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Mercersburg Academy – Center for the Arts

Mercersburg Academy – Center for the Arts. Brad Cordek 2005 Senior Thesis Construction Management Option. A little about myself …. 5 th year MAE/BAE Construction Management Option Graduate in December 2005 James G. Davis Construction. Project Team MACA Building Statistics Owner

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Mercersburg Academy – Center for the Arts

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  1. Mercersburg Academy –Center for the Arts Brad Cordek 2005 Senior Thesis Construction Management Option

  2. A little about myself … • 5th year MAE/BAE • Construction Management Option • Graduate in December 2005 • James G. Davis Construction Brad Cordek

  3. Project Team MACA Building Statistics Owner Curtainwall Background Overall Thesis Goals Analysis I – Trends in CW Design & Construction Analysis II – CW Constructability Analysis III – Daylighting Study of the CW Analysis IV – Heat Transmission Study of the CW Project-wide effects of recommendations Questions Presentation Outline Brad Cordek

  4. Project Team • Owner – Mercersburg Academy • GC – Davis Construction • Architect – Polshek Architects Brad Cordek

  5. MACA Building Statistics • Located in Mercersburg, PA • Home to Mercersburg Academy’s Music & Theater Departments • Total project cost of $21.76 million • 4 Stories • 66,500 square feet Brad Cordek

  6. Owner • Mercersburg Academy • Not the typical owner • Owner favors “quality” over “schedule & cost” • No strict schedule for MACA • Plenty of funding from wealthy alumni • HS Boarding Tuition • $34,700 / year Brad Cordek

  7. Curtainwall Background • Teak & mahogany CW system • Wooden, custom built by Duratherm Windows • Present on all building elevations • 16,864 square feet of CW • 32 typical panels • 30 feet tall Brad Cordek

  8. Curtainwall Background • CW Cost = $1,294,563 • Material = $61 / SF • Labor = $29 / SF • Total = $91 / SF • 12 week schedule • 3 weeks per elevation Brad Cordek

  9. Overall Thesis Goals • Make recommendations to Mercersburg concerning the CW system • Educate • Owners • Project Managers • Myself • Create a curtainwall reference Brad Cordek

  10. I – Trends in CW Design & Construction Background • Many issues presently troubling the building industry concerning the design and construction of curtainwall systems • General lack of knowledge • Unique T&M curtainwall system will require intense coordination efforts from design and construction ends Brad Cordek

  11. I – Trends in CW Design & Construction Analysis I Process • Research & building industry survey to gather information • Formulate solutions to critical issues Analysis I Goal • Improve design & construction process for CW projects • Summary chart of key issues & respective solutions • Implementation on MACA and other CW projects Brad Cordek

  12. I – Trends in CW Design & Construction Questions with unanimous responses • #7 – Holding CW coordination meetings for all subs, somewhat like MEP meetings, would reduce field conflicts • Agree • #12 – Subs certified to install wooden CW systems are much rarer than those that install aluminum CW systems • Agree Brad Cordek

  13. I – Trends in CW Design & Construction Brad Cordek

  14. I – Trends in CW Design & Construction Conclusion • CW coordination meetings are an important tool in combating CW issues • The previous summary chart will serve as a reference tool to educate Mercersburg Academy and other building industry personnel Brad Cordek

  15. II – CW Constructability Background • CW construction is frequently on the critical path in a CPM schedule • Must fit into & interact well with the rest of the schedule • Completion of the CW signifies the “building enclosure” • Allows for the start of interior trades Brad Cordek

  16. II – CW Constructability Analysis II Process • Analyze & compare the T&M and aluminum CW systems based on schedule & material/installation costs Analysis II Goal • Provide Mercersburg Academy with comparison chart Brad Cordek

  17. II – CW Constructability Comparison Table Brad Cordek

  18. II – CW Constructability Conclusion • The aluminum CW system outperforms the T&M CW in every aspect on the previous chart, except for one: • Mercersburg's value of “quality” over “schedule and cost” • The final recommendation is to keep the current T&M CW system Brad Cordek

  19. III – Daylighting Study of the CW Background • Over 90% of the curtainwall façade is composed of glazing units • Daylighting is an important tool for achieving safely illuminated spaces and cutting energy costs Brad Cordek

  20. III – Daylighting Study of the CW Analysis III Process • Daylighting study of various CW arrangements • safely illuminate “lobby” & “outdoor patio” areas • cut energy costs Analysis III Goals • Achieve safely illuminated “lobby” & “outdoor patio” • Save on annual lighting energy costs Brad Cordek

  21. III – Daylighting Study of the CW Brad Cordek

  22. III – Daylighting Study of the CW • Two proposed changes to the lighting system surfaced during the daylighting study: • Add outdoor fixtures on patio area • Cost = $5,661 • Lighting Energy Impact = Adds $372 annually • DOUBLES FC value on “outdoor patio” at night • Turn off lobby lights during the day* • Cost = Nothing • Lighting Energy Impact = Saves $1,896 annually *Assumes lights are going to be running during the day Brad Cordek

  23. III – Daylighting Study of the CW 7% SAVINGS Brad Cordek

  24. III – Daylighting Study of the CW Conclusion • Changing frame/glazing type has no effect on the daylighting abilities of a CW system • Keep the T&M CW system • The final recommendation is to implement the changes to the lighting system • Safer outdoor patio area • Saves over $1,500 in annual lighting energy costs • Payback period of 5 years Brad Cordek

  25. IV – Heat Transmission Study of the CW Background • CW composition can have enormous implications on energy costs for a building • Majority of MACA façade composed of T&M CW • The T&M CW on MACA becomes an important tool in preventing heat loss Brad Cordek

  26. IV – Heat Transmission Study of the CW Analysis IV Process • HAP analysis & thermal gradient to determine effect CW glazing has on mechanical loads & heat transmission • Energy costs from the mechanical system • Changes based on cost & performance of glazing types Analysis IV Goal • To determine if the switch to Viracon Low-E glazing should be made Brad Cordek

  27. IV – Heat Transmission Study of the CW • Thermal gradient study was performed for the original T&M CW system with the following glazing types • Default glazing units • U-value of 0.29 • Viracon Low-E glazing • U-value of 0.25 • Following increases in temperature across the glazing were obtained • Default glazing = 47.5°F • Viracon Low-E glazing = 48.1°F Brad Cordek

  28. HAP analysis Mechanical Energy impact IV – Heat Transmission Study of the CW 7% SAVINGS Brad Cordek

  29. IV – Heat Transmission Study of the CW Conclusion • Though the thermal gradient produced no useful results, the HAP analysis provided excellent feedback • The final recommendation is to switch to the Viracon Low-E glazing units • Annual mechanical energy savings of $2,300 • Payback period of 10 years • Higher quality, better performing system Brad Cordek

  30. Project-wide Effects of Recommendations • Analysis I – Summary chart • Analysis II – Keep T&M CW • Analysis III – Adding outdoor fixtures & turning off lobby lights during the day • Outdoor fixtures additional task for lighting sub • Coordination between lighting, electrical & roofing sub • Analysis IV – Switch to the Viracon Low-E glazing units • Both glazing units are from Viracon • No extra schedule time required • Installation can be done by same sub as before Brad Cordek

  31. Questions ? • Thanks to: • Penn State University • Dr. Riley & the CM Faculty • Dr. Mistrick • James G. Davis Construction • Ted Holt • Bill Moyer • George Robinson • Mercersburg Academy • Polshek Architects • My friends & family • Fellow 5th years Jason Borowski, Pat Dempsey, & Ben Mitten ? Brad Cordek

  32. Architecture • Architecture (Design and Functional Components) – The Center for the Arts has some very unique interior space layouts such as recital/dance studios, set design/prep/construction areas, orchestra/ensemble practice areas, and a 600 seat auditorium complete with full stage, sound/lighting systems, and a 12,000 pound orchestra lift. All of these areas possess the most exquisite high-end finish and millwork. Exterior-wise, MACA’s skin is a combination of stone, glass and metal panels, with balconies surrounding the building on three sides. The Center for the Arts also has an attached two-story performing theater constructed as a “stone cylinder.” Brad Cordek

  33. Zoning & Historical • Zoning and Historical – The zoning for the Center for the Arts could be best classified as an academic campus. Mercersburg Academy was founded in 1893. Currently the campus has a large collection of historical buildings and old growth trees, both of which will need protection from construction activities. Brad Cordek

  34. Building Envelope • Building Envelope – The vast majority of the Ground and Second Floor façade is composed of a teak and mahogany window-wall system, while the high roof skin, on the other hand, consists mainly of zinc, copper, and aluminum wall panels. Lastly, on the lower level North, South and West elevations, there exists a Pennsylvania Limestone façade. Brad Cordek

  35. Electrical • Electrical – The system consists of a 5 KV feed, stepped down by a 1500 KVA transformer. The main switchboard is a 277/480 V – 3 phase – 4 wire 3000 amp bus. A 230 KW emergency generator provides back-up power. Brad Cordek

  36. Lighting • Lighting – The main theater is equipped with a 50 watt MR 16 recessed halogen adjustable accent light, while the drama/sculpture/drawing/painting classrooms are equipped with a 90 watt PAR 38 halogen adjustable accent lights (on tracks). Brad Cordek

  37. Lighting • Lobby area lighting • AM-1: Recessed PAR30 metal halide adjustable accent light • 39/70 watts • Were eventually turned off during the day • AP-2: Track mounted PAR38 halogen adjustable accent light • 90 watts • YY-1A: Recessed one circuit track • 75 watts per linear foot Brad Cordek

  38. Lighting • Added outdoor lights (17 total) • 100 W flood lights • Surface mounted • $333 per light • Material and installation Brad Cordek

  39. Mechanical • Mechanical – The mechanical room is located on the Lower Level floor on the North side of the building. An all air, VAV system is employed in the Center for the Arts. It distributes air through aluminum ductwork. Brad Cordek

  40. Structural • Structural – MACA has a combination of diagonal bracing and lateral moment connections as its bracing system. Every floor, except the SOG, is composed of a 5.5” NWC 18-gauge composite slab on metal deck. The only CIP concrete on the job is the spread footings, floor slabs, and a two-story architecturally exposed concrete exterior foundation wall on the South, East and North sides of the building. Brad Cordek

  41. I – Trends in CW Design & Construction Brad Cordek

  42. II – CW Constructability • T&M CW Installation Process: • Shim sill level and space equally at bottom. • Check unit for location and shim jambs at bottom center. • Check unit head for plumb and shim jambs at top center. • Check for square, adjusting accordingly. • Install fasteners at four corners. • Shim adjacent to intermediate anchor point and install fasteners. • Re-check for square. • Install matching wood plugs. • Install backer rod and sealant at exterior joints. • Attach exterior trim with stainless steel fasteners. Brad Cordek

  43. II – CW Constructability • Aluminum CW Installation Process: • Building layout – clip installation. • Erect vertical sticks. • Install horizontal frames. • Prep system for glass. • Install glass. • Install exterior covers and sills. • Install interior covers and sills. • Perimeter caulking. Brad Cordek

  44. III – Daylighting Study of the CW Brad Cordek

  45. Lobby & Outdoor Patio Floor Plans

  46. Default T&M – No Lights Brad Cordek

  47. Aluminum – No Lights

  48. Default T&M – Outdoor Lights Added

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