturing process, primarily for molding equipment and other pneumatic devices in the assembly area that operate the high-speed assembly equipment.

Aluminum: Alternative to Copper

Initially, Nypro wanted to install a copper CDA piping system, which would have taken more than 1,300 labor hours, said Lynch’s president, Mac Lynch. The complex project schedule did not provide enough time for a CDA installation. After exploring options to reduce manhours, Lynch recommended Parker Hannifin’s Transair aluminum piping.

“The initial design had about 2,300 feet of CDA piping,” Lynch said. “As the project evolved and all parties saw the advantages of using this system, other phases of the project incorporated Transair into the design. Total installed CDA pipe was more than double the initial design—about 5,400 feet, a little over a mile—and we still met the project deadline.”

Parker Hannifin’s Transair aluminum piping was so easy to install that Lynch was able to install twice as much as the initial design called for and still meet Nypro’s six-month project deadline.
Parker Hannifin’s Transair aluminum piping was so easy to install that Lynch was able to install twice as much as the initial design called for and still meet Nypro’s six-month project deadline.
Unlike traditional copper piping, Transair does not require any brazing or purge gases, eliminating the need for that added labor expense for the Nypro retrofit. “One man can install most of the pipe alone, and the fittings save quite a bit of labor,” said Mac Lynch, president of Lynch.
Unlike traditional copper piping, Transair does not require any brazing or purge gases, eliminating the need for that added labor expense for the Nypro retrofit. “One man can install most of the pipe alone, and the fittings save quite a bit of labor,” said Mac Lynch, president of Lynch.
The Nypro installation required about 5,400 feet of CDA pipe, which would have taken more than 1,300 labor hours with copper— exceeding the project’s six-month deadline. With Parker Hannifin’s lightweight Transair piping and quick-connect fittings, Lynch met the deadline and the CDA requirements.
The Nypro installation required about 5,400 feet of CDA pipe, which would have taken more than 1,300 labor hours with copper— exceeding the project’s six-month deadline. With Parker Hannifin’s lightweight Transair piping and quick-connect fittings, Lynch met the deadline and the CDA requirements.

Using Transair allowed Lynch to meet the deadline and the CDA requirements. Aluminum is lighter and easier to manage than copper and does not require any brazing or purge gases, observed Lynch, thus eliminating the need for that added expense.

“We didn’t need a big crew hanging the larger Transair pipe,” Lynch said. “One man can install most of the pipe alone, and the fittings save quite a bit of labor.”

Easy to Install, Repair

During the project, workers built section mock-ups on the shop floor before fitting them in the ceiling braces. Only one pipe joint in the entire installation leaked during the testing process, and the quick-connect fittings allowed for an easy fix.

“With a brazed joint, we would have had to cut it out, replace with new, rebraze and purge again, costing a day’s labor plus materials,” Lynch said. “With Transair the repair was about 20 minutes, even at 25 feet above floor level.”

Transair also costs less than copper, said Lynch. The Transair cost savings over a pressed copper system were $24,100, just under 10 percent, and would be more if compared with a brazed system. The cost savings were a big selling point for Nypro.

“Long-time, experienced facility managers have ways of doing things that work for them and are hesitant to move in a different direction. It’s just human nature,” Lynch said. “We believe that the Transair system, once assembled, is as good as any other. We knew we could give Nypro the same quality they expected for a lower price.”

Transair’s smooth interior and full-bore design ensure optimal and constant airflow. Once installed, Transair is guaranteed to resist corrosion, which prolongs the life of both the piping and the facility’s equipment.

“I’ve known about Transair for a while and knew their specifications and claims,” Lynch said. “They delivered on these claims.”

Two compressors (150 horsepower and 350 horsepower) supply the CDA, and a branch for a future 350-horsepower compressor was added. Piping was sized and installed based on the specific pressure delivery needs throughout the facility.

Over sixty percent of the system ranges from 3″ to 6″ in diameter, and the rest from 1/2″ to 1 1/2″.

Quick Turnaround

With Parker’s extensive distributor network, the project’s supplier, F. W. Webb of Boston, was able to get Lynch materials quickly, sometimes with a one-day turnaround.

“Timing was everything for them,” said F. W. Webb’s Inside Sales/Customer Service Representative Mike Costa. “Webb has a good reputation of going out of our way to keep a customer happy. We paid the extra freight charges and did what we could do to get materials out to Lynch when they needed them.”

F. W. Webb pulled from nearby distribution centers that keep a large quantity of material in stock, helping the company meet same-day orders, Costa said. Webb’s intercompany trucking services helped get materials from one place to another quickly, sometimes with two orders in one day. “That’s a value-added thing for Webb that a lot of companies don’t do,” Costa noted.

The project was completed in October 2014, meeting the deadline. From planning to completion, the entire project took nine months, with design work continuing through part of the build-out.

“Transair was very helpful in walking us through their product and getting things off on the right foot,” Lynch said. “As contractors, we don’t like surprises. For this project, Transair’s support eliminated surprises, making us and the owner very happy.”

For more information, visit www.parker.com.

MCAA thanks Parker Hannifin for being a supporter of MCAA 2015.

F. W. Spencer & Son Meets Levi’s Stadium’s Tight Deadline Thanks to Jay R. Smith Prefab-Ready Products

With just over two years to build the NFL’s new Levi’s® Stadium, F. W. Spencer & Son, Inc. turned to Jay R. Smith Mfg. Co.® for products designed with prefabrication in mind, allowing them to meet the accelerated deadline. Installing a big battery of water closets typically involves prefabrication to save time, but the building of Levi’s Stadium in Santa Clara, CA, took prefab work to another level entirely. With careful planning and quick turnaround on materials, F. W. Spencer & Son succeeded in constructing all the fixtures in its warehouse and installing them in time. The stadium is home to the San Francisco 49ers.

Usually, a contractor gets everything approved and then starts the project. But for Levi’s Stadium, timing was everything. All aspects of the work had to be done efficiently and quickly. F. W. Spencer & Son was able to manage multiple complex tasks occurring all at the same time. To keep the project moving quickly, Jay R. Smith Mfg. Co. got the materials requested together and shipped them before they were even needed on the job.

Prefab Paves the Way for Smooth Installation

“We built the entire job basically in a warehouse,” said Steve Sandkohl, project manager at F. W. Spencer & Son. That meant every battery, every fixture location, and all the rough-in plumbing work for the concessions and restrooms were completely built and fastened right into a concrete slab in the prefab warehouse. Jay R. Smith Mfg. Co. Quarterback Water Closet Supports were designed with prefabrication in mind. F. W. Spencer & Son chose them based on anchorage requirements and ease of mounting to shipping channel for transport to the jobsite. Levi’s Stadium was the first project to use the new Quarterback Water Closet Support.

F. W. Spencer & Son relied on prefabrication to ensure smooth, speedy installation of plumbing fixtures to meet the accelerated schedule for the new Levi’s Stadium. Jay R. Smith Mfg. Co. Quarterback Water Closet Supports were designed with prefabrication in mind.
F. W. Spencer & Son relied on prefabrication to ensure smooth, speedy installation of plumbing fixtures to meet the accelerated schedule for the new Levi’s Stadium. Jay R. Smith Mfg. Co. Quarterback Water Closet Supports were designed with prefabrication in mind.

Because F. W. Spencer & Son was building as much as possible ahead of time, how to transport the finished build to the stadium was a key consideration in choosing the materials. “It doesn’t do any good to do prefab if you can’t safely transport without damage,” said Sandkohl. “A lot of the decision-making on elements we used weighed all those factors.”

Once everything was air-tested and complete, F. W. Spencer & Son cut the finished installation into manageable sections to be transported to the jobsite. Because everything had been staged with precision, it was a case of simply coupling everything together onsite.

Custom Designs Meet Client Demands

The job also called for modified heavy-duty trench drains to be installed on both sides of the field, specifically in areas where heavy equipment would be moving in and out of the stadium. Once again, Jay R. Smith Mfg. Co. moved quickly. They designed a heavy-duty grate to go with the trench drains that could withstand different load ratings. Ninety-foot sections were shipped to the staging warehouse where all the channels were connected together for each layout. Each section was framed and bonded together. The trench drains were then lifted onto flatbed trucks with cranes and taken to the stadium.

The prefabrication allowed longer runs to be installed faster on the jobsite with no delays to the job schedule because the joints were already made. All the contractor needed to do once the assembly was delivered to the jobsite was to set in place and secure the trench drain run for the pour.

Because the trench drains were made of fiberglass, there was some concern that they could be brittle. To address the concern, a strut channel was used to box the trench drains in, essentially using the channel for support. As a result, everything stayed straight on the ground.

“The only way we could get the job done in such a short timeframe was to do it this way. You can have the prefab work going on for a longer amount of time. While they were building we were prefabbing,” said Sandkohl. At the job’s peak, they had 200 plumbers working.

Levi’s Stadium, the first United States professional football stadium to achieve LEED Gold certification, hosted its first regular-season NFL game in September 2014. It will also host domestic and international soccer, college football, motocross, concerts, and various civic events and can expand for major events, such as Super Bowl 50 in February of 2016.

For more information, visit www.jrsmith.com.

MCAA thanks Jay R. Smith Mfg. Co. for being a supporter of MCAA 2015.

Message from Jim Allen, M/SC Chairman: Proud To Be Partners

page2Finding new ways to increase productivity and save money means constantly keeping an eye out for products and services that can help. Jim Thomas, president and owner of JS Thomas Service, Inc., found the answer he needed in a story he read in Smart Solutions. In this issue, learn how JS Thomas moved from paper service tickets to iPads® using iBusiness Technologies’ MobiliForms, speeding up customer billing and payment.

That’s just one example in this issue of how contractors rely on MCAA Supplier Partners. William F. Lynch Co., Inc. recommended Parker Hannifin’s Transair aluminum piping over copper piping to meet a tight deadline and save costs. Environmental Mechanical Contractors, Inc. teamed with Victaulic’s Construction Piping Services department to create 3D renderings, minimizing rework and troubleshooting potential problems. Working with Sauer Group, Tri Tool Field Services developed weld procedures and deployed its portable machine tools and AdaptARC multiprocess welding systems, improving Sauer Group’s productivity as much as 300 percent. Supplier partners take partnership seriously. The enduring relationship between Major League Baseball’s Chicago Cubs and the Sloan Valve Company has led to the Cubs naming their spring training facility Sloan Park.

Also in this issue, Zurn Industries, LLC engineered a range of customized products in less than four weeks for the rapid renovation of Orlando’s Citrus Bowl Stadium. Carrier worked closely with New Jersey’s Shore Medical Center to achieve LEED® Silver certification and earn a $117,000 energy-efficiency rebate in the process. By installing a Variable Refrigerant Flow zoning system, Mitsubishi Electric US Cooling & Heating Division helped an energy-efficiency consulting firm slash their electricity and gas costs.

Contractors are always looking for creative ways to achieve their goals. Thomas J. Dyer used innovative aerial service provider Erickson Incorporated to place air handling units and a condenser on a plant roof in less than one hour. Geiler Plumbing found that using Wayne Water Systems’ Blue Angel Pumps cut down their installation time, improving overall productivity. F. W. Spencer & Son, Inc. turned to Jay R. Smith Mfg. Co.® for products designed with prefabrication in mind, allowing them to meet the accelerated deadline for the NFL’s new Levi’s® Stadium. The Waldinger Corporation discovered that PENTA Technologies’ Mobile Field Service application not only saved time but also boosted sales and marketing opportunities.

Smart Solutions also includes advice you can use to manage risk. Viega offers tips to improve plumbing design to avoid bacteria build-up. CNA describes how to protect laptops and mobile devices from theft and data breaches. This issue is filled with examples of how MCAA Supplier Partners are proud to be your partners in productivity.

Jim Allen, Chairman

Chicago Cubs’ Spring Training Facility To Be Named Sloan Park

Sloan Signs On as Cubs’ Legacy Partner and Official Water Efficiency Partner

As reported in the Summer 2014 issue of Smart Solutions, Major League Baseball’s Chicago Cubs specified Illinois-based Sloan Valve Company’s plumbing systems for its spring training facility in Mesa, AZ. Recently, the Cubs announced that Sloan has joined the organization as a Legacy Partner and the team’s Official Water Efficiency Partner. As part of this agreement, the Cubs’ spring training facility will be named Sloan Park.

Sloan, the world’s leading manufacturer of intelligent water solutions, will help the Cubs expand their ongoing sustainability efforts and improve the fan experience at Sloan Park and at Wrigley Field. Sloan’s expertise in water efficiency will help the Cubs reduce their overall environmental impact—especially important in drought-prone areas such as Arizona.

“We are a global organization founded in Chicago, so partnering with another iconic Chicago brand is a natural fit.

Sloan products have been in Wrigley Field since 1914, and this exciting new partnership with the Chicago Cubs helps Sloan tell its story on a major-league level,” said Jim Allen, president of Sloan.

Allen continued, “Water is an increasingly important natural resource. By helping communities and organizations like the Chicago Cubs save water, Sloan helps to raise awareness of water conservation in this country and around the world. Responsible use of water is critical to local communities and to the world. Our partnership with the Chicago Cubs organization gives us the opportunity to help build winning teams through sustainable solutions.”

Cubs Chairman Tom Ricketts noted, “Teaming up with Sloan is an important move for the Chicago Cubs. Sloan brings more than a century of experience and success in creating cutting-edge water solutions for a wide variety of venues all around the world. We are pleased to work with and learn from Sloan as we enhance our facilities and build for the future.”

As part of the expansion and restoration of Wrigley Field and its surrounding facilities, known as the 1060 Project, the Cubs will use Sloan’s products to expand their sustainability efforts. At Sloan Park and Wrigley Field, Sloan will showcase their products and state-of-the-art water-saving technologies. Sloan is the sixth Legacy Partner of the Chicago Cubs, joining Anheuser-Busch, ATI Physical Therapy, Starwood Hotels and Resorts, Under Armour, and Wintrust.

For more information, call 800-9-VALVE-9 (982-5839) or visit sloanvalve.com.

MCAA thanks Sloan Valve Company for being a benefactor of MCAA 2015.

EMC Sees 30-Percent Labor Savings with Victaulic 3D Renderings and Installation-Ready Couplings

Having installed Victaulic grooved products numerous times, Environmental Mechanical Contractors, Inc. (EMC) knew Victaulic could help them meet a tight deadline for renovations at Kansas’ Fort Leavenworth. Working with Victaulic’s Construction Piping Services department (CPS) to create 3D renderings of the project also allowed EMC to minimize rework and identify and troubleshoot potential problems.

“We picked up a 30-percent labor savings from fabrication to install[ation] because of the isometric drawings and Victaulic Installation-Ready™ couplings,” said Marcus Howell, EMC’s senior project manager on the Fort Leavenworth project (now director of construction operations).

Going Deep

Renovations at Fort Leavenworth, the oldest active United States Army post west of Washington, D.C., focused on Building 120, also known as Eisenhower Hall. It includes the Combined Arms Research Library, high-tech classrooms, a conference center, and the DePuy auditorium. In operation for over 180 years, the facility required a full restoration of its three-story, 220,000-square-foot interior.

With their expertise in sustainable projects and quick-turnaround commercial/ industrial HVAC heating and cooling, sheet metal, ductwork and piping design, EMC was selected for the renovations. The most involved aspect of the project was replacing the existing HVAC system with a more energy-efficient hybrid geoexchange system featuring 240 geothermal wells drilled 500 feet into the earth. The new system would enable Building 120 to achieve a 40-percent energy savings under the ASHRAE 90.1- 2001 standards. Other renovations included a new HVAC installation within the library, complete removal and revamp of restrooms on all three floors of the building, general mechanical and maintenance repairs, and a full-building test and balance of the HVAC system.

Racing against the clock with $8 million for mechanical upgrades and a tight deadline of only 540 calendar days, EMC engaged Victaulic to overcome the challenge of not only a compressed schedule, but also configuring the piping around an existing geothermal system. Howell was familiar with CPS, Victaulic’s drafting and building information modeling (BIM) services, and called on them to draw and coordinate the mechanical room. At EMC’s request, the CPS team developed isometric 3D renderings to identify the pad, equipment, and overall piping layouts and provide prefabrication support.

EMC partnered with Victaulic’s CPS for BIM, creating isometric drawings that solved unique challenges. For example, laying out piping in 3D allowed EMC to overcome space constraints and include more piping in the mechanical room at Fort Leavenworth.
EMC partnered with Victaulic’s CPS for BIM, creating isometric drawings that solved unique challenges. For example, laying out piping in 3D allowed EMC to overcome space constraints and include more piping in the mechanical room at Fort Leavenworth.

Strategic Planning

“Environmental Mechanical Contractors firmly believes that if we spend time upfront to make the right decisions prior to construction, like we did with Victaulic Construction Piping Services, it will have a direct and positive result on the project’s success,” said Howell. “Having this aspect under our control helps assure the project schedule. That means responsiveness, cost-effectiveness, and delivering on time to the specifications the project requires.”

Using the drawings allowed for strategic planning to ensure economical, practical, and proper installation and to avoid conflict and changes at the time of implementation. For example, refining pipe routings in the drawings guaranteed there would be proper clearance for installation and maintenance, which was especially beneficial when making accommodations for the new geothermal water system.

“The isometrics changed the way EMC communicated,” said Howell. “It gave our team a clear picture of how the finished job would look and allowed us to accelerate project collaboration and efficiency in real time. It also minimized the potential for miscommunication by eliminating the need to use our own imagination to interpret the plans.”

Improving Safety and Savings

To help avoid delays and save time and money, EMC enacted a variety of processes, including developing accurate bills-of-material (configured from the pipe routing drawings) to ensure precise material orders and roll grooving and prefabricating the pipe at their headquarters. Using detailed pipe cut sheets provided by CPS, pipe marking, lengths, and quantity data offered a guide for crew members to match the pipe to the isometrics. Furthermore, to help increase the speed and ease of field installation, EMC shipped preassembled lengths to the jobsite for final assembly. They also labeled the additional grooved products and accessories with location and date information.

Victaulic’s BIM services and Installation-Ready couplings saved EMC 30 percent in labor costs as they renovated Building 120 (Eisenhower Hall) at U.S. Army post Fort Leavenworth. Projects included replacing the existing HVAC system with a more energy-efficient hybrid geoexchange system featuring 240 geothermal wells.
Victaulic’s BIM services and Installation-Ready couplings saved EMC 30 percent in labor costs as they renovated Building 120 (Eisenhower Hall) at U.S. Army post Fort Leavenworth. Projects included replacing the existing HVAC system with a more energy-efficient hybrid geoexchange system featuring 240 geothermal wells.

Isometric drawings solved unique challenges within the mechanical room. Space constraints were overcome by laying out the piping in 3D. Four-inch pipes connected the distribution piping and heat pumps for the 640-ton geothermal heating and cooling system, while pipes 12″ in diameter and smaller were used for connections off the chilled, hot, condenser, and geothermal waters in the mechanical room. Just as large as the other systems in the mechanical room, the geothermal water piping connected to the underground heat exchange, requiring EMC to reroute the pipes to accommodate the new system. To avoid costly specialty joints, Victaulic CPS specified tightly stacked triple-service valves, providing elasticity and vibration attenuation while avoiding flexible connectors for pumps.

At the onset of the project, EMC planned to weld the systems. But to increase productivity and safety on the job and meet compressed schedules, they chose Victaulic couplings, which feature proprietary Installation-Ready technology for piping up to 8″ in diameter. Howell stated that these couplings contributed to labor savings on the project because they can be installed in less than half the time of standard grooved couplings and up to five times faster than welding.

“We are huge fans of these new couplings,” said Howell. “Victaulic standard grooved couplings are fast and easy to use, but these are even more so. We’d use them for everything if we could, and we’re excited that they’re available for 10″ and 12″ sizes now as well.”

While cost, schedule, and a job’s bottom line are important components to a project, even more so is the safety of its team. Grooved mechanical systems require no hot work, making them inherently safer than welding by minimizing the risk of arc flash and fire hazard. With no welding, EMC was able to eliminate the unproductive time associated with fire watch. Additionally, transporting complete assemblies to the construction site allowed EMC to reduce material handling, further controlling the work environment and minimizing risk.

“We use Victaulic on every project we can because we know the value they bring in helping us deliver a successful job,” said Howell. “After working with the Victaulic CPS team on the Fort Leavenworth project, our people were really sold on it, so now we also use Victaulic drawing services on large mechanical rooms when we can.”

For more information, visit www.victaulic.com.

MCAA thanks Victaulic for being a major sponsor of MCAA 2015.

Graco Mechanical Expedites Office and Field Operations Using Davisware Solutions

When Graves Mechanical, Inc. formed Graco Mechanical, Inc.—a 24/7 service arm concentrating on preventive maintenance—the company needed a business solution that would support its essential and continuous office-to-field communication and its promise to stay constantly connected and available to customers. In addition, Graco Mechanical needed to expedite many of its processes, especially its 10–14-day billing turnaround time. With Davisware technology, the company reduced its billing turnaround time to 3–5 days and decreased its invoice processing time. In addition, Davisware’s Remote Field Service solution allowed Graco Mechanical to reduce its gas costs by 10–20 percent.

Graco Mechanical adopted Davisware’s S2K software (formerly S2000), fully integrated Global One Fleet GPS Tracking System, and Remote Field Service modules. The modular setup allowed Graco Mechanical to purchase essential business tools as needed. The Service Dispatching & Mapping application has proven to be extremely effective for Graco Mechanical by making scheduling more efficient and increasing call-per-technician ratios.

With Davisware’s Remote Field Service tools, Graco Mechanical has enhanced customer experiences, provided greater accuracy and efficiency to its accounts, simplified communication between office employees and technicians, and reduced the need for paperwork. Now, the company’s customer service representatives can electronically assign and route service calls through the BEST TECH Dispatch Board, and office staff can upload manuals to a service order. Using Android tablets in the field, technicians can receive assigned work orders; view work order details, comments, manuals, and service history; electronically fill out inspection forms and weekly timesheets; type or speak work notes; upload images from a site; verify time onsite; capture customer signatures; enter payment methods; and send all the information back to the office in real time.

Since partnering with Davisware, Graco Mechanical has increased customer satisfaction and boosted both its own and its customers’ bottom lines. The HVAC company has successfully improved many of its processes, including reducing billing turnaround time and invoice processing time.

For more information, visit www.davisware.com, or call Jennifer Davis at 847-426-6000 (ext. 111).

Built-In Freeze Prevention Makes Woodford Rooftop Hydrant Ideal for Colorado School

Ease of installation and reliability made the Woodford RHY2-MS roof water hydrant the ideal choice for a school in Parker, CO. Roof hydrants provide access to rooftop water, which is then used to clean condenser coils, windows, cooling towers, green roofs, and other types of rooftop equipment.

Because the installation was in Colorado, hydrant freezing was a concern. The last thing a contractor wants is a leaking hydrant on the roof. The RHY2-MS features a built-in vent that allows automatic draining. There is no need to drain the hydrant for freeze protection, even with a hose attached.

Installing the Woodford roof hydrant at the school was simple. Its heavyduty cast-iron mounting system can be installed by the roofer or plumbing contractor, and the hydrant can be installed later during the water piping process. The mounting system secures above and below the roof deck, providing exceptional strength and security—which is important when the hose is stretched or pulled and in potentially harsh rooftop weather conditions. The product comes with a 2-degree shim for pitch adjustment.

Maintenance and repairs are easy with the RHY2-MS. All repairs can be made from the top of the hydrant; it is not necessary to remove the hydrant. The Woodford RHY2-MS roof hydrant has an ASSE 1052 double-check backflow preventer that can be field tested. Woodford also offers a freezeless sanitary roof hydrant, the SRH-MS, that does not require a drain, and a mild-climate roof hydrant, the RHMC-MS, for nonfreezing environments.

For more information, visit www.woodfordmfg.com or call 719-574-1101. 

Alliantgroup Offers Insight on R&D Tax Credits for Mechanical Contractors

For those MCAA members looking for a practical way to grow their business, the answer may lie in an often overlooked section of the tax code. The research and development (R&D) tax credit—an incentive that rewards internal improvements made to a company’s products, processes, and techniques—has been around since 1981. Producing tax relief at a rate of nearly $10 billion a year for U.S. businesses, it is one of the most generous and lucrative tax incentives offered by the federal government.

In one example, a mechanical contractor received $245,099 in federal credits for innovative and practical solutions made while working on the dormitories of a college. The company improved its designs and equipment while in the field to ensure that the dormitories’ mechanical systems were efficient and operational. Another contractor received $81,696 in federal credits for a number of projects, including fabricating and installing a new HVAC system and asbestos treatment. Yet another received $33,809 in federal credits and $10,477 in state credits for projects including the design and installation of a new generator and the design and installation of a new 1,000-ton chiller.

The R&D tax credit was designed to reward practical solutions for the kind of problems a mechanical contractor deals with on a daily basis. However, when it comes to R&D, people tend to think of scientists in white lab coats. You don’t need to reinvent penicillin or put a man on the moon to qualify. The problem-solving that occurs in the field or onsite—even if it is just a way to improve a building’s plumbing or HVAC—is also eligible for R&D tax credits.

The R&D tax credit has been around for over three decades. It has bipartisan support in Congress and has been supported by every administration since 1981. In addition, 38 states have introduced their own versions of the incentive, and a number of court rulings have further expanded the reach of the federal credit. Among those applicable to mechanical contractors are Trinity Industries, Inc. v. U.S., a ruling allowing businesses to claim the credit for their designs, even if said building designs are under contract with a client the firm is working for, and FedEx Corp. v. U.S., a ruling providing that businesses only need to prove a substantial and economically significant reduction in cost or improvement in speed—in short, your work only has to be “new to you,” not “new to the world.”

For more information, visit www.alliantgroup.com.

Western Allied Mechanical Gains Competitive Advantage by Demonstrating Rapid ROI with BuildingAdvice Technology

After completion of an HVAC controls retrofit project, Western Allied Mechanical engaged AirAdvice energy analysts to demonstrate that the upgrades yielded a return on investment (ROI) of 65 percent and a payback time of 1.5 years. Being able to demonstrate rapid ROI on HVAC upgrades gives the contractor a significant competitive advantage.

Western Allied relied on AirAdvice energy analysts’ SavingsTracker tool to demonstrate the energy savings realized by improvements to their customer’s HVAC systems. The $420,000 project saved the customer over $200,000 in just the first nine months.
Western Allied relied on AirAdvice energy analysts’ SavingsTracker tool to demonstrate the energy savings realized by improvements to their customer’s HVAC systems. The $420,000 project saved the customer over $200,000 in just the first nine months.

Rob Monaghan, executive vice president of Northern California-based Western Allied, is always looking for an edge to gain the trust of his customers and prospects. Western Allied has long used BuildingAdvice™, an energy services delivery platform, to help uncover PM and project opportunities justified through potential energy savings. Monaghan had been working with an Abbott Laboratories hematology facility in Santa Clara, CA. Through ongoing assessment, he determined that substantial savings could be gained by upgrading their controls systems.

Western Allied proposed a number of measures, including the following:

• Taking control of the chiller set points, hot water set points, and the start/stop mechanisms on both

• Putting variable frequency drives (VFDs) on both systems to manage speed and startup control

• Revising sequencing on both systems

• Adding VFDs to the control towers

Monaghan and his team convinced the customer to move forward based on the simple payback of the project, which he projected would pay for itself within three years based on measured energy savings. On completion of the project, AirAdvice’s energy analysts deployed SavingsTracker™, a proprietary measurement and verification tool, to evaluate the results.

Western Allied gains a competitive edge by using AirAdvice technology to demonstrate energy savings and ROI. They will use the 65-percent ROI achieved recently by one customer as a case study to convince other skeptical clients about the benefits of PM and upgrades.
Western Allied gains a competitive edge by using AirAdvice technology to demonstrate energy savings and ROI. They will use the 65-percent ROI achieved recently by one customer as a case study to convince other skeptical clients about the benefits of PM and upgrades.

After building a baseline energy model for the period prior to the retrofit project, the AirAdvice analysts, working with the Western Allied team, assessed the post-implementation impact on energy costs. From February 2013 to October 2013, the study’s window of analysis, the project had already lowered energy utility bills from the predicted cost of $658,900 to $455,420—saving the customer $203,480.

“The combination of our team, the BuildingAdvice suite of tools and services, and these kinds of results positions me well in a very competitive market.”

— Zach Denning, Controls Sales Representative, Western Allied

In only nine months, Western Allied’s measures had recovered almost half the entire project cost of $420,000, well ahead of the projected savings budget. Average monthly savings were over $22,000 per month. While initial savings at project implementation were only 10 percent, by the end of the study period, savings were trending as high as 45 percent.

The average savings over the ninemonth period were used to generate a conservative ROI estimate. Using this method, the estimated year-one savings is $271,300, yielding an ROI of 65 percent and a payback of 1.5 years.

Needless to say, the customer is ecstatic with the results. Having had to convince a skeptical financial team, the facility manager felt that Monaghan and his team had underpromised and overdelivered with these results, building credibility, a compelling case study, and a longterm reference.

Zach Denning, controls sales representative at Western Allied, said, “I feel like we achieved a lot in this project. First, I’m proud of our team. We delivered a quality project that exceeds all expectations. Second, I now have a case study I can use to open doors with a lot of prospects that are just as skeptical about savings claims made by my competitors. The combination of our team, the BuildingAdvice suite of tools and services, and these kinds of results positions me well in a very competitive market.”

For more information, visit www.airadvice.com.

Vanguard HVAC Technologies Lays Foundation for New Tavern on the Green with Easy-to-Install Viega ProRadiant Heating

Installing Viega ProRadiant™ systems as part of the renovation of New York City’s famous Tavern on the Green restaurant was a simple process—so simple, in fact, that Robert Stewart, steamfitter foreman for Vanguard HVAC Technologies, joked, “I was disappointed there wasn’t more to do.” Completing the radiant floor heating installation quickly allowed the rest of the project to move forward.

“This was our first time using Viega,” said Stewart “I have a lot of years of knowledge in the business, and basically the Viega systems were very simple, very easy. They worked great.”

Located in Brooklyn, NY, Vanguard HVAC Technologies was selected to install the air conditioning and heating systems in the new Tavern on the Green, including boilers, chillers, air handler units, heat recovery units, and unit heaters. Vanguard HVAC Technologies installed radiant heating in the terrace, which features a glass-enclosed dining area with views of Central Park.

Viega ProRadiant systems were listed in the building specifications, so Vanguard HVAC Technologies installed 1,500 square feet of ViegaPEX™ Barrier tubing with insulated panels, as well as stainless manifolds and manifold cabinets.

A Restaurant Revived

Few restaurants in American history have had as great an influence on popular culture as the Tavern on the Green on the Upper West Side of New York City’s Central Park. From its original opening in 1934, it has appeared or been mentioned in several movies and television shows and has even played a role in commercial advertising.

During the financial crisis of 2009, the Tavern on the Green closed its doors. Nearly a year later, the city reopened the building as a visitor’s center and gift store. In 2012, a pair of restaurateurs from Philadelphia won the bid to redesign and reintroduce New York City’s famous landmark. The only problem was the condition of the building. It needed to be completely renovated.

Unfamiliar but Easy to Install

Stewart explained that despite his years of experience he still prefers to understand a system completely before installing it, and he appreciated the availability of local Viega sales team members who took the time to help.

“Even though you’re familiar with the product, you still want to have a guideline of that manufacturer’s procedure,” he said. “I did have a couple of questions here and there, which they answered quickly. They were at the ready. If I needed anything, literally within the hour they were back to me with the answer.”

As with any other radiant floor heating installation, ideally, the entire project is on hold until the tubing is laid and the concrete floor is poured.

The faster the radiant heating portion of the job can be completed, the more quickly the rest of the project can get under way.

“Installing the radiant tubing was one of the easiest things I had to do on the job,” Stewart said. “The insulated panels are great because they line everything up. It’s a great product to work with.”

Vanguard HVAC Technologies found that the ease of installation of the Viega radiant floor heating meant that the rest of the project to restore this New York City landmark could move forward more quickly.
Vanguard HVAC Technologies found that the ease of installation of the Viega radiant floor heating meant that the rest of the project to restore this New York City landmark could move forward more quickly.

Cost Savings

Viega offers a variety of panel options—insulated, uninsulated, assembled, and unassembled—along with tracks and plates. Insulated panels, which Vanguard HVAC Technologies installed at the Tavern on the Green, are a versatile radiant option that incorporates insulation, vapor barrier, and a grid system to secure tubing all in one convenient product. Compatible with ViegaPEX Barrier tubing in sizes 3/8”, 1/2” and 5/8”, Viega insulated panels allow you to walk the tubing in easily. The approach also saves on material costs, because you don’t need fasteners.

Viega ProRadiant heating and cooling solutions are designed to integrate with other Viega systems, such as Viega ProPress®, Viega MegaPress®, and Viega PEX solutions. Viega is the only manufacturer to offer press fitting systems in multiple materials, including copper, stainless, carbon steel, and high-performance polymer. The Smart Connect® feature helps installers easily identify unpressed connections, and Viega’s Zero Lead™ alloy is specifically engineered for pressing.

“I definitely recommend it for its ease of installation,” Stewart said. “To anyone thinking about installing radiant, Viega would be a company you should look at.”

For more information, visit www.viega.us.

CNA Offers Strategies for Mitigating Workers’ Compensation Costs

Take a look around your company. Chances are, your workplace has changed in the past 10 years. Your workforce has changed as well. Regardless of industry, the U.S. workforce is aging. The U.S. Bureau of Labor Statistics has estimated that 25 percent of the workforce will be age 55 or older by 2020. This aging workforce brings with it the potential for escalating workers’ compensation costs, particularly since older employees typically experience more severe workplace injuries and illnesses than younger ones.

One of the most effective ways to reduce these costs is through a commitment to workplace safety. A commitment to safety is the key to a successful workers’ compensation process and cost containment. A successful process creates a better work environment and improves productivity. A commitment to workplace safety makes your company an attractive place to work, helping you retain employees and reduce employee turnover.

Below are some workers’ compensation mitigation strategies that you should keep top of mind during the time of hire, during day-to-day operations, and when an injury occurs in the workplace.

Time-of-Hire Considerations

Make every effort to ascertain that new or potential hires are physically capable of handling the requirements of the job. A job interview provides an opportunity to gauge a potential employee’s safety commitment. Including a section on your company’s safety policies and procedures in employee orientation reinforces your safety culture from day one.

A new or potential hire should be mentally capable of understanding and consistently applying safety training, procedures, and protocols. Companies with safety in their DNA want to make sure they hire employees with the same mindset.

Understand that age, obesity, and co-morbidities will generally result in more time and treatment for injured workers to return to full duty after an accident. A more extensive transitional duty program may be necessary to mitigate off-duty status.

Day-to-Day Strategies

Build a safety culture. A safety-focused work culture attracts safety-minded employees. With a strong safety culture, both management and employees are engaged in the process and share responsibility for accident prevention and effective injury management.

Encourage collaboration and communication to promote safety as the priority. When collaboration and communication are encouraged, employees feel comfortable voicing their suggestions and concerns and may be involved in developing and revising safety procedures. If an accident happens, everyone knows what to do and how to report the incident.

Treat “near misses” as accidents. Conduct defect check processes and root cause analyses, and develop the best safety solutions for operational activities. Share knowledge. In states where it is permitted, inform injured workers and managers about which occupational medical providers in the area are available to treat work-related injuries.

When an Injury Occurs

Contact the insurance company as soon as possible after an occurrence. Prompt reporting assures that the necessary medical attention is provided and a return-to-work process is put into place. Claims reported to the carrier within three days of injury cost up to 20 percent less than claims reported outside that time frame.

Conduct a thorough investigation to determine what caused the accident and make workplace adjustments to prevent similar accidents. Carriers may need your support in validating the accident or to pursue subrogation against a third party. Don’t wait to complete this step before reporting to the carrier.

Maintain regular contact with the injured employee throughout the course of recovery. Management should accompany the injured worker for treatment and should make sure that the medical provider is aware of the availability of transitional or modified duty when the injured worker is capable of performing that duty safely.

For more information, please contact your local independent agent or visit www.cna.com.

This information is presented for illustrative purposes only and has been developed from sources believed to be reliable. CNA accepts no responsibility for the accuracy or completeness of this information. CNA is a registered trademark of CNA Financial Corporation. Copyright © 2014 CNA. All rights reserved. Used with permission.

Greenheck Offers Ten Tips to Save Time and Money on Fan Installations

When it comes to installing fans, contractors ask 1) Where can I save money? 2) Where can I save time? and 3) How can I reduce problems after the “equipment has been installed? There is nothing worse than hearing You are short on air because you installed it wrong.”

Saving money is critical for success, but the lowest fan bid does not always equate to the lowest installed cost. Greenheck Fan Corporation products have timesaving features and accessories that result in money savings for contractors. In reality, the contractor provides the equipment, the labor to install the fan, and all required components. If the manufacturer of the equipment can provide an option, accessory, or feature already installed, the contractor’s overall cost will be reduced. The following tips for installing fans properly to ensure effective airflow can save you time and money.

1. Make sure there are no obstructions close to the inlet or outlet of the fan (e.g., a damper, elbow, duct transition, or guard). Typically, allow 2.5 duct diameters (approximately 2.5 wheel diameters) of space away from both ends of the fan.

2. Avoid placing a damper too close to the inlet or outlet, which will cause an uneven flow of air. 3. Adding extra guarding can restrict the airflow through the fan. Avoid expanded metal guards; use thin wire guards if possible.

4. Avoid damper actuators that block 25 percent or more of the free area. They can add up to 1/2” of static pressure. Typically, large damper actuators can be mounted outside the duct.

5. Avoid elbows and transitions directly after inline fans. A good solution for commercial inline fans is to use a side discharge option. The fan acts as the elbow—the air discharges out the side of the fan, preventing poor outlet conditions.

6. Placing a damper too close to the propeller of a sidewall propeller fan will cause vibration. As a general rule of thumb, have at least one half of a propeller diameter between the damper and the propeller.

7. Be certain the wheel is rotating in the correct direction. An exhaust fan with a backward inclined wheel will exhaust air, even if it is rotating backwards. Remember, you have a 50/50 chance of wiring a three-phase motor correctly the first time. To change the rotation, reverse any two of three leads.

8. Utility sets are designed so the fan’s discharge can be rotated, eliminating the need for an elbow at the outlet. Performance will be greatly reduced if you do not use 2.5 duct diameters of straight outlet ductwork.

9. For fans with no inlet duct, the distance between the fan’s inlet and a wall or housing must be at least one inlet diameter to ensure proper performance.

10. When wiring the fan motor and the damper actuator, confirm that the wiring is correctly run so it does not get caught in the damper, preventing proper operation.

From a performance perspective, remember that the fans were originally tested under ideal conditions. If the fan is not installed the way it was tested, it will not perform as specified. If you encounter a jobsite problem, one of these timesaving installation tips may help you quickly resolve the issue.

For more information, visit www.greenheck.com or contact Mike Wolf, product manager, fans and ventilators at mike.wolf@greenheck.com.

Hill York Meets Growing Campus’ Energy Demands with BAC’s Innovative, Efficient Ice Thermal Storage

With 26,000 students and a growing campus, Florida’s Nova Southeastern University (NSU) was challenged with finding a reliable cooling system that kept both expenses and the environment in mind. Baltimore Aircoil Company (BAC) and Hill York mechanical contractors worked together to find a solution for NSU, finally settling on BAC’s innovative ice thermal storage. Now, NSU is reducing their peak electrical demand and saving electricity costs while remaining environmentally sensitive.

Located in steamy Fort Lauderdale, FL, NSU is one of the nation’s largest independent universities. In 2009 NSU began phase 1 of its expansion project and set out to find a cooling solution for their growing campus. Their goal was to provide chilled water to the entire university from one central energy plant. Five years ago, Hill York installed the first BAC ice tank, with a cooling capacity of 2,220 tons and 19,800 ton-hours of ice storage capacity.

Now, half a decade later, Hill York and BAC have come together again to help NSU with phase 2 of the cooling system as the campus further expands, installing two more BAC coils. Chip Lafferty, CEO of Hill York, commended the partnership with BAC, saying it was fostered around trust and teamwork, making the project at NSU not only a successful installation but a successful collaboration as well.

Hill York used BAC’s innovative ice thermal storage to meet NSU’s demands for a reliable cooling system that kept both expenses and the environment in mind. Here, a truck delivers the BAC coils.
Hill York used BAC’s innovative ice thermal storage to meet NSU’s demands for a reliable cooling system that kept both expenses and the environment in mind. Here, a truck delivers the BAC coils.

Ice Thermal Storage Cuts Costs

The ice thermal storage system used at NSU is a sustainable alternative to traditional cooling that stores energy as ice during off-peak hours (usually at night), allowing the system to take advantage of cleaner and more efficient energy sources. Ice thermal storage systems are up to 35 percent more efficient than traditional cooling systems and offer several unique qualities. For example, because ice is formed at night, using ice thermal storage avoids the high cost of the electricity needed to run the chiller during peak hours.

The local power company offers lower rates during off peak hours to help customers save on electric bills. With melting ice providing the cooling needs for the campus, the plant is able to achieve a running cost of less than $8 per hour during peak hours, significantly less than that of a traditional cooling system, according to Kevin Gamble, central plant supervisor for Hill York.

Environmentally Friendly Solutions

Universities, hospitals, sports stadiums, and even office buildings around the world have been using ice thermal storage for years to shift their energy load. By lowering peak demand, ice thermal storage can offset the need to build new power plants, helping to reduce greenhouse gas emissions. According to John Nix, senior engineer at Florida Power and Light, thermal energy storage has helped to avoid building 13 power plants in Florida alone in the past 20 years. Additionally, an ice thermal storage system can help qualify for a number of LEED® credits in the following areas: energy performance, refrigerant management, acoustic performance, and demand response.

Room to Grow

The NSU central energy plant has a total cooling load of approximately 1,800 tons with the 16 buildings it currently serves. The second phase of the NSU project is finally coming to a close, and in two months the fourth and final ice tank will be installed. Each tank has a maximum capacity of 2,220 tons, allowing NSU plenty of room to grow with 8,800 total tons of cooling capacity for their current load and future cooling plans. Lafferty noted, “NSU has plans for a research facility and a university park plaza and are waiting for approval on a hospital. NSU chose to install the cooling system as an aggressive growth campaign and as assurance for room to expand.”

The central energy plant began with less than 20,000 ton-hours of ice capacity. When installation is complete, it will have a total of 79,200 ton-hours, making it one of the largest thermal energy storage systems in the world. This fall, NSU will name the central energy plant the Robert S. Lafferty, Sr., Central Energy Plant after Hill York’s founder, the current CEO’s grandfather.

For more information, visit www.hillyork.com.

Tips from WennSoft for Getting the Most Out of Your Existing Software

When a business has been using the same software system for years, it is easy for employees to get trapped in a cycle of doing things the way they have always done things. It does not occur to them that there are different—and sometimes better—ways to tailor their software to fit their needs.

When a software system is first implemented, it is designed to meet the needs of the business at that time. But soon, two things happen. First, the software changes. Most software companies are continuously improving their software and often provide free upgrades. The improvements typically include a lot of newer functionality. Second, the needs of businesses change. A function that was not needed just a few years ago may now be the company’s key to success.

When it comes to discovering previously unused features of your software, how do you figure out what is available and what could be of the most benefit to your company? First, step back and look at your software as if you were buying it for the first time. Does it fit the needs of your company today? Where are your areas of greatest inefficiencies? Here are a few other ways to educate yourself about all the features of your existing software:

Take advantage of online demonstrations and e-learnings provided by your software vendor. Even executives should periodically reeducate themselves about how their systems can work. If your company had a tool in the field that your technicians were only using half right, you would immediately insist that they learn how to fully utilize that tool. Your software is no different.

Ask for a system review. Many software companies will spend time at your company shadowing your users and reviewing current processes, then provide advice on areas for improvement. These checkups are designed to provide recommendations tailored to your specific business needs.

Network with other companies using the same software. Talking to a similar business about the way you each use your software can be invaluable. In talking through each other’s successes and failures, you will learn what to try and what to avoid. If you do not already know another company that uses the same system in a similar way, ask your software company to connect you with one or more businesses.

Attend a users’ conference. Many software companies host an annual customer conference that brings together a diverse mix of different users of that company’s software. In addition to providing opportunities to meet and network with other users, these events expose users to new software functionality. Breakout sessions showcase new product features, and experience centers offer the opportunity to test drive those new features.

For more information, visit www.wennsoft.com.

Legacy Mechanical Gets New Transit Hub on Track with Efficient Victaulic Grooved Products and Prefabrication Services

Speed and Safety of Installing Grooved Pipes Saves Contractor Time and Money

To meet the complex requirements of a massive public transit expansion, Legacy Mechanical, Inc. called on Victaulic. “We’ve worked with Victaulic grooved mechanical systems for nearly a decade so we know we can trust them to help us maximize productivity and address compressed work schedules, while increasing worker safety,” said Scott Krum, president at Legacy Mechanical. “We also know we can count on them for expert prefabrication and minimizing time in the field.”

Big Project, Big Challenges

The $650-million revitalization of Denver’s historic Union Station is the nation’s largest public transit expansion project. The site was once a key transportation hub for the United States, connecting Denver to the transcontinental railroad line. Serving as a distinctive gateway to downtown Denver, the modernized facility brings together many different transportation modes (including light rail and commuter rail, regional bus lines, taxis, Amtrak trains, and local shuttles), along with private development, to create a new bustling urban center.

Spreading across 20 acres, the Union Station site includes a 1,100’-long underground bus depot with 22 bus bays and also houses aboveground transportation hubs. The site also incorporates two million square feet of mixed-use development, including office, retail, residential, and restaurant space. It goes without saying that a task of this magnitude requires significant planning and strategy, but building the new facility in the center of one of the fastest growing metropolitan areas in the United States presented a unique set of challenges.

“By using grooved mechanical systems and eliminating welding, we were able to speed up productivity, increase cost savings, and minimize field labor by at least 10 percent.”

—Matthew Archuletta, Project Manager, Legacy Mechanical

As a full-service mechanical contracting company, Legacy Mechanical was up for the challenge. In addition to working onsite in a design/assist capacity starting in March 2012, the Legacy Mechanical team was responsible for all mechanical, plumbing, and HVAC work in the underground bus station. The work included 3D coordination services and modeling of the entire project as well as pipefitting, HVAC, plumbing, fuel, and gas pipe work, which required the contractors to work subgrade. The work had to be conducted in phases, and the team was tasked with completing the project in just three years.

To help them meet the compressed schedule and handle intricate structuring and phasing, as well as simplifying their subgrade work, Legacy Mechanical chose Victaulic. Together, the teams needed to install miles of pipe safely, including approximately 6,000’ of hot water piping, 8,000’ for chilled water, 4,000’ for domestic water, and 1,500’ for snow melt.

Alleviating Time and Safety Constraints

Timing was critical with the Union Station project. Thousands of pedestrians, motorists, and businesses were affected by detours and construction zones. The phased approach made for a very fragmented construction process, further compressing the work schedule. To alleviate time constraints and to further streamline the installations, Legacy Mechanical decided to avoid welding whenever possible on the project. This decision helped eliminate the burden of stringent safety regulations as well as the potential for fire hazards and extra man-hours required for fire watches. In addition to increased safety on the jobsite, removing welding from areas such as the two subgrade mechanical rooms also improved overall efficiency on the project.
“By using grooved mechanical systems and eliminating welding, we were able to speed up productivity, increase cost savings, and minimize field labor by at least 10 percent,” said Matthew Archuletta, project manager at Legacy Mechanical.

Legacy Mechanical used Victaulic Style 155 Expansion Joints (shown here) to address space constraints in Union Station’s subgrade bus box and reduce installation time.
Legacy Mechanical used Victaulic Style 155 Expansion Joints (shown here) to address space constraints in Union Station’s subgrade bus box and reduce installation time.

Increasing Productivity

Additionally, Legacy Mechanical used the manufacturer’s installation-ready™ QuickVic Style 107 Rigid Couplings and QuickVic Style 177 Flexible Couplings. The patented technology is twice as fast to install as standard grooved couplings, up to 10 times faster than welding, and six times faster than flanging, while offering the same high-performance capabilities. The couplings expedite the project construction by requiring only standard handheld tools for assembly and by reducing installation steps. With no loose parts and no need to disassemble before installation, the coupling is simply pushed into the grooved end of the pipe, fitting, valves, or accessories as a fully assembled unit and joined by a second grooved end and tightened. In addition, no flame or heat is required for installation, furthering project efficiency and increasing jobsite safety.

Prefabrication also played a critical role in ensuring the project’s installations stayed on course. By roll grooving most of their piping in a prefabrication setting, which largely consisted of 20’ to 40’ lengths of straight runs, Legacy Mechanical significantly increased productivity. Because the bulk of the work was executed in a controlled environment at the Legacy Mechanical prefabrication shop, the team had fewer on-site field hours when assembling the piping. This approach also meant fewer overall man-hours and fewer workers onsite, reducing the risks of accidents on the job, while improving safety and efficiency. Krum said the practice helps Legacy Mechanical remain competitive.

In addition to using grooved mechanical systems, Legacy Mechanical also engaged the Victaulic Engineering Services Department for design recommendations related to expansion joints. With tight spaces in the subgrade bus box, the firm wanted to eliminate large welded expansion loops requiring a perpendicular louver arm. As an alternative, Legacy Mechanical installed Victaulic Style 155 Expansion Joints and Mover Expansion Joint Style 150. The linear grooved mechanical systems not only saved space and reduced installation time over welding but also eliminated the need for field welding.

Partnership Pays Off

Working with Victaulic paid off for Legacy Mechanical. “The success we had on the Union Station project once again confirms why we continue to go to Victaulic for our piping needs,” said Krum. “In addition to increasing our productivity, they also have the ability to help us meet compressed timeframes, increase jobsite safety, reduce man-hours on the job, and provide us with greater design flexibility—all while staying under budget.”

In addition, Legacy Mechanical improved productivity during the commissioning and pressure-testing of the thousands of feet of piping. According to Archuletta, testing for each system of the phased project was initially planned to take two to three weeks, but with Victaulic couplings the firm was able to finalize each phase of testing within a week.

“On the Denver Union Station project, we reduced our testing time in half, if not more,” said Archuletta. “That allowed us to stay ahead of schedule and reduced our man-hours on the job, translating into increased productivity.”

For more information, visit www.victaulic.com.

Murphy Company Slashes Billing Time, Saves Costs with PENTA

Even though Murphy Company has over a century of experience in delivering mechanical solutions and a long record of excellent performance (it is consistently recognized by Engineering News Record as a top-20 contractor), it was saddled with a 25-year-old software system. Since adopting the PENTA construction Enterprise Resource Planning (ERP) platform, Murphy Company took five days off its service billing process and cut more than $100,000 per year in costs related to lost/missing tools, among other benefits.

Under the old software system, access was limited. The system lacked desired functionality in project management, billing, and other areas, and enhancements were not being added. In 2010, a team was assembled to analyze the issues and review software providers. Chief Financial Officer Robert L. Koester said, “We’re a full-service mechanical contractor with multiple business units. Our idea was to have an ERP software platform designed for construction that understands service and has enterprise-level content management functions.”

“We need to use every tool at our disposal to add value for our customers. We couldn’t do everything we do without PENTA.”

—Robert L. Koester, Chief Financial Officer, Murphy Company

Cutting Costs with Inventory Control

“A real success story is how our warehouse uses PENTA,” said Koester. “We wanted to use the system to track our durable tools and rental equipment. At first they were skeptics, but now, they’re believers and advocates. Since implementing PENTA, we have seen our costs related to lost/missing tools decrease in excess of $100,000 per year.”

Better Billing and Payroll Procedures

“We’ve been able to reduce our days to bill by approximately five days in our service department. So many hours used to be put into physically preparing each invoice, taking information from the job reports, and retyping it in Excel,” said Koester. “When I saw what PENTA could do, I said, ‘That’s what we’re going to do.’”

For labor-intensive organizations, particularly those that manage union reporting, payroll can be one of the most difficult administrative challenges. The PENTA eTimesheet and eExpense modules provide self-service time entry and approval capability for those who charge time and expense to projects or overhead expense accounts. “When we implemented PENTA eTimesheet and eExpense, we took a 25-year leap forward, because it had all been done in paper,” Koester observed.

Combining Service and Project Management Systems

With over 100 service technicians who make over 15,000 service calls per year, field service is a crucial aspect of customer satisfaction and revenue for Murphy Company. Managing field service within the same system used for managing projects and financials was a “must-have” for the new system.

“We had previously built our own service application and underestimated the complexity involved with software required to support our service offerings” said Koester. “Over time we began to realize that even though we developed a fully-customized service program, we didn’t always get the reliability we had hoped for. We found ourselves having issues where people didn’t trust the accuracy of the data. Since we’ve been on PENTA, we no longer have those issues.”

For project management, Koester said, “Our goal was to get away from having so many folks doing clerical data entry and more of our project staff and project engineers able to manage projects using information in the system.”

“The old blue-screen systems were efficient for data entry, but with PENTA we get much better management capabilities. The data goes into the system once, the right people see the data and review it, and, based on the trends that surface, they can implement change, which helps to improve our opportunities to enhance profit margin on projects.”

“Now when someone needs project data, they get the information themselves. They get exactly what they want, when they want it, right from PENTA.”

—Robert L. Koester, Chief Financial Officer, Murphy Company

Simplifying Reporting and Financial Statements

“In the past, we had enough reports to fill a huge, thick binder. If someone wanted data, the culture was to ask a person to generate a report—that’s just how it was done. If the person who pulled the report was out or on vacation, the report would have to wait,” said Koester. “Now when someone needs project data, they get the information themselves. They get exactly what they want, when they want it, right from PENTA.”

Koester added, “We got tremendous benefit from PENTA’s organizational unit structure. We set up new financial statements very, very easily. It would have been extremely difficult in our previous system to create new legal entities or operating groups. Now it’s no problem: It’s done in half an hour.”

While functionality is important, the ongoing relationship between the two companies was also considered critical. “From the start, we knew we wanted to work with a provider with industry experience who views us as a long-term partner,” said Koester. “The system has been really well received and our experiences with the implementation and support teams have been very positive.”

Koester recognizes the competitive advantage that PENTA provides Murphy Company. “We need to use every tool at our disposal to add value for our customers,” he said. “We couldn’t do everything we do without PENTA.”

For more information, call 262-782-7700 or visit www.penta.com.

C.J. Erickson Anticipates Needs of Future Scientists with Jay R. Smith Specialty Products

C.J. Erickson Plumbing Co. took on the complex task of installing plumbing systems not only to meet the individual needs of an exacting group of tenants already scheduled to move in, but also to anticipate the needs of unknown future tenants. The new William Eckhardt Research Center at the University of Chicago will offer world-class scientific research facilities, and thanks to C.J. Erickson and Jay R. Smith Mfg. Co., those facilities are prepared for just about anything.

The William Eckhardt Research Center is a 277,000-gross-square-foot facility with five above-grade floors, basement, and subbasement. The building will house offices, conference rooms, and laboratories for the university’s Division of Physical Sciences units, including the Astronomy and Astrophysics Department, the Kavli Institute for Cosmological Studies, and the Enrico Fermi Institute. It will also house the university’s new program in molecular engineering, providing offices, conference rooms, an 11,000-square-foot clean room, and specialized laboratory and imaging facilities.

C.J. Erickson used acid-resistant pipes from Jay R. Smith Mfg. Co. throughout a new scientific research center to ensure that all researchers, regardless of the work they were doing, would have the appropriate plumbing in their lab space.
C.J. Erickson used acid-resistant pipes from Jay R. Smith Mfg. Co. throughout a new scientific research center to ensure that all researchers, regardless of the work they were doing, would have the appropriate plumbing in their lab space.

Making Adjustments

Because of the complexity of the project and all the entities involved, the design phase alone was a five-year project. C.J. Erickson got involved in 2012. Among the many challenges with this project was the base of the structure. The five above-grade floors and the two subfloors sit on a 3’ slab of concrete. C.J. Erickson had to encase all the piping within that slab so that if the building settled, the plumbing would settle along with it.

C.J. Erickson digitally mapped out the area. Using 3D modeling, they set up a grid that included all the field layout points. When construction began, they laid and suspended all the piping, and the concrete slab was poured over the piping.

Another challenge was in the design of the plumbing for the two floors of laboratory space. Dan Whitehead, project manager for C. J. Erickson, said the designs for individual laboratories were shown to the researchers who would use them.

“Each researcher came in with very specific and special needs, so we had to go back and design the space for each of those researchers. We constantly had to pause and make adjustments,” said Whitehead.

All parties involved decided that even though the process may have been slower up front, having the researchers who would be using the space involved at the start of construction was the better process. It was easier to redesign each space than to shell it out and make the adjustments after construction.

Products for the Future

Another challenge, but perhaps the easiest to overcome, was the specification of products. With all the individual laboratories in the building, most drains and piping had to be acid-resistant.

Whitehead said that you could not just do your specification based on the needs of particular researchers lined up to come to the facility and the type of research they were planning to do. You had to plan for potential future research and design to accommodate the “worst-case scenario” to ensure that anyone coming into the lab, regardless of the work they were doing, would have the appropriate plumbing in their lab space.

C.J. Erickson worked closely with Jay R. Smith Mfg. Co. through the constant changes to spec out the appropriate drains, piping, and eye wash stations. In addition to specialty products, Jay R. Smith Mfg. Co. also supplied water closet carriers, urinal supports, roof drains, and wall hydrants for this project.

The job is now sixty-percent complete, and Whitehead said they are on track to finish up by June 2015.

Whitehead offered his take on the challenges faced while building the research center: “There’s a saying: ‘There is no hill for a climber.’ These are all just challenges you need to manage to complete the job.”

For more information, visit www. jrsmith.com.

Message from Jim Allen, M/SC Chairman: Partnership, Performance, and Productivity

jim-allen

At Sloan, I’ve seen firsthand how Smart Solutions can make a difference. A previous issue featured Sloan fixtures used in the renovation of New Orleans’ Superdome. More than a year later— thanks to social media—that news was still making the rouds among potential clients. That story, like so many in Smart Solutions, demonstrated how manufacturers work closely with contractors to meet their unique needs and challenges.

Join me in welcoming our
newest supplier partners:

  • BELIMO Americas
  • Chase Brass and Copper Company, LLC
  • Mathey Dearman, Inc.
  • Leica Geosystems
  • Wayne Water Systems

For example, in this issue, learn how Hill York is satisfying the increasing demands of a Florida campus for cost- and energy-efficient power by using Baltimore Aircoil Company’s innovative ice thermal storage product. A host of Jay R. Smith Mfg. Co. products fit the bill when C.J. Erickson Plumbing Co. took on a research facility with complex requirements. Legacy Mechanical relied on Victaulic grooved systems to meet the compressed schedule for a sprawling project.

W.J. Maloney Plumbing, Heating & Cooling appreciated the durability of Sloan products, which they used for the Chicago Cubs’ new spring training facility in Arizona. Woodford’s reputation for reliability and ease of installation made its roof water hydrant the ideal choice for a school in Colorado.

Work Smarter, Not Harder

This issue includes lots of examples of contractors using products and services to improve efficiency. Vanguard HVAC Technologies, for example, was surprised how quickly they could install Viega ProRadiant™ floor systems and move on to other tasks. J.C. Cannistraro put its Autodesk® Fabrication CADmep™ system to work along with prefabrication to meet a tight schedule with time to spare.

Western Allied Mechanical is using AirAdvice technology to show customers how quickly they can recoup their investments in HVAC upgrades. Graco Mechanical, Inc. has relied on Davisware software to cut billing turnaround times and improve office processes. Murphy Company took five days off its service billing process and cut costs by adopting PENTA software. To put your IT system to work for you, see WennSoft’s tips on how to get more out of your existing software.

Our supplier partners can help you find other ways to save as well. CNA describes steps you can take to mitigate workers’ compensation costs. AlliantGroup explains how to take advantage of tax credits for the kinds of clever solutions you create to handle challenging jobs. Greenheck provides advice on fan installation to avoid costly problems later on. Read on to learn more about how you can partner with manufacturers for better performance and productivity.

Jim Allen, Chairman

J.C. Cannistraro Meets Tight Installation Deadline—With Time to Spare—Thanks to Autodesk BIM and Prefabrication

To upgrade the water systems at the University of Massachusetts Boston’s central utility plant—in a single weekend and without disrupting any other system functions—J.C. Cannistraro put to work the Autodesk® Fabrication CADmep™ system it has used since 2003.

Thanks to building information modeling (BIM) and prefabrication technologies, Cannistraro installed in one day the temporary systems it needed to ensure a smooth transition for the rest of the project.

“Given our limited time to install the temporary systems and the large number of systems we had to connect, BIM-enabled prefabrication was a perfect fit on this job,” said Cannistraro’s project manager Eric Beck. “We used Fabrication CADmep software to create 3D models of the existing plant, the temporary systems, and the new systems. This helped us coordinate the new HVAC systems and hangers with the existing connections and services and prefabricate a tremendous amount of work.”

The project was part of a major infrastructure overhaul involving the development of a new utility corridor and roadway network for the 175-acre campus overlooking Boston Harbor. As part of the project, the school’s existing 40-year old central utility plant will be upgraded to a more energy-efficient primary and secondary pumping arrangement to serve the campus’ hot and chilled water utility loop. The upgrade includes four 2,000-ton centrifugal chillers, three 800-horsepower hot water boilers, and one 400-horsepower hot water boiler. The new hot water system has piping sizes up to 16” in diameter and the chilled water system has piping up to 30”.

Keeping Campus Up and Running

“The campus operates 24 hours a day, all year long, which complicated the logistics of the project and installations,” explained Beck. “To keep the campus running, we had to install temporary chillers and repipe the 400-horsepower boiler to serve the campus while the balance of the heating plant was upgraded.” The installations had to be done within a very small window: a weekend in the spring to install system isolation valves for both the 400-horsepower boiler and 30” chilled water valves to isolate the campus/temporary chillers from the central utility plant’s chiller piping upgrades.

Furthermore, many services running through the plant were not affected by the HVAC update. These systems—including electrical, domestic water, and fire protection—had to remain undisturbed while the HVAC systems were upgraded. “We had to fit a large amount of substantially-sized piping through this maze of existing services, without reliable as-built documentation for the plant,” said Beck.

Tight Quarters

In addition, the existing plant is below ground and features concrete construction, including the roof. “We were not permitted to attach hanger rods to the underside of the deck, only to the sides of the concrete beams that were supporting the deck,” said Colin Detra, Cannistraro’s HVAC coordinator on this project. “This limited our pipe hanger locations, requiring careful layout of the new piping systems.”

“With support from [Autodesk] Fabrication CADmep software, it took half the time to create [several hundred spool] sheets than it would using 2D drafting software, and the quality is better.”

— Colin Detra, HVAC Coordinator, J.C. Cannistraro

Virtual Layout and Coordination

Instead of traditional tape measures and plumb bobs, Cannistraro captured the existing conditions of the plant with laser scanning technology. “I used the resulting point cloud as a reference to build a model of the existing plant, turning everything (from 3/4” conduits to 30” chilled water piping) into 3D objects,” said Detra. “Then I used this model and the software’s 3D modeling environment to precisely layout all the new systems—more effectively coordinating the 50-plus connections and finding suitable locations for the hanger rods, while helping avoid interferences with existing services.”

Cannistraro also used the Fabrication CADmep software model to help virtually plan and coordinate demolition and installation, phase by phase. “For example, while we installed the hot water systems, we knew the chilled water piping would still be there,” said Detra. “So in our planning model, I displayed the new hot water and existing chilled water systems, as well as all unaffected services, to verify the layout and minimize clashes during installation. Later on, I did the same thing to route the new chilled water system—toggling off the old chilled water system and toggling on the new hot water piping and unaffected services.”

Beck noted, “We use prefabrication whenever possible. It gives us a controlled environment and lets us perform months of work beforehand—helping to increase project quality and safety while minimizing project cost and schedule.” Fabrication CADmep software plays a critical role, helping Cannistraro automatically produce intelligent shop drawings from the project model with the necessary detail for fabrication, including manufacturer-specific content and components.

“We generated several hundred spool sheets for this project,” said Detra. “With support from Fabrication CADmep software, it took half the time to create these sheets than it would using 2D drafting software, and the quality is better.” In addition, the Fabrication CADmep software model has the intelligent data to drive automated welding machines, translating to almost 9,500” of X-ray-quality welding on this job.

Beating the Clock

The project is currently in the late stages of completion. “For the temporary installations, we didn’t even need the whole weekend,” said Detra. “We had the systems installed and running within a day.”

“We pay attention to details and strive to be the professional standard for quality and reliability in mechanical construction,” said Beck. “Autodesk Fabrication CADmep software helps us achieve that goal. We are more accurate, efficient, and deliver more innovative building strategies.”

For more information about Autodesk Fabrication software, visit www. autodesk.com/fabrication.

W.J. Maloney Relies on Durable Sloan Systems at Chicago Cubs’ New Spring Training Facility

Cubs Honor Hometown Roots by Specifying the Illinois-Based Manufacturer

Dedicated Chicago Cubs fans who attended the Major League Baseball team’s spring training in Arizona this year were rewarded with modern restrooms (among other amenities), thanks to W.J. Maloney Plumbing, Heating & Cooling and Sloan Valve Company. W.J. Maloney chose Sloan plumbing because its products have such a good batting record at the Cubs’ main stadium and on other W.J. Maloney projects.

While Cubs fans defend their beloved, yet rapidly aging, Wrigley Field in Chicago during the official baseball season, their surroundings for preseason have improved substantially, and no one is complaining. In March, the team debuted Cubs Park, its preseason stadium near Phoenix.

W.J. Maloney of Phoenix was tapped for the 14-month design/assist project, which had to be finished in time for the 2014 preseason. Before the Cubs Park project, W.J. Maloney had installed Sloan plumbing in the Los Angeles Dodgers’ portion of the Camelback Ranch Spring Training Complex in Glendale, AZ, as well as in other local commercial facilities.

The firm’s good experience with Sloan over the years made the plumbing choice for Cubs Park a logical one. “We’ve used Sloan on other projects and never have had any problems,” said Alan Boughton, vice president of construction for W.J. Maloney.

It was the Cubs organization, however, that really went to bat for Sloan, so to speak. The Cubs specifically requested that the Illinois-based Sloan, which has manufactured its flushometers in the Chicago area for more than 100 years, supply plumbing for its new park.

Although saving water is a major issue for plumbing projects in Arizona—and Sloan’s water-efficient products help reduce water consumption—that was not a top consideration for Cubs Park. “Because the restrooms get used heavily for one month out of the year, we were looking more for durability,” said Boughton. Arizona’s poor water quality can also take its toll on plumbing, and Boughton knew that Sloan systems could stand up to the challenge.

The fact that the Sloan systems could save the park water was a bonus, as well as save money and improve aesthetics.

Cubs Park has installed 188 wall-mount water closets, plus 82 ADA-compliant water closets with Royal® flushometers and 124 complete Sloan urinal systems. The public restrooms have Sloan wall-hung vitreous china lavatories; the more upscale clubhouse and private restrooms have countertop lavatories.

The Cubs Park’s public restrooms far surpass those at Wrigley—especially the notorious trough urinals in the men’s restrooms. Cubs fans treated to the modern restrooms in Cubs Park may find it easy to forgo that Wrigley tradition.

For more information, visit www. sloanvalve.com