AE Senior Thesis: Research: Modular Construction Applied to Sullivan Trail Junior High

2. AE Senior Thesis: • Research: Modular Construction Applied to Sullivan Trail Junior High • Breadth 1: Structural Implications of Modular Construction • Breadth 2: Modularizing Mechanical Systems

3. Goals of Presentation: • Inform on state of modular construction in today's industry • State advantages and disadvantages of modular construction • Apply a modular construction design to Sullivan Trail Junior High • Show minimal changes to floor plan • Show a schedule reduction of four months

4. Background information: Pocono Mountain School District • Over 11,200 students and 1,400 faculty members • 305 square mile coverage area • Increase in enrollment of about 4% or 400 students a year • Pocono Mountain West High school: Completed in 2002 is already 200 students over capacity.

5. Background information: Sullivan Trail Junior High • Features • 285,575 Sq. Ft. • 44.6 million dollars • 16 Prime Contractors • Built into the side of a hill and is two stories on each level • Auditorium • Multi Purpose Room • Cafeteria • Three Classroom Pods • Construction started in March 2004 • Completion date December 2005

6. Background information: Sullivan Trail Junior High • Structure • Structural steel frame • Concrete spread footings and piers • 18 Foot high retaining wall • Combination of CMU and steel stud and drywall walls • Split-face CMU facade • Mechanical Systems • 3 boilers • 2 Chillers • 41 Single and Multi-Zone Air handling units • Fully Sprinkled

7. Modular Construction • Advantages • Requires little or no shake out area • Generally saves money • Reduces construction time by 1/3 because modules can be started while foundations are being dug • Reduced schedule leads to a faster payback period for the building • Minimizes schedule risks by having portions of the construction take place in a controlled environment and shortens critical path • Safety concerns are reduced because of controlled work environment • Portions of the building can easily be added or removed as needed

8. Modular Construction • Disadvantages • Requires substantial planning so front end of projects can be prolonged • Sometimes there will be an up cost • Works best on repetitive buildings such as jails and hotels • Increase in columns • Maximum clear span of 28 feet • Modular designers prefer to have very little or no CMU

9. Types of Modular Construction • Static Modular Construction • Modules are built similar to a conventional building • The modules are fully assembled them portions removed on match line • Typically are shipped on flat bed trucks • Adaptable to existing floor plans • NRB Incorporated • Assembly Line Modular Construction • Module moves to different stations • Modules are never fully assembled until on site • Typically have wheels attached to frame • Focuses on efficiency • Mark Line Industries

10. Static Build Modular Construction

11. Static Build Modular Construction - Connections

12. Static Build Modular Construction - Connections

14. Assembly Line Modular Construction

15. Assembly Line Modular Construction

16. Sullivan Trail Junior High Modularization • Reduce schedule to have school completed by August 31, 2005 • Use static built modularization • Modular design follows classroom pods • Auditorium, Gyms and Cafeteria would be conventionally built

17. Area A Floor Plan

20. Area C Floor Plan

23. Area D Floor Plan

26. Area E&F Floor Plan

29. Modular Construction • Erection Sequence • Area A, C and D2, D1 and F and E

32. Modularization Recommendations • Floor to floor heights would have to be lowered • Redesign of locker rooms to accommodate new columns • Flat roofs with roof top mechanical units • Modularize mechanical systems rather than mechanical room • Labor costs could be reduced by 1/3 because prevailing wage would not need to be used on off site construction • Save temporary modular classrooms and estimated cost of over $650,000

33. Special Thanks to.. • Turner Construction: Bill Booth and Steve Miller • NRB Incorporated: John Crisp and Don Engle • AE Faculty • Gilbert Architects • Pocono Mountain School District