DTA TACOM Miscellaneous Repairs, Bldg. 230, US Army Tank Automotive Command

B230DetroitArn

DTA TACOM Miscellaneous Repairs, Bldg. 230, US Army Tank Automotive Command

Location: Detroit Arsenal, Warren, MI
Client: US Army
Completion: 2018
Value: $3.6M

Highlights:

  • Award of Excellence in Construction, Federal Government/Military/Under $10M category, Associated Builders and Contractors (ABC), Indiana/Kentucky Chapter, 2018
  • Multi-building renovation project
  • D-B interior reconfiguration resulted in 35 new offices, 4 printer/copier and file rooms, conference and team rooms, and 200 work stations

Role in US National Defense

The Detroit Arsenal (DTA) was the first manufacturing plant ever built for the mass production of tanks in the US, with its top production years occurring between 1941 and 1945. Today a portion of the original plant remains an active Army facility that houses several defense agencies, including the US Army Tank Automotive Research, Development and Engineering Center (TARDEC) and the US Army TACOM Life Cycle Management Command.

Scope

CMS managed a design-build (DB) project for the complete renovation of Building 230, consisting of the Integrated Logistics Support Center (ILSC) North, ILSC East, and ILSC West. The renovation included interior finishes and furniture. Upon completing the base contract, CMS was granted the project’s single option, which included upgrading the existing HVAC system and installing an additional HVAC unit.

Interior Reconfiguration. The interior scope of work included extensive interior renovation. We added walls to create new rooms and spaces, as well as new fire-rated doors with frames and hardware. Interior renovations included installing carpet tile flooring and rubber base; painting all walls, columns, doors, and trim; installing new HVAC vents, diffusers and return grilles; refinishing all surfaces; and adding interior signage and fire extinguishers with cabinets to achieve the appearance of a completely new area. In the ILSC North area, we reconfigured the area for 15 new offices; 2 areas for printers, copiers, and file cabinets; a 12-person Conference Room with a video telecommunication conference (VTC) system; a kitchenette/break room; and 50 workstations. In the ILSC East area, we create 10 new offices; a printer/copier and file room; a 6-person Team Room; and 75 workstations. Finally, in the ILSC West area, we reconfigured the area for 10 new offices; a printer/copier and file room; and 75 workstations.

HVAC Renovation. The HVAC scope of work required a comprehensive analysis of the existing HVAC system to determine new ventilation requirements and new cooling load for the areas served by the AHU. Our analysis showed where supplemental cooling was needed to meet the new load requirements. The mechanical upgrades required that the air distribution system be reconfigured, and new heating and cooling zones created. A direct digital control (DDC) system was installed for maximum control of heating/cooling output by building managers from on- or off-site.

As the prime contractor for this $3.6M multiple-building renovation project, CMS was responsible for meeting all of the Army’s requirements and expectations for constructability, design, function, operation, and life span. We were also responsible for ensuring that the upgrades, repairs, and newly-installed systems integrated seamlessly with the Detroit Arsenal’s other buildings and finishes. Overall, we provided aesthetically pleasing, comfortable space for Army personnel that was like-new, durable, maintainable and sustainable.

Energy Savings Performance Contract (ESPC)

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Energy Savings Performance Contract (ESPC)

Location: Joint Systems Manufacturing Center (JSMC), Lima, OH
Client: Siemens Government Technologies (SGT)
Completion: 2018
Value: $8.7M

Highlights:

  • CMS self-performed installation of new steam piping connections at roof-top units
  • Air cranes used to remove existing 19,000-lb. units from the roof and then lift and place new replacement units on the roof
  • Zero OSHA-recordable incidents, despite unique site conditions/safety hazards (e.g., fall protection, cranes/air lifts/rigging, lock out/tag out, etc.)
  • Work in operating manufacturing facility with minimal impact to facility mission

Scope

CMS was awarded a design-build turnkey contract to install 37 roof top steam-fired heat recovery units (HRUs) and a single large air handling unit (AHU) at the JSMC (aka Lima Army Tank Plant) in Lima, OH. The scope of work included the removal and demolition of the existing HRUs and associated piping, electrical services, controls, and appurtenances. CMS also supplied and installed controls with native BACnet connectivity to permit integration to a new facility-wide building management system on the new HRUs, as well as variable frequency drives (VFDs) on the HRUs and exhaust fans.

Following disconnection/demolition of the existing HRUs and AHU and placement of new roof curbs, new 19,000-lb. units were air lifted and placed on the roof of the facility using air cranes (specially equipped helicopters), where the waiting CMS crew reestablished new piping and electrical connections.

USACE Huntsville District has oversight of JSMC Lima – America’s last major tank factory. Built in 1941, the facility currently turns out 11 upgraded Abrams tanks a month. This project not only dramatically reduces the facility’s carbon footprint, but also is entirely funded by the energy savings resulting from the system upgrade..

Boiler House External Piping

allisonboilerpipe

Boiler House External Piping

Location: Indianapolis, IN
Client: Allison Transmission
Completion: 2018
Value: $1.9M

Highlights:

  • Bid-build new construction
  • Install over 6,000 LF of elevated process piping from one building to another
  • 400-foot crane work for lifting and placing materials
  • Welding

Scope

CMS was the prime contractor on this contract to install 6,800 LF of boiler piping from the rooftop of the new boiler house to the existing on-site plant, a distance of several hundred feet. The large piping systems, varying in size from 1.5” to 18” diameter, were routed across an above ground trestle.

The scope included mechanical, electrical, structural, and controls, and consisted of piping distribution systems for steam, make-up water, waste water, compressed air, and condensate return.

CMS performed on-site fabrication and welding of the various sizes of piping, both carbon steel (CS) and stainless steel (SS), as compatible with each system’s use and function. Also included was the installation of piping supports, hangers, rollers, slides, guides, and anchors to complete the installation of each piping system. A waste water pump was installed inside the new boiler house as well, and controls were provided for the new equipment.

Renovation of the SGT JH Cooney US Army Reserve Center

USARCMilan

Renovation of the SGT JH Cooney US Army Reserve Center

Location: Milan, OH
Client: US Army
Completion: 2017
Value: $5.3M

Highlights:

  • Design-Build
  • Renovations and additions to 18,000 SF of US Army Reserve facility
  • Sustainable design and LEED features

Role in US National Defense

The US Army Reserve (USAR) is the federal reserve force of the US Army. Together the USAR and the Army National Guard constitute the Army element of the Reserve components of the US Armed Forces. USAR is a peacetime pool of trained Reserve officers and enlisted men for use in war. The Cooney US Army Reserve Center (USARC) in Milan, OH provides meeting and training facilities for regional support of Army Reserve personnel.

Scope

This design-build project renovates approximately 13,000-SF of an existing training building and an approximate 4,300-SF organizational maintenance shop. The project also requires an addition of approximately 710 SF to the organizational maintenance shop. Repairs to the facilities include extensive refurbishing of the HVAC systems, mechanical systems, security systems, electrical systems and all interior spaces. Physical security measures are incorporated in the design, including entry control points, maximum standoff distance from roads, parking areas, and vehicle unloading areas. Berms, heavy landscaping, and bollards are used to prevent access when standoff distances cannot be maintained.

This project includes a variety of sustainable design features for the building as well as low-impact design techniques for the site to help the project achieve LEED Silver Certification.

Building 212 Miscellaneous Repairs, US Army Tank Automotive Command

DetroitArsenal

Building 212 Miscellaneous Repairs, US Army Tank Automotive Command

Location: Detroit Arsenal, Warren, MI
Client: US Army
Completion: 2017
Value: $2.6M

Highlights:

  • Design-Build
  • Repair mechanical systems and infrastructure for eight Test Cells
  • Install new custom radius steel door with integrated wind/weather seals, sound and fire attenuation

Role in US National Defense

The Detroit Arsenal (DTA) was the first manufacturing plant ever built for the mass production of tanks in the US, with its top production years occurring between 1941 and 1945. Today a portion of the original plant remains an active Army facility that houses several defense agencies, including the US Army Tank Automotive Research, Development and Engineering Center (TARDEC) and the US Army TACOM Life Cycle Management Command.

Scope

Building 212 at the Detroit Arsenal is a test facility consisting of eight Test Cells whose purpose is to test equipment in various types of environments as produced individually within the reinforced cells. The objective of this project was to repair features of each Test Cell in the facility to improve its individual performance and effectiveness.

CMS was responsible for repairing mechanical systems, including HVAC and HVAC infrastructure, including louvers, dampers, coils, valves, and DDC controls. Included in the scope were specialty doors for three of the cells. The use of a 40-ton crane was needed to move and install these large, heavy custom doors. Also included was pipe insulation, concrete placement, reinforcement of existing concrete, and HAZMAT abatement.

Excavation was required to place a flowable-fill sub-base prior to concrete placement. Concrete was placed, broom finished, and control joints were saw-cut as required.

Flex Lab Facility, Purdue University

PurdueFlexLab

Flex Lab Facility, Purdue University

Location: West Lafayette, IN
Client: Purdue University
Completion: 2017
Value: $6.5M

Highlights:

  • Winner of Award of Excellence in Construction, Mechanical/Commercial category, Associated Builders and Contractors (ABC), Indiana/Kentucky Chapter, 2018
  • Prime mechanical contractor for a $54M multidisciplinary research building
  • University-wide compatible BAS HVAC modular control system

Scope

Flex Lab is a 107,800-SF multidisciplinary engineering research building at Purdue University that features state-of-the-art wet and dry labs and open collaboration spaces. With a focus on flexibility and visibility throughout, the transform-ative and functionally efficient environment promotes collaborative learning and discovery while addressing the changing nature of research. In alignment with national academic research trends, it houses multiple lab types in a flexible arrangement to accommodate Purdue’s evolving research needs.

This three-story-plus-basement research facility supports the College of Engineering. The project team evaluated structural systems based on the 2,000 micro-inches-per-second vibration criteria for the elevated floors, along with factors of cost and speed of construction. The building features 1,840 SF of high-bay lab space, a canopy with a 20’ cantilever, and a structural steel vestibule to mark the entry to the facility. The scope also includes 142 LF of new utility tunnel to service the Flex Lab.

The Building Automation System (BAS) designed for this project is a complete HVAC control system designed for use with Enterprise IT Systems and is directly compatible with other existing campus systems. It controls the air handling units (AHUs), VAV/CAV boxes, and utility systems. The system is modular in nature to permit future expansion of both capacity and functionality through the addition of sensors, actuators and operator devices. It will be integrated with the Laboratory Airflow Control System (LACS).

Included in the mechanical scope was the installation of instrumentation, control valves, VAV boxes, damper actuators, multiple transmitters (dew point, static and differential pressure, temperature, humidity), switches, thermostats, control panels and direct digital controls (DDCs).

Building 930 HVAC Repairs

B930FtPolk

Building 930 HVAC Repairs

Location: Fort Polk, LA
Client: US Army
Completion: 2017
Value: $3.6M

Highlights:

  • Design-Build
  • Demolish/remove existing HVAC system including process piping, electrical, mechanical
  • HAZMAT abatement

Role in US National Defense

Fort Polk, a US Army installation located in west central Louisiana, was built in World War II to serve as a basic training post. Today the Joint Readiness Training Center (JRTC) and other combat divisions on Base improve unit readiness by providing realistic arms training across a full spectrum of conflict scenarios.

Scope

Building 930 at Fort Polk houses the Bayou Theater, which serves the Base in the capacities of conference hall, large-scale training room, and entertainment for troops and their families, offering stage productions and movies.

CMS was responsible for repairing all mechanical systems in the building, including the stage area itself, including HVAC and HVAC infrastructure. The work required draining, capping, demolishing, and removing existing mechanical, electrical, ductwork, and plumbing, and replacing all with a new high-efficiency system and components. HAZMAT abatement was performed during and after demolition and prior to installing new equipment.

The scope also included placing new concrete equipment pads, new walls, and electrical conduit and lines; adding direct digital controls; performing TAB (test/adjust/balance) and commissioning of the new system prior to turnover to the Government.

Ozone Systems/Ozone Neutralization System (ONS) Refurbishment City of Indianapolis Department of Public Works

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Ozone Systems/Ozone Neutralization System (ONS) Refurbishment
City of Indianapolis Department of Public Works

Location: Indianapolis, IN
Client: Reynolds, Inc.
Project Value: $1.9M
Completion: 2008

CMS was subcontracted by Reynolds, Inc. to fabricate and install over 6,000 LF of process piping and perform other mechanical scopes of work at two Wastewater Treatment Plants in south-Indianapolis communities. Our responsibility included providing special-function process piping for various ozone neutralization systems (ONSs) that purify wastewater to potable standards. Work included:

  • Fabricate and install over 6,000 LF of stainless steel piping
  • Refurbish diffusion system piping
  • Clean existing piping
  • Pneumatically test all oxygen, ozone, and chilled water pipes
  • Clean and inspect all inline devices to CGA G-4.1 and B31.3 standards and specifications
  • Install expansion joints, butterfly valves, isolation valves, and flow valves in the supply lines
    CMS scheduled all work to prevent interruption to ongoing operations at the AWT facility.

VPSA VS-120L Plant Piping Installation

Prxair_Utah

VPSA VS-120L Plant Piping Installation

Location:   Nucor Steel Plant, Plymouth, UT
Client:   Praxair, Inc.
Project Value: $670K
Completion:   2008

CMS provided and installed over 3,000 LF of mechanical piping and various control valves for a new Vacuum Pressure Swing Absorption (VPSA) VS-120L oxygen plant. We prefabricated all pipe spools in-house prior to field installation to reduce cost. This project involved the use of various types (carbon steel, stainless steel, monnel, and copper) and sizes (from 48” to 1/2”) of mechanical piping run in tight quarters. We performed extensive oxygen cleaning on prefabrications and marked spools for easy installation. We then performed an extensive site layout

and set the equipment using large cranes (some up to 100,000 lbs). While the equipment was being set, crews performed extensive motor alignment on the Aerzen blower train, which included a double-ended drive motor, two speed-reducing gearboxes, one feed blower and one vacuum blower. All welds were TIG rooted for cleanliness for oxygen use. CMS then performed pre-ground and final alignment and poured with epoxy grout. CMS performed 10% radiograph inspection (non-destructive testing) to ASME B31.3 code.

Design-Build Historical HVAC and A/C Upgrades and Repairs, Various Buildings

HVAC-&-AC-upgrades

Design-Build Historical HVAC and A/C Upgrades and Repairs, Various Buildings

Location:   Marine Corps Base, Kaneohe Bay, Oahu, HI
Client:   US Navy
Project Value: $4.5M
Completion:   2015

Highlights:

  • Received letter Exceptional performance ratings from the
    client.
  • Recipient of 2015 Award of Excellence from the Indiana/
    Kentucky Associated Builders and Contractors, Inc.

Historic Value

All five buildings in the scope of this project were present
and in operation during the Japanese invasion of the US in
1941. For this reason they are considered US historic
property and subject to special handling for renovation and
repair projects to maintain the integrity of historic indicators and
landmarks.

Scope

This project required demolition of the existing outdated
and inefficient heating, ventilation, and air-conditioning (HVAC)
systems and installing new high-efficiency equipment. The new
systems were tested, adjusted, balanced, and commissioned
before delivery to the customer. All five buildings were present
and in operation during the Japanese invasion of the US in
1941. For this reason, all five buildings are considered historic
US property and subject to special handling for renovation and
repair projects to maintain the integrity of historic indicators and
landmarks.