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.
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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Using 3D Animation to Help Summa Health Visualize Project
October 31, 2016, 8:06 amSumma Health is embarking on a journey to build a new bed tower at Akron City Hospital in Akron, Ohio. Shook Construction has joined forces with Donley’s to provide construction management services for this $152 million project. During the interview process, the Donley’s – Shook team set out to not only help Summa Health see their project come to life, but also help them understand the construction process along with how our team would approach their project. To accomplish this, our team developed a 3D model of the project and the construction sequencing (as shown below). * Note: this is only a short snippet of the full model Using this model, the Donley’s – Shook team was able to explain visually the major milestones in construction, along with what some of the logistic challenges might be. Beyond the interview, this model will help with so much more than simply visualizing the project:
- Engage in a more collaborative working environment allowing for higher quality of work
- Identify conflicts/issues earlier in the project through clash detection, which ultimately leads to greater productivity in the field
- Improved communication and project coordination by utilizing a 3-D logistics plan
- Better design and spatial coordination where the design is completed with fabrication in mind
- Minimize, reduce or eliminate waste
- Increase productivity through prefabrication on or off-site
- Improved constructability reviews, schedules, quantity takeoffs cost estimating and scheduling
Project ScopeThe new six-story, 331,000 SF west bed tower will serve as the hospital’s new main entrance and will house two 36-bed medical/surgical units with all private rooms, a breast center, eight new operating rooms, 65 same-day surgery rooms and a women’s health center that includes a 36-bed post-partum unit. The project also includes the renovation of 64,000 square feet of the existing hospital. These renovations will focus on the ground floor imaging department and first floor surgery, as well as create private inpatient rooms within the existing patient floors. Construction will begin in early 2017 with substantial completion in the spring of 2019. The architect on the project is a partnership between Akron-based Hasenstab Architects and Cleveland-based Perspectus Architecture.
Groundbreaking of New Design-Build Water Treatment Plant
September 30, 2016, 1:24 pmShook Construction is making history as the Village of Yellow Springs broke ground on its new water treatment plant. What is unique about this project is that it will be constructed under the design-build project delivery method. It is the first of its kind for Shook within its water resources market channel, and it is the first brand new design-build water treatment plant in the State of Ohio. Ohio legislation made the design-build delivery model available to public entities just a few years ago. Since then, eight other public agencies have broken ground on their water/wastewater treatment plant-related projects, making the Village of Yellow Springs #9. Not only that, but the Village’s project is the 2nd largest design-build water/wastewater project in the state. What makes the design-build project delivery beneficial to public entities? Here are a couple reasons:
Single Point of ResponsibilityUnlike the design-bid-build process where the owner is responsible for hiring a designer and contractor and then is responsible for serving as the liaison between the two, now the owner can hire one firm who manages both the design and construction. This in turn fosters heightened collaboration among team members, which ultimately sets the stage for a successful construction project.
Cost SavingsIn the design-bid-build process, design changes late in the process (particularly after construction has started) are extremely costly to the owner. Having the construction team at the table early on under the design-build model means scope decisions can be made earlier in the process. In addition, the design and construction teams work together to ensure the project is designed to budget.
Time SavingsUnder the design-build model, the design and construction phases can overlap, allowing construction to begin while the design is still underway. This helps expedite the overall project schedule, as well as reduces costs and makes a new facility available to the owner earlier. The Village of Yellow Springs recognized these advantages when it chose to build its water plant under the design-build model. Karen Wintrow, president of Council for the Village, shared that they selected design-build as a way to be more involved in the design process, as well as to have more control over the budget. Shook Construction is proud to partner with designer Jones & Henry. Also on the team is D.A.G. Construction, Chapel Electric and Dmytryka Jacobs Engineers. The $7.2 million project will be complete in late 2017.
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.
Cleveland Office Lands Two Education Projects
April 25, 2016, 8:08 amWe are one of the most active PK-12 builders in the state. This month, we celebrate two new education projects in northeast Ohio! Lorain County Joint Vocational School This $2.5 million project includes:
- renovating three laboratories to meet the curriculum needs of the Connections Academy
- relocating the Business Academy to the 2nd floor and renovating that 15,000 SF space
- improving various technology and fire alarm systems
- two-story classroom wing
- dedicated auditorium
- competition gym with a second-floor running track
- auxiliary gym
A Kid’s Perspective: Starting in a Newly Constructed School
February 1, 2016, 2:03 pmShook Touchstone just completed the construction of a new 119,682 SF elementary school in northwest Ohio. While we are extremely proud of our work on the new Napoleon PK-8 school, we always must remember that the true significance is not the facility we built; it is the future generations of students who will benefit from studying and growing in improved learning environments. We thought “who better to evaluate the new school than the students themselves?” Meet Ryan and Nathan Lawinsky, 4th and 6th grade students, respectively. They have spent almost three weeks in their new school and already are enjoying the improved features. They were excited to share with us their experience. Shook: Tell me about some of the things you like about your new school building. RL: The new gym; it’s so big! NL: The new band room. There’s more space and there’s padding on the walls so it’s not as noisy. Shook: What new features make it easier to learn? RL: New classrooms are bigger; easier to move around. NL: New touch boards; they’re not as complicated Shook: What don’t you miss about the old school building? RL: They didn’t have A/C! NL: There was a weird smell in the old building. The new school smells fresh. Shook: How did you feel on your first day of class in the new building? RL and NL: Excited and nervous! Mom Lawinsky: The District held an open house/tour before classes started, which helped the kids find their respective classes on the first day. It also helped that each grade has different “line” of paw prints on the floor; so if a student gets lost, they simply need to follow their colored path. Shook: Is there anything else you’d like to tell us? RL and NL: The new school has lots of bright and cheery colors, which makes it more fun. There are more computers, so we don’t have to wait for one to become available. As one of the largest PK-12 builders in the state, we are constantly looking for ways to learn, improve our craft and provide more value to our clients. According to Ryan and Nathan, the new Napoleon Elementary School was a job well-done!
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Wright State’s Nutter Center Celebrates 25 Years
December 28, 2015, 3:10 pmThis month, Wright State University celebrated the 25th anniversary of its Erwin J. Nutter Center in Fairborn, Ohio. Why is this particularly important to Shook Construction? It is one of our most notable construction projects! The 260,000 square foot, multi-use facility includes flexible seating capacity ranging from 2,200 seats to 13,000 seats. We built this project from the top down, installing the structural steel before constructing the concourses and seating. Main project elements included:
- 63-acre site
- 23,000 cubic yards of excavation
- 700 tons re-steel
- 14,700 cubic yards of concrete
- 2,500 tons of structural steel
Celebrating a Successful Project and Announcing a New One
August 27, 2015, 12:41 pmChaminade Julienne High School (CJ) recently celebrated the completion of its $2.5 million renovation of Building One in downtown Dayton. Building improvements included modernized classrooms and hallways, new mechanical and lighting systems, enhanced performing arts rehearsal spaces and a complete renovation of the cafeteria. After the ribbon cutting ceremony of the Building One improvements, school officials announced its next project: the new Roger Glass Stadium. The $6 million athletic stadium will be the home for soccer, football and lacrosse games. It will feature a 99,600 SF artificial turf playing field, home field grandstands with pressbox, away bleachers, stadium lighting, a support building which includes concessions, restrooms, and storage, two ticket booth gateways, plaza for community events and an 80,600 SF practice field. The 2,150-seat stadium will open in fall 2016. Leading the construction team on these two projects is Project Manager Suzanne Whisman. Working alongside Suzanne on the Building One project was Project Superintendents Mike Poynter and Jeff Schlarman. Project Superintendent John Gudorf will be involved in the new stadium project. Shook Construction has worked with Chaminade Julienne since 2010 on their $20 million initiative as a result of their LIFT (Leading in Faith Today) campaign. These projects have included the new STEMM Center, a renovated gym, installation of the Eagle Tennis Center—the school’s first outdoor competition venue—an interior facelift to two floors in the Marianists’ building and—most recently—the above mentioned renovation of Building One.
Emergency Operations Center Groundbreaking
May 4, 2015, 2:54 pm
The new Cuyahoga County Emergency Operations Center project is underway with the groundbreaking taking place earlier this month.
Located in Broadview Heights, OH, the new 45,000 SF facility will provide Cuyahoga County with better coordination and management of emergency preparedness and disaster management by consolidating the following systems under one roof:
- Office of Emergency Management
- Emergency Operations
- Cuyahoga Emergency Communications Systems
In addition, the $24 million center will include a Special Operations Garage to house multi-jurisdictional public safety equipment and vehicles.
For this design-build project, Shook Construction has partnered with Architects Design Group and Osborn Engineering. Shook’s project team includes Keri Ash, Mike Schmidlin, Matt Gray, David Sedensky and Joe Lammlein.
Construction is expected to be complete in fall 2016.