Transcript Power Point File - Penn State Engineering

Mercersburg
Academy –
Center for the
Arts
Brad Cordek
2005
Senior Thesis
Construction Management
Option
A little about myself …
• 5th year MAE/BAE
• Construction
Management Option
• Graduate in December
2005
• James G. Davis
Construction
2
Brad Cordek
Presentation Outline
•
•
•
•
•
•
Project Team
MACA Building Statistics
Owner
Curtainwall Background
Overall Thesis Goals
Analysis I – Trends in CW
Design & Construction
• Analysis II – CW
Constructability
• Analysis III – Daylighting
Study of the CW
• Analysis IV – Heat
Transmission Study of the
CW
• Project-wide effects of
recommendations
• Questions
3
Brad Cordek
Project Team
• Owner – Mercersburg
Academy
• GC – Davis
Construction
• Architect – Polshek
Architects
4
Brad Cordek
MACA Building Statistics
• Located in
Mercersburg, PA
• Home to Mercersburg
Academy’s Music &
Theater Departments
• Total project cost of
$21.76 million
• 4 Stories
• 66,500 square feet
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Brad Cordek
Owner
• Mercersburg Academy
– Not the typical owner
• Owner favors “quality”
over “schedule & cost”
– No strict schedule for
MACA
– Plenty of funding from
wealthy alumni
• HS Boarding Tuition
– $34,700 / year
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Brad Cordek
Curtainwall Background
• Teak & mahogany CW
system
– Wooden, custom built by
Duratherm Windows
– Present on all building
elevations
• 16,864 square feet of
CW
– 32 typical panels
– 30 feet tall
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Brad Cordek
Curtainwall Background
• CW Cost = $1,294,563
– Material = $61 / SF
– Labor = $29 / SF
– Total = $91 / SF
• 12 week schedule
– 3 weeks per elevation
8
Brad Cordek
Overall Thesis Goals
• Make recommendations to Mercersburg
concerning the CW system
• Educate
– Owners
– Project Managers
– Myself
• Create a curtainwall reference
9
Brad Cordek
I – Trends in CW Design &
Construction
Background
• Many issues presently troubling the building
industry concerning the design and
construction of curtainwall systems
– General lack of knowledge
• Unique T&M curtainwall system will require
intense coordination efforts from design and
construction ends
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Brad Cordek
I – Trends in CW Design &
Construction
Analysis I Process
• Research & building industry survey to gather
information
• Formulate solutions to critical issues
Analysis I Goal
• Improve design & construction process for CW
projects
– Summary chart of key issues & respective solutions
– Implementation on MACA and other CW projects
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Brad Cordek
I – Trends in CW Design &
Construction
Questions with unanimous responses
• #7 – Holding CW coordination meetings for all subs,
somewhat like MEP meetings, would reduce field
conflicts
– Agree
• #12 – Subs certified to install wooden CW systems
are much rarer than those that install aluminum CW
systems
– Agree
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Brad Cordek
I – Trends in CW Design &
Construction
Key Issue
Poor team communication &
coordination
Presence of field conflicts
Curtainwall leaks
Curtainwall schedule problems
Solution
Comments
Design-build team arrangement
Sub submitting bid & completed drawings
Sub reward
Complete work on-time and solve own issues
CW coordination meetings
All subs involved must attend
CW mock-up
Time/money for mock-up nothing compared to lost time
Accurate submittal log
Must begin at an early date
CW coordination meetings
Subs discuss which activities they are responsible for
Accurate schedule
Must be effectively communicated
CW coordination meetings
Subs discuss schedule
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Brad Cordek
I – Trends in CW Design &
Construction
Conclusion
• CW coordination meetings are an important
tool in combating CW issues
• The previous summary chart will serve as a
reference tool to educate Mercersburg
Academy and other building industry
personnel
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Brad Cordek
II – CW Constructability
Background
• CW construction is frequently on the critical
path in a CPM schedule
– Must fit into & interact well with the rest of the
schedule
• Completion of the CW signifies the “building
enclosure”
– Allows for the start of interior trades
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Brad Cordek
II – CW Constructability
Analysis II Process
• Analyze & compare the T&M and aluminum
CW systems based on schedule &
material/installation costs
Analysis II Goal
• Provide Mercersburg Academy with
comparison chart
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Brad Cordek
II – CW Constructability
Comparison Table
Total SF Curtainwall = 16,864
System
Teak &
Mahogany
Aluminum
Total Cost
$
$
Material / SF
Labor / SF
Schedule
(weeks)
Construction
Process
1,294,563
$
61
$
30
12
Rigid
1,011,840
$
45
$
15
5
Flexible
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Brad Cordek
II – CW Constructability
Conclusion
• The aluminum CW system outperforms the
T&M CW in every aspect on the previous
chart, except for one:
– Mercersburg's value of “quality” over “schedule
and cost”
• The final recommendation is to keep the
current T&M CW system
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Brad Cordek
III – Daylighting Study of
the CW
Background
• Over 90% of the curtainwall façade is
composed of glazing units
• Daylighting is an important tool for achieving
safely illuminated spaces and cutting energy
costs
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Brad Cordek
III – Daylighting Study of
the CW
Analysis III Process
• Daylighting study of various CW arrangements
– safely illuminate “lobby” & “outdoor patio” areas
– cut energy costs
Analysis III Goals
• Achieve safely illuminated “lobby” & “outdoor patio”
• Save on annual lighting energy costs
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Brad Cordek
III – Daylighting Study of
the CW
AGI Tests
CW Arrangement
Daylight
Night
3:00 PM
3:00 PM
12:00 AM
Lights
No Lights
Lights
X
X
X
Teak & Mahogany
Original Viracon
Low-E Viracon
X
Add Outdoor Lights
X
Mahogany
Original Viracon
X
X
X
X
X
X
Low-E Viracon
Add Outdoor Lights
Aluminum
Original Viracon
Low-E Viracon
X
Add Outdoor Lights
X
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Brad Cordek
III – Daylighting Study of
the CW
• Two proposed changes to the lighting system
surfaced during the daylighting study:
– Add outdoor fixtures on patio area
• Cost = $5,661
• Lighting Energy Impact = Adds $372 annually
• DOUBLES FC value on “outdoor patio” at night
– Turn off lobby lights during the day*
• Cost = Nothing
• Lighting Energy Impact = Saves $1,896 annually
*Assumes lights are going to be running during the day
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Brad Cordek
III – Daylighting Study of
the CW
Lighting Energy Cost
Summary
Annual KWh
Implementing BOTH Proposals
429392
$ per KWh
$
$
21,470
ANNUAL SAVINGS
$
1,524
SAVINGS IN 20 YEARS
$
30,480
Cost of Proposed Changes
$
5,661
7% SAVINGS
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Brad Cordek
0.05
Yearly Cost
III – Daylighting Study of
the CW
Conclusion
• Changing frame/glazing type has no effect on the
daylighting abilities of a CW system
– Keep the T&M CW system
• The final recommendation is to implement the
changes to the lighting system
– Safer outdoor patio area
– Saves over $1,500 in annual lighting energy costs
– Payback period of 5 years
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Brad Cordek
IV – Heat Transmission
Study of the CW
Background
• CW composition can have enormous
implications on energy costs for a building
• Majority of MACA façade composed of T&M
CW
• The T&M CW on MACA becomes an
important tool in preventing heat loss
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Brad Cordek
IV – Heat Transmission
Study of the CW
Analysis IV Process
• HAP analysis & thermal gradient to determine effect
CW glazing has on mechanical loads & heat
transmission
• Energy costs from the mechanical system
– Changes based on cost & performance of glazing types
Analysis IV Goal
• To determine if the switch to Viracon Low-E glazing
should be made
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Brad Cordek
IV – Heat Transmission
Study of the CW
• Thermal gradient study was performed for the
original T&M CW system with the following glazing
types
– Default glazing units
• U-value of 0.29
– Viracon Low-E glazing
• U-value of 0.25
• Following increases in temperature across the
glazing were obtained
– Default glazing = 47.5°F
– Viracon Low-E glazing = 48.1°F
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Brad Cordek
IV – Heat Transmission
Study of the CW
• HAP analysis
Cost
Glazing Unit
• Mechanical Energy
impact
Sum of
of Curtainwall
Default
$
1,294,563
Viracon LowE
$
1,320,455
Peak
CFM
515
485
KWh
Annual Energy
Cost
Default Glazing
637180
$
31,859
Viracon Low-E
Glazing
598914
$ 29,629
Total
System
Coil Load
10.9 MBH
10.3 MBH
Viracon SAVINGS
7% SAVINGS
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Brad Cordek
$
2,230
IV – Heat Transmission
Study of the CW
Conclusion
• Though the thermal
gradient produced no useful
results, the HAP analysis
provided excellent feedback
• The final recommendation
is to switch to the Viracon
Low-E glazing units
– Annual mechanical energy
savings of $2,300
– Payback period of 10 years
– Higher quality, better
performing system
Glazing Unit
Cost
Annual
of Curtainwall
Energy Costs
Default
$
1,294,563
Viracon Low-E
$
1,320,455
$
31,859
$
29,629
Switch to Viracon
Difference
Payback
$25,890
$2,230
10
Years
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Brad Cordek
Project-wide Effects of
Recommendations
• Analysis I – Summary chart
• Analysis II – Keep T&M CW
• Analysis III – Adding outdoor fixtures & turning off
lobby lights during the day
– Outdoor fixtures additional task for lighting sub
– Coordination between lighting, electrical & roofing sub
• Analysis IV – Switch to the Viracon Low-E glazing
units
– Both glazing units are from Viracon
• No extra schedule time required
• Installation can be done by same sub as before
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Brad Cordek
Questions ?
• Thanks to:
– Penn State University
• Dr. Riley & the CM Faculty
• Dr. Mistrick
– James G. Davis Construction
• Ted Holt
• Bill Moyer
• George Robinson
–
–
–
–
Mercersburg Academy
Polshek Architects
My friends & family
Fellow 5th years Jason Borowski, Pat Dempsey,
& Ben Mitten
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Brad Cordek
Architecture
 Architecture (Design and Functional Components) – The
Center for the Arts has some very unique interior space
layouts such as recital/dance studios, set
design/prep/construction areas, orchestra/ensemble practice
areas, and a 600 seat auditorium complete with full stage,
sound/lighting systems, and a 12,000 pound orchestra lift. All
of these areas possess the most exquisite high-end finish
and millwork. Exterior-wise, MACA’s skin is a combination of
stone, glass and metal panels, with balconies surrounding
the building on three sides. The Center for the Arts also has
an attached two-story performing theater constructed as a
“stone cylinder.”
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Brad Cordek
Zoning & Historical
 Zoning and Historical – The zoning for the
Center for the Arts could be best classified as
an academic campus. Mercersburg Academy
was founded in 1893. Currently the campus
has a large collection of historical buildings
and old growth trees, both of which will need
protection from construction activities.
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Brad Cordek
Building Envelope
• Building Envelope – The vast majority of the
Ground and Second Floor façade is
composed of a teak and mahogany windowwall system, while the high roof skin, on the
other hand, consists mainly of zinc, copper,
and aluminum wall panels. Lastly, on the
lower level North, South and West elevations,
there exists a Pennsylvania Limestone
façade.
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Brad Cordek
Electrical
• Electrical – The system consists of a 5 KV
feed, stepped down by a 1500 KVA
transformer. The main switchboard is a
277/480 V – 3 phase – 4 wire 3000 amp bus.
A 230 KW emergency generator provides
back-up power.
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Brad Cordek
Lighting
 Lighting – The main theater is equipped with
a 50 watt MR 16 recessed halogen adjustable
accent light, while the
drama/sculpture/drawing/painting classrooms
are equipped with a 90 watt PAR 38 halogen
adjustable accent lights (on tracks).
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Brad Cordek
Lighting
 Lobby area lighting
 AM-1: Recessed PAR30 metal halide adjustable accent
light
 39/70 watts
 Were eventually turned off during the day
 AP-2: Track mounted PAR38 halogen adjustable accent
light
 90 watts
 YY-1A: Recessed one circuit track
 75 watts per linear foot
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Brad Cordek
Lighting
 Added outdoor lights (17 total)
 100 W flood lights
 Surface mounted
 $333 per light
 Material and installation
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Brad Cordek
Mechanical
 Mechanical – The mechanical room is
located on the Lower Level floor on the North
side of the building. An all air, VAV system is
employed in the Center for the Arts. It
distributes air through aluminum ductwork.
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Brad Cordek
Structural
 Structural – MACA has a combination of diagonal
bracing and lateral moment connections as its
bracing system. Every floor, except the SOG, is
composed of a 5.5” NWC 18-gauge composite slab
on metal deck. The only CIP concrete on the job is
the spread footings, floor slabs, and a two-story
architecturally exposed concrete exterior foundation
wall on the South, East and North sides of the
building.
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Brad Cordek
I – Trends in CW Design &
Construction
Survey Responses
Percent Answers
120%
100%
80%
60%
40%
20%
0%
#3A C
#4 A/B
#5 C
#6 A
#7 A
#8 A
Top Answer
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Brad Cordek
#9 A
#10 A
#11 A
#12 A
II – CW Constructability
•
T&M CW Installation Process:
–
–
–
–
–
–
–
–
–
–
Shim sill level and space equally at bottom.
Check unit for location and shim jambs at bottom center.
Check unit head for plumb and shim jambs at top center.
Check for square, adjusting accordingly.
Install fasteners at four corners.
Shim adjacent to intermediate anchor point and install fasteners.
Re-check for square.
Install matching wood plugs.
Install backer rod and sealant at exterior joints.
Attach exterior trim with stainless steel fasteners.
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Brad Cordek
II – CW Constructability
•
Aluminum CW Installation Process:
–
–
–
–
–
–
–
–
Building layout – clip installation.
Erect vertical sticks.
Install horizontal frames.
Prep system for glass.
Install glass.
Install exterior covers and sills.
Install interior covers and sills.
Perimeter caulking.
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Brad Cordek
III – Daylighting Study of
the CW
AGI 32 Curtainwall Lighting Studies
Surface
Location of FC Value*
Outside Concrete
5 feet in from the center of the curtainwall
Painted Hardwood
5 feet in from the center of the wall
2nd Floor Walkway
3 feet in from the center of the wall
* Note - Average taken of two
typical layout
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Brad Cordek
Footcandle Values
CW Arrangement
Outside Concrete
Painted Hardwood
2nd Floor Walkway
3:00 PM Lights
183
106
88
3:00 PM NL
180
55
33
Night Lights
3
52
54
3:00 PM NL
194
49
34
Night Lights
3
52
53
3:00 PM Lights
183
106
89
3:00 PM NL
181
55
34
Night Lights
3
52
55
3:00 PM Lights
202
106
85
3:00 PM NL
199
55
33
Night Lights
3
52
56
3:00 PM NL
198
49
30
Night Lights
3
52
55
Teak & Mahogany
9
55
54
Aluminum
10
55
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Teak & Mahogany
Original Viracon
Low-E Viracon
Mahogany
Original Viracon
Aluminum
Original Viracon
Low-E Viracon
Outdoor Lights
Low-E Viracon
Lobby & Outdoor Patio
Floor Plans
Default T&M – No Lights
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Brad Cordek
Aluminum – No Lights
Default T&M – Outdoor Lights Added
Surface
Current T&M Glazing
Viracon Low-E Glazing
Outside
10
10
Outer Film
12.5
12.4
Glazing
60.0
60.5
Inside
70.0
70.0
47.5
48.1
Increase in
Temperature
Across
Glazing
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Brad Cordek
Energy Cost
Summary
Lighting Arrangement
Annual
KWh
Current Scheme
459872
$ per KWh
$
0.05
Yearly Cost
$
22,994
Proposed Changes
Add outdoor fixtures
Energy impact
$372
Cost
$5,661
Turn off lobby lights during
daytime hours
Energy impact
$1,896
Cost
Proposed Scheme
NA
429392
$
0.05
$
21,470
ANNUAL SAVINGS
$
1,524
SAVINGS IN 20 YEARS
$
30,480
Cost of Proposed
Changes
$
5,661
Comparison of Curtainwall Costs
Curtainwall System
Glazing
Cost
Original Viracon
$
1,294,563
Low-E Viracon
$
1,320,455
Original Viracon
$
1,165,107
Original Viracon
$
1,011,840
Low-E Viracon
$
1,032,077
Low-E Viracon
$
1,326,116
Low-E Viracon
$
1,037,738
Teak & Mahogany
Mahogany
Aluminum
T&M w/ Outdoor Lights
Alum. w/ Outdoor Lights
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Brad Cordek
IV – Heat Transmission
Study of the CW
Keeps you warmer in the winter
U-Value
Keeps you cooler in the summer
Solar Heat Gain
Coefficient
Reduces UV energy and allows
visible light
Transmittance
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Brad Cordek
IV – Heat Transmission
Study of the CW
Default Glazing Properties
Glass Type
% of
Visible
Solar
Winter
Shading
Typical CW
Transmittance
Transmittance
U-Value
Coefficient
Annealed
5%
0.73
0.37
0.299
0.45
Tempered
28%
0.73
0.37
0.299
0.45
Fritted
58%
0.46
0.23
0.29
0.31
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Brad Cordek