Diamond Wire Sawing Process of Twin 108″ Concrete Pipes
September 1, 2017, 7:23 am
As part of the Easterly treatment facility project on the shores of Lake Erie in Cleveland, Ohio, our project team built six 110-foot diameter by 18-foot deep settling tanks. The discharge from these new tanks (as well as four existing tanks) were connected to a NEW concrete junction chamber via 2500 lineal feet of 36-inch through 84-inch diameter Flowtite® fiberglass underground pipe.
This new junction chamber was constructed around two temporarily supported 108-inch diameter concrete pipes. These pipes have carried the treated discharge from the existing plant to Lake Erie since 1931.
Once the new facilities were complete, the challenge was tying the new facilities to the old discharge. To accomplish this, the project team removed 11 feet of pipe from each of those two 108-inch diameter, 10.5-inch thick concrete pipes.
To ensure this process did not interrupt the existing flow to the lake, the project team engaged DOT Diamond Core Drilling who suggested a diamond wire sawing system to make two cuts in each of the two pipes.
To accomplish this feat, the project team first installed temporary pipe supports and made preparations for hoisting and handling both pipes while the chamber was still dry. DOT then began the diamond wire sawing process, aided by external cooling water. When the first in-service pipe’s circumference was penetrated, the plant flow began to flood the chamber. The remaining sawing process was completed without any personnel having to enter the chamber. The resulting cuts totaled 1,620 lineal inches of reinforced concrete.
Once cut, General Crane Rental used a 130-ton capacity crane to hoist out the two 11-foot cut pieces, each weighing about 37,000 pounds.
Making this effort even more impressive is that the pipe removal and subsequent joining of the old and new flow systems were completed during 15-degree temperature and blustery winds in mid-December.
Despite the frigid weather and the difficulty of this task, the entire operation took only two 12-hour days to complete.
This process was part of the larger $74.3 million project which began in September 2013. The overall purpose was to increase the capacity of the Easterly Wastewater Treatment Plant from 140 million gallons per day to 400 million gallons per day, which will help the environment.
The Northeast Ohio Regional Sewer District (NEORSD) contracted the Shook Walbridge Joint Venture to complete these improvements, which were designed by MWH Global and Brown & Caldwell. The design called for the installation of 26 new pumps, piping, automated valves and meters, as well as adding chemical storage, distribution, metering, instrumentation and process equipment to more effectively enhance the treatment process. To accomplish this, the Shook Walbridge team selectively removed, rerouted and replaced interior and underground piping, existing structures, and equipment.
The multi-phase project took four years to complete.
Our Core Values: Safety
April 28, 2017, 8:00 am
We operate by a core set of nine values. This month, we focus on safety.
Safety is our most important core value as our people are our most important assets. Without them, our business would not run. It is vital that our people remain healthy and safe, returning home in the evenings in the same condition they arrived to work in the mornings. The same goes for our clients and subcontractors.
How do we keep safety at the forefront of our team’s minds? Here are just a few ways:
It Starts at the Top
Our commitment to safety begins with active senior management involvement, beginning with the chief executive officer/president (who chairs our safety and health committee) and continues throughout all levels of our organization.
It’s a Part of Operations
Our preconstruction department analyzes potential hazards associated with a project and determines whether or not to pursue if a project cannot meet certain risk standards. Safety continues into the bid process. Subcontractor selection criteria includes an evaluation of their safety statistics and OSHA history. Once our team mobilizes on site, a site-specific safety plan is developed and any worker that enters the site must go through a formal orientation before beginning work.
Daily Pre-Task Safety Planning Meetings
Every morning before work begins on a project site, we hold a Toolbox Talk. The agenda reviews the day’s goals… What needs to get done? What is the plan? What are the hazards associated with performing the work? How will we eliminate or control the hazard?
Corporate Safety Audits
Shook maintains a team of safety professionals within our safety and risk management department. These team members provide regular, unscheduled safety audits on every Shook project, every month. Survey results are distributed to both project and company leadership. In addition to providing inspections, our safety professionals are a proactive resource to help our project teams plan how to safely go about their work.
Communication is Key
A key element to our program’s success is communication. Safety audits, incident reports and any OSHA activity is communicated within 24 hours to: CEO/president, executive vice president, market channel leader, project manager and project superintendent. On a weekly basis, all employees receive information regarding safety audit findings from the previous week, OSHA activity, work-related incidents and a summary of the current OSHA recordable incidents. When warranted, we will cease work and hold a “safety-stand-down-meeting” to address major issues.
We always will stand by our safety motto: “Safely, the only way to work!” Our award-winning safety program simply validates that.
Our Core Values: Quality
March 27, 2017, 12:32 pm
We operate by a core set of nine values. This month, we focus on quality.
Quality equals building excellence. Our goal is to ensure our clients are receiving the construction project they expect for the dollars they are investing. Why do we do this? First, it is the right thing to do. Second, we cannot be a successful company by offering sub-par quality. We are proud of our “reputation built on performance”—and performance begins with quality.
It is important to us to establish the standard and measure quality from the beginning of a project rather than simply evaluating quality at the end of a project. What processes do we have in place to ensure that every project is a quality one? Here are just a few:
We create a detailed model that shows the work in place, which helps trade contractors visualize their scope of work. We also use the model to coordinate building elements and to plan the project’s sequencing and durations.
Mock-Ups and First-in-Place Inspections
Particularly for projects that contain repetitive spaces (such as hospital patient rooms), we use a first-in-place inspection process. This involves the inspection of the first piece of work put in place to verify quality. This install then becomes the quality standard for the balance of the project. This process can include mock-ups of a specific area, which our team reviews for quality (and our owners review for aesthetics and functionality).
Weekly Progress Meetings
We hold weekly job coordination meetings with subcontractors, trades and material suppliers during which we review schedule, coordination of work, quality of work and safety/security requirements.
Quality Control Checklist
Each of our field personnel carry a pocket-sized quality control checklist, which breaks down standards of work by division. This provides us a portable tool to review the quality of work with each of our subcontractors.
Ongoing Punch Lists
We do not believe in waiting until the end of the project to develop a punch list. We create an ongoing punch list at the beginning of a project so that our subcontractors can correct deficiencies in a timely manner. We review this punch list at our weekly progress meetings. We also encourage our owners and design partners to participate in developing the punch list items. This helps our subcontractors understand the expectations early on in the project and facilitates prompt close-out of the job.
Making it Matter in 2017
February 21, 2017, 12:05 pm
Every year, Shook Construction gathers our employees to celebrate the successes of the past year and to create excitement for the years to come. February’s corporate annual meeting was no exception.
This year’s theme was “Make it Matter.” In everything we do, we must ensure that each of us is contributing to the service of our clients. From acquiring the latest technology to making our own health a priority to being cost conscious in every decision to providing exemplary customer service…each of us plays a part in the success of this company.
To help us prepare to make it matter, we learned more about many initiatives already taking place here at Shook. From recruiting high school kids into the construction industry to putting staff through leadership training to incorporating formal mentoring programs, we are preparing current and future employees to make a huge impact and to set them up for some amazing careers.
In light of our theme, we asked our team how they are making it matter. Here are a few of their responses.
As we continue to invest in our people, we are excited for the continued success and growth we anticipate for years to come.
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Wrapping Up Our 90th Anniversary
December 20, 2016, 7:05 am
What an exciting anniversary year this has been! We have had so much fun working with our clients and in our communities.
Shook’s theme this year has been celebrating our history and recognizing why we do the work we do. Over the course of the year, we have been fortunate to strengthen our relationships, to form new ones and to contribute to the communities that make us who we are. Thanks to a great year, we can look forward to continued growth as we enter our 10th decade in business.
Safety continues to be a #1 priority in everything we do. Thanks to our team’s relentless efforts, the Associated General Contractors (AGC) of Ohio once again awarded Shook Construction a 2016 Construction Safety Excellence Award within the Heavy Division.
In celebrating our 90th anniversary, we know it is imperative that we give back to our communities and clients that make everything that we do possible. We had the opportunity to build a new veterans memorial, raise funds for a major children’s hospital and partner with our local United Way chapters, among many other things.
“We’re fortunate enough to be a part of really creating the fabric of the communities in which we work,” shares Bill Whistler, president and chief executive officer. “It’s fun!”
Not many construction companies can tout a 90-year history. We are proud to have reached this milestone. As long as we continue to reflect on our humble beginnings along with why we do what we do, we can look forward to another 90 years.
Click here to learn more about our history.
Honoring Veterans by Volunteering Time and Expertise
November 29, 2016, 6:56 amCommunity is a vital component of who we are as a company. As such, it is not uncommon to learn of ways that our employees donate their time, money and expertise to worthy causes. Most recently, two of our employees went above and above the call of duty to honor our veterans by assisting two communities to design and construct a Veterans Memorial.
Kettering Veterans and Inventors PlazaThe Kettering Parks Foundation in Kettering, Ohio celebrated the dedication of its new Veterans and Inventors Plaza (also known as the Kettering Veteran’s Plaza and Charles F. Kettering History Walk). The plaza includes five pillars, each representing a different branch of the military. These pillars serve as a public expression of gratitude to those who have served and continue to serve our nation. Meanwhile, the walkway shares information about Charles F. Kettering who is an innovator, as well as the founder of Delco (Dayton Engineering Laboratories Co.). Three interactive history stations along the walkway highlight the history, inventions and philanthropic contributions of Mr. Kettering to the local community, the automotive industry and the world. Shook’s Mike Eckley is on the board of directors for the Kettering Parks Foundation, so it only made sense that he use his 40+ years of construction experience to manage the design and construction of this memorial. In addition, 15 local contractors provided in-kind services to complete the project. Those volunteer hours and additional private donations funded the $400,000 project.
Troy-Miami County Veterans MemorialThe Troy-Miami County Public Library and the Miami Valley Veterans Museum dedicated its new Veterans Memorial in Troy, Ohio. The new memorial highlights all branches of the armed services with a distinct image set into concrete around a flagpole. Local individuals, organizations and businesses came together to make this memorial a reality. This includes Shook’s Jeff Schlarman who donated his time to install the concrete for the project while Shook Construction donated the materials. Troy Mayor Mike Beamish shared that the project is a “demonstration of what community spirit is all about” and a “lasting tribute” to all veterans.
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The Process of Removing a Digester Tank Lid
August 24, 2016, 10:27 amIt’s not every day a wastewater treatment plant project requires the replacement of a digester tank lid. What makes this feat so impressive? The lid itself is 50-feet in diameter and weighs about 77,000 pounds, which required a 210-ton crane to lift. During the lift, it looked like there was a UFO hovering over the property. Why did the tank lid need to be removed in the first place? A hole had developed on the underside of the lid, thus allowing the hollow lid to be filled with sludge. The tank will receive a new membrane-style cover during Phase II of the project. The overall project for Phase I involves the following:
- New chlorine contact basin on the end of the existing equalization tanks.
- New chemical building for feed of sodium hypochlorite and sodium bisulfite to the new chlorine contact basin.
- New aeration basin #7.
- Renovation of the sludge control building, including all new sludge heating equipment.
- New ultraviolet disinfection building including a new non-potable water system and new effluent aeration system.
- New pump station to handle the centrate from the existing sludge dewatering building.
- New electrical service and electrical feeds to all buildings.
- Various site piping.
Planning Our Work Using VDC
June 10, 2016, 12:39 pmDo you have trouble picturing how your construction partner plans to protect your existing environment during a renovation project? We understand that not everyone comprehends information in the same way. That is one of many benefits from incorporating Virtual Design & Construction (VDC) into our construction pre-planning process. VDC uses 3D modeling to optimize project planning. It allows our team to visualize, analyze, plan and manage complex projects. It also helps us visually share our plan with clients. For example, we recently renovated a data center that remained operational throughout construction. To avoid interrupting business operations, we divided the project into six phases. As we worked through each phase, we erected temporary partitions to separate our work zones from office personnel. The video below helped our client visualize how we planned to protect their data center during construction activities. The client then used this same video to relay the plan to their employees. Communication is paramount no matter the business or the project. It is equally vital during a construction project. VDC is helping us take that communication to a new level.
Equipment Warranties: Do You Know What You’re Getting?
April 20, 2016, 10:38 amPicture this: You recently completed construction of your brand new facility. Contractors have vacated the site. The equipment manufacturer performs its annual service inspection and discovers “wear and tear” items that are not covered under the existing warranty. To top it off, the manufacturer claims that these items should not be wearing out so early in their life cycle and you are stuck with the bill to replace these parts. Sound familiar? How can you make sure this doesn’t happen? 4 WAYS YOUR CONSTRUCTION PARTNER CAN HELP
1: Make sure your construction partner completes a Certification of Warranty Commencement FormThis form details each new piece of equipment along with its respective warranty start dates and its warranty duration. This information should be provided to you for every warranty item on the project, in a well-organized format so that you can clearly review and understand what is or is not covered.
2: Ensure your construction partner verifies you are getting the right warranty specific to your needsThis “begin with the end” mentality will minimize a lot of heartache later on. Warranties are not a “one size fits all” concept. As such, your construction partner will review the warranties for each piece of equipment to verify they will satisfy your needs in the long run.
3: Request that your construction partner performs an 11-month walk-thruDon’t let your construction partner wash its hands of your project once the construction trailers are gone. Ensure they plan a walk-thru of your facility with your staff and all appropriate subcontractors to make sure everything is working properly. If something isn’t right, they can get it addressed before the warranty period expires.
4: Ask (before you hire) if your construction partner will be available beyond not only the project end-date, but also the warranty periodDue diligence in purchasing the best equipment, guaranteeing the best warranty and ensuring the building was working properly prior to the warranty expiration date doesn’t ensure issues won’t arise. Things happen; it’s life. A stand-up construction firm will continue to look after your best interests well beyond the warranty period. An even better construction firm will take ownership of the issues and personally ensure they are fixed.
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90th Anniversary Kick-Off Party
February 17, 2016, 8:27 amWhat better way to kick off our 90th anniversary than a celebration with our very own employees! Every year, Shook Construction gathers our employees to celebrate the successes of the past year and to create excitement for the years to come. Of course, this year is special because we are celebrating 90 years in business. We took advantage of having most everyone under the same roof by kicking off our yearlong celebration. This allowed us the perfect opportunity to reflect on our humble beginnings and to remember why we do what we do. Welcoming the attendees in the lobby was a memorabilia display exhibiting some of Shook’s artifacts and an awards table highlighting our most recent achievements, as well as a commemorative quilt designed and crafted by one of our own employees. We kicked off the meeting with a 90-year documentary highlighting our humble beginnings when Charles H. Shook first started the company, along with the trials and successes that make us who we are today. The rest of the day included presentations from each of our market channels and departments, which celebrated the successes of the prior year, shared lessons learned and new technologies being tested and encouraged more efficient techniques to implement in the field. A few of the highlights included:
- Our Canton Water Reclamation Facility project team shared their experience in using Bluebeam in the field to streamline communication and the sharing of updated files.
- President Bill Whistler encouraged the use of our new pocket Quality Assurance Daily Checklist handbooks to improve overall construction quality in the field.
- Director of Safety and Risk Management Joe Reich distributed safety awards to 38 project teams for achieving zero injuries or illnesses in 2015 on their project sites.
- Our Raleigh office celebrated the completion of its first project since we launched that office in 2012.
- Every market in which we work applauded our successes with repeat clients and welcomed many new clients.