TP Implements New Fabrication Method – Fully Prefabricated Mechanical Rooms

In today’s ever-changing construction environment, TP Mechanical continues to adapt and innovate. We know the challenges of large-scale construction projects, and for over thirty years we’ve answered them with our market-leading, quality-driven fabrication division. As a leader in the fabrication industry, TP continues to push the envelope with new technology and capabilities. We are proud and excited to announce we are now building and pre-assembling entire mechanical rooms in our fabrication facilities.

There are many benefits to pre-assembling a mechanical room offsite. TP’s Distribution Center is an extremely safe and controlled environment where production continues even when there is inclement weather. With a portion of the project’s manpower shifting from the jobsite to our distribution center, onsite assembly requires less time while still achieving a seamless installation process. This strategy also ensures we have eliminated any and all issues before the field installation occurs. This high-level prefabrication allows for us to avoid jobsite delays and meet strict deadlines, which is a continued priority for all our projects.

TP Mechanical was thrilled to utilize this strategy for a new central energy plant at Big Walnut Schools with general contractor, Gilbane Building Company. This energy plant is equipped to provide a total of 1500 tons cooling capacity, twenty-four million BTU’s of heating, which supports the over 350,000 square feet for the new Big Walnut High School and Prairie Run Elementary.

To ensure the installation of piping and equipment went as effortlessly and fast as possible, TP built the entire mechanical room in our 100,000 square foot distribution center. This energy plant consists of (4) six million BTU boilers, (3) 500-ton chillers, hydronic pumps, (2) air separators, (2) expansion tanks, a chemical feeder, (3) 1500-gallon cooling towers, a makeup water system and more.

The mechanical room was completely pre-assembled while the energy plant structure was simultaneously being built.  Once the building was dried-in, the pre-assembled portion of the mechanical room was broken down into segments, then shipped to the jobsite to allow for an efficient and expedited installation. From disassembly to reassembly on-site, the process was performed in a period of four days.

To learn more about TP’s fabrication division, visit https://www.tpmechanical.com/fabrication/. Discover how our team offers unparalleled skill with sophisticated software to generate innovative, customized solutions for your primary challenges.

TP’s Quality Workmanship, Refrigeration Experience and Excellent Safety Record Leads to a New Project

TP Mechanical is part of the design-build team constructing a distribution facility addition featuring refrigerated storage for Team Modern in Somerset, Kentucky. Jordan Lewis, project manager for Denham Blythe – the design firm in charge of the project – engaged TP Mechanical in part to our team’s proven experience with Denham Blythe on a 2016 project for Senko. Pride, quality workmanship, refrigeration experience and an excellent safety record were all phrases used to describe TP’s successful involvement on the Senko project.

Team Modern is a supplier of snacks, cold drinks, ice cream, and other inventory to a wide network of convenience store clients throughout southern Kentucky and northern Tennessee. In addition to installing air rotation and exhaust fans for the entire 110,000 square foot facility, our crews will install 12 walk-in cooler condensers and 23 cooler evaporators in order to chill the facility’s 13,000-square foot freezer, 8,000-square foot cooler, and 4,000-square foot refrigerated dock.

The same, agency-wide defining characteristics that describe TP’s involvement on Senko will shape and define our work on the new Team Modern project, of which we’re proud to be a part.

TP Mechanical Employee Spotlight: Ben Handley

Now in his fourth and final year with TP Mechanical’s Apprenticeship Program, Ben Handley is a rising star both in the classroom and in the field. Currently the lead operator of the Trimble® Control Unit (TCU) on our Big Walnut High School project in Sunbury, Ohio, Ben also holds down a 98.9% GPA in his coursework and serves as an ambassador for TP’s Apprenticeship Program. In this role, he travels to local high schools and career centers to speak about the advantages of working with our company.

At the Big Walnut project, Ben’s work on the TCU provides essential GIS (geographic information system) mapping details, which enables TP teams to properly design and position the project’s plumbing and HVAC systems. Ben is so skilled at using the TCU technology, he now trains other team members on its operation. Last year, Ben worked in the mechanical rooms at TP’s Covelli Arena project on the campus of The Ohio State University, learning to weld in the process.

We feel fortunate to have Ben serving as an ambassador for TP’s Apprenticeship Program – an industry-leading training program including 8,000 hours of on-the-job training plus 576 hours of classroom learning across four years. Ben truly has a passion for working with our company and serves as a shining example of the talented, new generation of skilled team members we have in our ranks.

TP Mechanical’s Indianapolis Office Provides Maintenance and Service to Avalign

Avalign Technologies, a leading manufacturer of surgical instruments and medical implants, has turned to TP Mechanical for trusted preventative maintenance and service at its nearly 200,000-square foot facility in Greenwood, Indiana.

Avalign recently requested TP Mechanical for their next sizable project – air conditioning the entire plant and installing duct work for machinery exhaust.  Earning this project is a testament to the company’s satisfaction with the ongoing preventative maintenance and service they are receiving from TP.

The TP Mechanical office in Indy is just five years old, but under general manager Mark Hunter, the office has grown to a dedicated team of 15 employees. Already, the office has a substantial regional reach throughout Indiana, servicing clients across an array of industries from manufacturing and industrial to heavy commercial and assisted living.

The Indianapolis office – like our offices in Cincinnati, Columbus, Dayton, and Lexington – provides preventative maintenance, service and installation for mechanical equipment.  With a full-time electrician on staff, the Indy office uniquely delivers a full scope of electrical services as well.   

Please contact TP Mechanical if we can help you with your upcoming service or installation needs.

 

Project Spotlight: Norwood Middle School Renovation for Norwood City Schools

 

The original building of Norwood Middle School, which houses students in grades 6, 7 and 8, was built over 100 years ago, in 1914. Although the school was renovated in 1965 and again in the mid-1980s, the school began another major renovation to update facilities in early 2018.

Charles Douglas, who happens to be a Norwood alumnus (‘91), serves as the onsite superintendent for TP Mechanical. The TP team, including Douglas and project manager Michael Schneider, started with demolition of the existing mechanical systems followed by new duct work and the installation of a VRV system. This project is a significant upgrade as prior to this renovation, the 148,000 square foot school building used steam radiators for heat and was without central air conditioning.

The age of the building has revealed several unknowns and challenged the team to think creatively. SHP, the architect & engineer, and Monarch Construction continue to help provide imaginative and cost-effective solutions enabling the team to stay on schedule and minimize disruptions to the occupied facility.

Currently TP Mechanical is about 80% complete on this project, with full completion of the renovation in the west wing and nearing completion of the east wing in March. Part of the project involved completing the field house during phase two—just in time for basketball season.

This was TP’s first project with Norwood City Schools; we have built strong relationships and look forward to future projects within the district. Norwood City School District has been providing quality education in the Greater Cincinnati area for more than 100 years and includes three elementary schools, one preschool and one high school in addition to Norwood Middle School.

TP Mechanical Team:

  • Project Manager: Michael Schneider
  • Site Superintendent: Charles Douglas
  • Sheet Metal Foreman: Josh Schaffer
  • Sheet Metal Team: Jacob Stauffer, Robert Gilley
  • Refrigeration Lead: Greg Porter
  • Refrigeration Team: Matt Halusek

Project Partners:

A Top-Notch Approach to Complex Renovations: Spotlight on the Enoch Grehan Building Renovation for the University of Kentucky

TP Mechanical Team:

  • Project Manager: James Randall
  • Pre-Fabrication Shop Leader: Jerry Klein and Nicole Holland
  • Site Superintendent: Greg Jordan
  • BIM Coordination Team: Kameron Bledsoe, Zack Campbell, Randy Tillet, Jeremy Hassman, Mayur Kadakia and Greg Dennison

Project Partners:

When the University of Kentucky wanted to renovate the Enoch Grehan Building in the core of academic campus, we knew it would be a complex project requiring smart scheduling.  As a testament to our impressive project partners, we are currently ahead of schedule.

We thrive on complex projects with coordination challenges, like this one. To succeed, we look to our synchronized divisions —the BIM team, self-performed pre-fabrication, off-site distribution team and our installation team— to come together and provide high-quality systems.

Our process starts with the BIM coordination team developing detailed models to ensure the pre-fab systems are built to precision.  The models are the road map, guiding system fabrications to the final connections in the field.  Once the model for Grehan was created, the fabrication team took ownership of their scope.  On this project, the Carrier system prefab saved two to three days of site work.  We also used prefabbed systems for the sewage ejector pump and the 12-amp chilled water piping serving multiple buildings. By having this piping ready to set in the tunnel in the heart of campus, we saved the university from having to shut down the area for a week.

On this project, multiple trades were on-site at once, working in the same areas. By building much of the systems off-site, we were able to avoid working in and around other contractors. Not only does pre-fab keep our on-site team safer, because they don’t have to go into small, confined or subsurface areas, it also provides a huge time savings.

Our distribution center also played a key role in keeping our scope ahead of schedule.

UK’s campus is a flurry of active construction projects.  We knew the project would come with storage limitations on site.  The ability for TP to store equipment at our distribution center until the systems were needed on site, proved to be an invaluable asset.

The University of Kentucky is known for its sophisticated approach to building renovations. This project is a wonderful opportunity to show potential higher education clients our capabilities. We are proud to be working for the University and our project team.

 

 

 

Project Feature: Pre-Fabrications Benefit Fast Track Construction

Mount Carmel Health System in Columbus, Ohio needed to expand in order to meet patient demands without interrupting current patient care. Construction on Mount Carmel East Expansion included a new 128-bed tower, featuring all individual rooms, and 11 new operating rooms. An addition to the existing chiller plant for added cooling and an addition to the boiler plant was also part of the project.

TP Mechanical stepped in to meet the challenge of working within a fully operational hospital on a tight 13-month deadline. In order to help keep the project on schedule and incur the least amount of disruption to the hospital patients and staff, the team constructed much of the needed materials off site. Fabricated hallway racks, which each included supply air ductwork, hydronic HVAC piping, VAV Box’s, Domestic water piping and electrical conduits, were all assembled, tested and inspected prior to being delivered to the site. There was even drywall assembled on to the racks off site to help save time. TP mechanical also prefabricated medical gas zone valve box assemblies.

These off-site fabrications directly impacted time savings on the project, accelerating the installation per floor by an impressive 75%.  Partners on the project were Messer Construction and NBBJ Architects. The $25,832,089 project was completed on schedule in just 13 months—thanks in a big way to the ability to build much of the design off-site.