Maryland
Government Building
Penn State AE Senior Capstone Project
Andrew R. Pino | Construction Management Option
Advisor | Dr. John Messner
Maryland
Government Building
I. Introduction
II. Project Background
I. Site Overview
II. Project Features
III. Analysis 1 | Integrated Delivery Methods
I. Overview & Case Studies
II. Application to Project
III. Conclusion
IV. Analysis 2 | Modular Concrete Formwork
I. Potential Replacements & Chosen Formwork System
II. Structural Breadth
III. Cost and Schedule Impact Analysis
V. Analysis 3 | Terra Cotta Rain Screen Pre-fabrication
I. Research and Feasibility
II. Cost and Schedule Comparisons
III. Mechanical Breadth and Conclusion
VI. Conclusions and Recommendations
VII. Acknowledgements
Number of Stories | 10
Contract Value | $75 million
Estimated Cost-to-Date | $100 million
Dates of Construction | Jan 16, 2012 – Dec 2, 2013
Occupancy Type | Office (Type B)
CM at Risk | The James G. Davis Construction Corp.
Maryland
Government Building
Andrew Pino | AE Senior Thesis | Construction Management Option
Project Size | 520,000 SF (200,000 SF Parking Garage)
Owner/Developer | The JBG Companies
Architect | HOK
Government Building
Presentation Outline
I. Introduction
II. Project Background
I. Site Overview
II. Project Features
III. Analysis 1 | Integrated Delivery
I. Overview & Case Studies
II. Application to Project
III. Conclusion
IV. Analysis 2 | Modular Formwork
I. Formwork Systems
II. Structural Breadth
III. Cost and Schedule
V. Analysis 3 | Terra Cotta
I. Overview of Systems
II. Cost and Schedule
III. Mechanical Breadth
VI. Conclusions and
Recommendations
VII. Acknowledgements
Maryland
Existing Site Plan
Andrew Pino | AE Senior Thesis | Construction Management Option
Construction Site Plan
Site Logistics Plan - Structure
Government Building
Presentation Outline
I. Introduction
II. Project Background
I. Site Overview
II. Project Features
III. Analysis 1 | Integrated Delivery
I. Overview & Case Studies
II. Application to Project
III. Conclusion
IV. Analysis 2 | Modular Formwork
I. Formwork Systems
II. Structural Breadth
III. Cost and Schedule
V. Analysis 3 | Terra Cotta
I. Overview of Systems
II. Cost and Schedule
III. Mechanical Breadth
VI. Conclusions and
Recommendations
VII. Acknowledgements
Maryland
Project Features
Concrete batch plant
Post-tensioned concrete
Terra cotta rain screen
Pursuing LEED Silver
Andrew Pino | AE Senior Thesis | Construction Management Option
Concrete Batch Plant
Post-Tension Cables
Government Building
Presentation Outline
I. Introduction
II. Project Background
I. Site Overview
II. Project Features
III. Analysis 1 | Integrated Delivery
I. Overview & Case Studies
II. Application to Project
III. Conclusion
IV. Analysis 2 | Modular Formwork
I. Formwork Systems
II. Structural Breadth
III. Cost and Schedule
V. Analysis 3 | Terra Cotta
I. Overview of Systems
II. Cost and Schedule
III. Mechanical Breadth
VI. Conclusions and
Recommendations
VII. Acknowledgements
Andrew Pino | AE Senior Thesis | Construction Management Option
Maryland
Analysis #1 | Integrated Delivery Methods
Problem Statement:
Traditional design-bid-build delivery methods have
the potential to hinder the design change approval
process.
Presentation Outline
I. Introduction
II. Project Background
I. Site Overview
II. Project Features
III. Analysis 1 | Integrated Delivery
I. Overview & Case Studies
II. Application to Project
III. Conclusion
IV. Analysis 2 | Modular Formwork
I. Formwork Systems
II. Structural Breadth
III. Cost and Schedule
V. Analysis 3 | Terra Cotta
I. Overview of Systems
II. Cost and Schedule
III. Mechanical Breadth
VI. Conclusions and
Recommendations
VII. Acknowledgements
Andrew Pino | AE Senior Thesis | Construction Management Option
Government Building
Overview
Maryland
The JBG Companies
Owner/Developer
GSA
VIKA
Civil Engineer
HOK
Architect
DAVIS Construction
CM at Risk
Tadjer-Cohen-Edelson
Structural Engineer
Miller & Long
Concrete
W.E. Bowers
Mechanical
GHT Limited
MEP Engineer
FB Harding
Electrical
American Automatic
Fire Protection/Sprinkler
ARUP
Fire Protection Consultant
Miscellaneous Metals
Metal Fabrication
C.J. Coakley
Terra Cotta
MCLA
Lighting Designer
Deneau
Utilities
Tidewater
Glass and Glazing
Polysonics Corp.
Acoustics Consultant
GMP Contract
Prime Contract
Lump Sum Contract
Communication
Owner
A/E
CM
Subs
Presentation Outline
I. Introduction
II. Project Background
I. Site Overview
II. Project Features
III. Analysis 1 | Integrated Delivery
I. Overview & Case Studies
II. Application to Project
III. Conclusion
IV. Analysis 2 | Modular Formwork
I. Formwork Systems
II. Structural Breadth
III. Cost and Schedule
V. Analysis 3 | Terra Cotta
I. Overview of Systems
II. Cost and Schedule
III. Mechanical Breadth
VI. Conclusions and
Recommendations
VII. Acknowledgements
Government Building
Case Studies
Maryland
Case Study #1
Case Study #2
Project comparison
Survey of 200+ industry professionals
Success Criteria
Common Themes
Teams
Processes
Risk
Reward
Communication
Documentation
Agreements
Andrew Pino | AE Senior Thesis | Construction Management Option
Meeting client’s criteria
Budget and schedule met
Reduction in disputes
Overall quality
Success Factors
Unit cost fluctuations greater with D/B
D/B - 185 percentage points
D/B/B – 102 percentage points
Lower D/B labor cost percentage
Early contractor involvement is critical
Clearly defined scope
Good relationships
Contractor experience
End user’s early input
Client participation
Survey Results
Time/schedule
Cost
Quality
Functionality
Presentation Outline
I. Introduction
II. Project Background
I. Site Overview
II. Project Features
III. Analysis 1 | Integrated Delivery
I. Overview & Case Studies
II. Application to Project
III. Conclusion
IV. Analysis 2 | Modular Formwork
I. Formwork Systems
II. Structural Breadth
III. Cost and Schedule
V. Analysis 3 | Terra Cotta
I. Overview of Systems
II. Cost and Schedule
III. Mechanical Breadth
VI. Conclusions and
Recommendations
VII. Acknowledgements
Application to Project
Targeted Benefits
Early contributions to design
Reduced design conflicts and RFI’s
Improved schedule management
Reduced design documentation time
Andrew Pino | AE Senior Thesis | Construction Management Option
Government Building
Maryland
Presentation Outline
I. Introduction
II. Project Background
I. Site Overview
II. Project Features
III. Analysis 1 | Integrated Delivery
I. Overview & Case Studies
II. Application to Project
III. Conclusion
IV. Analysis 2 | Modular Formwork
I. Formwork Systems
II. Structural Breadth
III. Cost and Schedule
V. Analysis 3 | Terra Cotta
I. Overview of Systems
II. Cost and Schedule
III. Mechanical Breadth
VI. Conclusions and
Recommendations
VII. Acknowledgements
Andrew Pino | AE Senior Thesis | Construction Management Option
Government Building
Conclusion
Maryland
Recommended Structure
Integrated Project Delivery Method
True IPD offers highest level of integration
Individual success tied directly to project success
Single multi-party contract not appropriate
Design/Build Delivery Method
Benefits of integration without single contract
Co-location of major entities
Reduces layers of design change approval
Early contractor involvement
Full integration not present
Design/build
GSA
Client
The JBG Companies
Owner/Developer
Design/Build Team
Architect, engineers, consultants and CM
Subcontractors and
Suppliers
Government Building
Presentation Outline
I. Introduction
II. Project Background
I. Site Overview
II. Project Features
III. Analysis 1 | Integrated Delivery
I. Overview & Case Studies
II. Application to Project
III. Conclusion
IV. Analysis 2 | Modular Formwork
I. Formwork Systems
II. Structural Breadth
III. Cost and Schedule
V. Analysis 3 | Terra Cotta
I. Overview of Systems
II. Cost and Schedule
III. Mechanical Breadth
VI. Conclusions and
Recommendations
VII. Acknowledgements
Andrew Pino | AE Senior Thesis | Construction Management Option
Maryland
Analysis #2 | Modular Concrete Formwork
Problem Statement:
Wood panel post-and-beam formwork is labor
intensive and time consuming.
Presentation Outline
Formwork Systems
Maryland
Lightweight
Adaptable
Complex components
Desired Benefits
Rapid reuse cycle
Mobility
Andrew Pino | AE Senior Thesis | Construction Management Option
Lightweight
Drop heads
Fewer props
Simple components
Plywood table panels
DoKart required
Dokamatic Table
Lightweight materials
Aluma Dek
Simple components
Peri Sky Deck
I. Introduction
II. Project Background
I. Site Overview
II. Project Features
III. Analysis 1 | Integrated Delivery
I. Overview & Case Studies
II. Application to Project
III. Conclusion
IV. Analysis 2 | Modular Formwork
I. Formwork Systems
II. Structural Breadth
III. Cost and Schedule
V. Analysis 3 | Terra Cotta
I. Overview of Systems
II. Cost and Schedule
III. Mechanical Breadth
VI. Conclusions and
Recommendations
VII. Acknowledgements
Government Building
Presentation Outline
I. Introduction
II. Project Background
I. Site Overview
II. Project Features
III. Analysis 1 | Integrated Delivery
I. Overview & Case Studies
II. Application to Project
III. Conclusion
IV. Analysis 2 | Modular Formwork
I. Formwork Systems
II. Structural Breadth
III. Cost and Schedule
V. Analysis 3 | Terra Cotta
I. Overview of Systems
II. Cost and Schedule
III. Mechanical Breadth
VI. Conclusions and
Recommendations
VII. Acknowledgements
Government Building
Structural Breadth
Maryland
Purpose | Redesign to a Flat Slab System
Largest Column Span
Andrew Pino | AE Senior Thesis | Construction Management Option
Relocated and Added Columns
Presentation Outline
I. Introduction
II. Project Background
I. Site Overview
II. Project Features
III. Analysis 1 | Integrated Delivery
I. Overview & Case Studies
II. Application to Project
III. Conclusion
IV. Analysis 2 | Modular Formwork
I. Formwork Systems
II. Structural Breadth
III. Cost and Schedule
V. Analysis 3 | Terra Cotta
I. Overview of Systems
II. Cost and Schedule
III. Mechanical Breadth
VI. Conclusions and
Recommendations
VII. Acknowledgements
Government Building
Structural Breadth
Maryland
ACI Deflection Check
h > ln / 33 = (30 ft * 12) / 33 = 10.9 in
Minimum slab thickness of 11 in
12 in slab thickness chosen
Parameters
Deflection & Punching Shear
ACI Punching Shear Check
ACI 318-11 for calculations
Two-way slab w/o drop panels
Max span of 30 ft
Andrew Pino | AE Senior Thesis | Construction Management Option
Column of Highest Concern
Actual shear = Vu = qu*AT = (640 SF) * (352 psf)
= 225,280 lb
Allowable shear = 4*1*√(f’c)*bo1*d1
= 4*1*√(5000)*144in*(12in-0.75in)
= 458,205 lb
Vu < 0.75*Vc1
225,280 < 0.75 * 458,205
225,280 lb < 343,654 lb, punching shear is acceptable
Presentation Outline
I. Introduction
II. Project Background
I. Site Overview
II. Project Features
III. Analysis 1 | Integrated Delivery
I. Overview & Case Studies
II. Application to Project
III. Conclusion
IV. Analysis 2 | Modular Formwork
I. Formwork Systems
II. Structural Breadth
III. Cost and Schedule
V. Analysis 3 | Terra Cotta
I. Overview of Systems
II. Cost and Schedule
III. Mechanical Breadth
VI. Conclusions and
Recommendations
VII. Acknowledgements
Government Building
Cost Analysis
Maryland
Existing System Costs
Redesigned System Costs
Assumptions
RSMeans labor costs
65% labor reduction
Equipment cost +20%
Cost savings calculated for
single floor
Andrew Pino | AE Senior Thesis | Construction Management Option
Material (62%)
Material (80%)
Labor (35%)
Equipment (3%)
Labor (15%)
Equipment (5%)
Presentation Outline
I. Introduction
II. Project Background
I. Site Overview
II. Project Features
III. Analysis 1 | Integrated Delivery
I. Overview & Case Studies
II. Application to Project
III. Conclusion
IV. Analysis 2 | Modular Formwork
I. Formwork Systems
II. Structural Breadth
III. Cost and Schedule
V. Analysis 3 | Terra Cotta
I. Overview of Systems
II. Cost and Schedule
III. Mechanical Breadth
VI. Conclusions and
Recommendations
VII. Acknowledgements
Government Building
Schedule Analysis and Conclusion
Subsequent Cost Savings
Schedule Savings
25% increase in productivity
2-3 day reduction per floor
20-30 day total reduction
Critical path time savings
Andrew Pino | AE Senior Thesis | Construction Management Option
Roughly four week schedule reduction
$48,058 per-week general conditions costs
Significant cost savings
Maryland
Conclusion
Concrete redesign enables ideal use of modular formwork
Peri Sky Deck offers significant cost and time savings
Labor savings outweigh added material costs
Schedule reduction applies to the critical path
Government Building
Presentation Outline
I. Introduction
II. Project Background
I. Site Overview
II. Project Features
III. Analysis 1 | Integrated Delivery
I. Overview & Case Studies
II. Application to Project
III. Conclusion
IV. Analysis 2 | Modular Formwork
I. Formwork Systems
II. Structural Breadth
III. Cost and Schedule
V. Analysis 3 | Terra Cotta
I. Overview of Systems
II. Cost and Schedule
III. Mechanical Breadth
VI. Conclusions and
Recommendations
VII. Acknowledgements
Andrew Pino | AE Senior Thesis | Construction Management Option
Maryland
Analysis #3 | Terra Cotta Rain Screen Pre-Fabrication
Problem Statement:
The construction of the terra cotta rain screen is
complex, involving four layers to be installed
consecutively.
Presentation Outline
I. Introduction
II. Project Background
I. Site Overview
II. Project Features
III. Analysis 1 | Integrated Delivery
I. Overview & Case Studies
II. Application to Project
III. Conclusion
IV. Analysis 2 | Modular Formwork
I. Formwork Systems
II. Structural Breadth
III. Cost and Schedule
V. Analysis 3 | Terra Cotta
I. Overview of Systems
II. Cost and Schedule
III. Mechanical Breadth
VI. Conclusions and
Recommendations
VII. Acknowledgements
Government Building
Overview of Systems
Maryland
Current Rain Screen Design
Components
Risk Factors
Metal
CM
Sheathing with z-girts
Complex process
Insulation
Rain Screen
Trades
Architect
Labor intensive
Glazing
Support profile
Time consuming
Andrew Pino | AE Senior Thesis | Construction Management Option
Terra cotta panels
Terra
Cotta
Air /
Vapor
Presentation Outline
I. Introduction
II. Project Background
I. Site Overview
II. Project Features
III. Analysis 1 | Integrated Delivery
I. Overview & Case Studies
II. Application to Project
III. Conclusion
IV. Analysis 2 | Modular Formwork
I. Formwork Systems
II. Structural Breadth
III. Cost and Schedule
V. Analysis 3 | Terra Cotta
I. Overview of Systems
II. Cost and Schedule
III. Mechanical Breadth
VI. Conclusions and
Recommendations
VII. Acknowledgements
Overview of Systems
Current Installation
Process
Andrew Pino | AE Senior Thesis | Construction Management Option
Government Building
Maryland
Presentation Outline
I. Introduction
II. Project Background
I. Site Overview
II. Project Features
III. Analysis 1 | Integrated Delivery
I. Overview & Case Studies
II. Application to Project
III. Conclusion
IV. Analysis 2 | Modular Formwork
I. Formwork Systems
II. Structural Breadth
III. Cost and Schedule
V. Analysis 3 | Terra Cotta
I. Overview of Systems
II. Cost and Schedule
III. Mechanical Breadth
VI. Conclusions and
Recommendations
VII. Acknowledgements
Overview of Systems
Proposed Panel Layout
Panel Sizing
Width: 10’-0”– 17’-6”
Height: 10’-0”– 26’-9”
Total number of panels: 208
Andrew Pino | AE Senior Thesis | Construction Management Option
Government Building
Maryland
Presentation Outline
I. Introduction
II. Project Background
I. Site Overview
II. Project Features
III. Analysis 1 | Integrated Delivery
I. Overview & Case Studies
II. Application to Project
III. Conclusion
IV. Analysis 2 | Modular Formwork
I. Formwork Systems
II. Structural Breadth
III. Cost and Schedule
V. Analysis 3 | Terra Cotta
I. Overview of Systems
II. Cost and Schedule
III. Mechanical Breadth
VI. Conclusions and
Recommendations
VII. Acknowledgements
Cost Analysis
Government Building
Schedule Analysis
Maryland
Façade Breakdown
Precast Concrete: 49,000 SF
Unitized Terra Cotta Panel Installation Schedule
Terra Cotta: 22,000 SF
Glazing: 73,500 SF
Cost Estimate Data
Total Building: 144,500 SF
Andrew Pino | AE Senior Thesis | Construction Management Option
Glazing and terra cotta scopes combined under unitized system
Precast concrete excluded as it does not change
Square-foot cost data provided by DAVIS and others
Original
Sept
Unitized
Oct
Nov
Dec
Jan
Feb
Mar
Apr
Presentation Outline
I. Introduction
II. Project Background
I. Site Overview
II. Project Features
III. Analysis 1 | Integrated Delivery
I. Overview & Case Studies
II. Application to Project
III. Conclusion
IV. Analysis 2 | Modular Formwork
I. Formwork Systems
II. Structural Breadth
III. Cost and Schedule
V. Analysis 3 | Terra Cotta
I. Overview of Systems
II. Cost and Schedule
III. Mechanical Breadth
VI. Conclusions and
Recommendations
VII. Acknowledgements
Mechanical Breadth
Conclusion
Breadth Results
Relative humidity between layers never exceeds 100%
Condensation will not occur in this assembly
A unitized panel system would:
Breadth Assumptions
Interior:
RH = 40%
T = 28 C (82
K
Exterior:
RH = 80%
T = -15 C (5
K
Andrew Pino | AE Senior Thesis | Construction Management Option
F) = 297
F) = 258
Create a streamlined process
Reduce terra cotta installation duration
by roughly three weeks
Mitigate risk of labor and weather variables
Produce a higher quality end product
Cost an additional $1,458,996
Government Building
Maryland
Presentation Outline
I. Introduction
II. Project Background
I. Site Overview
II. Project Features
III. Analysis 1 | Integrated Delivery
I. Overview & Case Studies
II. Application to Project
III. Conclusion
IV. Analysis 2 | Modular Formwork
I. Formwork Systems
II. Structural Breadth
III. Cost and Schedule
V. Analysis 3 | Terra Cotta
I. Overview of Systems
II. Cost and Schedule
III. Mechanical Breadth
VI. Conclusions and
Recommendations
VII. Acknowledgements
Andrew Pino | AE Senior Thesis | Construction Management Option
Government Building
Final Recommendations
Maryland
Analysis #1 | Integrated Delivery Methods
Design/build better facilitates the design change approval process
Co-location of major entities offers ease of communication
Early contractor involvement is critical
Analysis #2 | Modular Concrete Formwork
Concrete redesign enables ideal use of the Peri Sky Deck
Schedule reduction of one month
Applies to the critical path
Total cost savings of $437,974
Analysis #3 | Terra Cotta Rain Screen Pre-Fabrication
Three week schedule reduction
Additional cost of $1,458,996
More streamlined installation process
Factory assembly means improved quality control
Original
Sept
Unitized
Oct
Nov
Dec
Jan
Feb
Mar
Apr
Presentation Outline
I. Introduction
II. Project Background
I. Site Overview
II. Project Features
III. Analysis 1 | Integrated Delivery
I. Overview & Case Studies
II. Application to Project
III. Conclusion
IV. Analysis 2 | Modular Formwork
I. Formwork Systems
II. Structural Breadth
III. Cost and Schedule
V. Analysis 3 | Terra Cotta
I. Overview of Systems
II. Cost and Schedule
III. Mechanical Breadth
VI. Conclusions and
Recommendations
VII. Acknowledgements
Andrew Pino | AE Senior Thesis | Construction Management Option
Government Building
Acknowledgements
Maryland
Academic Acknowledgements
Penn State Architectural Engineering Faculty
Dr. John Messner – CM Advisor
Ray Sowers – CM Advisor
Dr. Linda Hanagan – Structural Advisor
Industry Acknowledgements
Special Thanks
The DAVIS Construction Project Team
Tyler Moyer – DAVIS Project Manager
David Gibbons III – DAVIS Senior Project Manager
Leaha Martynuska – DAVIS Project Manager
PACE Industry Members
Family and Friends
Questions
Andrew Pino | AE Senior Thesis | Construction Management Option
Government Building
Maryland