This project entails the design and construction of a 400,000 SF neuroscience/cardiac patient tower, including:
- 224 individual private beds
- Renovation of existing surgery suites
- Linear accelerator
- MRIs and CT scans
- Operating rooms
- Interventional radiology
- Outpatient clinics
- 500-car addition to a parking garage
- 7.5 MW emergency generator plant
- Central plant expansion
- Several acres of sitework
By employing an off-site prefabrication strategy, the project team was able to pull key construction activities off of the project’s critical path. The primary patient floor above-ceiling MEP services (racks) were built concurrently with or ahead of the patient tower superstructure construction. The prefabricated racks were then installed as a finished product, once the structure was readied for them. This aided in completing 60% of the above-ceiling work within a two- to three-day time frame. The same concepts held true for the patient room bathroom pods and headwalls.
The prefabricated racks were built using the same 10- to 12-man composite crew through the course of the project, compared to a typical 16- to 20-man crew required for a similar field installation. Additionally, the entire above-ceiling rack prefabrication effort (1,680 LF of 16-foot-wide racks) generated less than a dumpster’s worth of waste.
The layout and engineering of the rack structure and services created an inherent organization of systems and consistency of both services and equipment locations. This created an improved serviceability for the owner’s routine maintenance in the future. All piping systems were tested prior to shipment to mitigate any leakage issues in advance of installation. All headwall components were constructed, then checked at the shop. prior to shipment. They were then double-checked in the field after installation, with the templates to achieve an exact fit with the finished architectural headwall panels.
All of the prefabrication elements were constructed in a controlled environment at bench height in lieu of overhead lifts and ladders. This off-site construction minimized the risk of worker injury by allowing our trades to work in areas with fewer people, less construction traffic, less materials and debris, and better environmental conditions.