Beyond the Build: High-quality construction is about patient care and treatment

At the University of Kentucky’s Markey Cancer Center, there is no better phrase then “cancer free and finished with treatment.” Patients who receive this good news ring a large, silver bell to celebrate.  Everyone within earshot joins in this special moment alongside the patient with loud cheers and claps. This is one of the many ways Markey provides compassionate care to cancer patients and it’s one reason TP Mechanical was honored to have a role in the recent brachytherapy expansion project (part of an overall expansion of radiation medicine at UK Healthcare).

The project, which is a 7,000 square foot expansion, included excavation, expansion, and modification of an existing basement treatment room and waiting area space between the Markey Cancer Center and Pavilion H. It also includes installation of a new Varian linear accelerator to go with the center’s existing two. The linear accelerator (LINAC) customizes high energy x-rays or electrons to conform to a tumor’s shape and destroy cancer cells while sparing surrounding normal tissue. This state-of-the-art equipment enables Markey to provide the latest care to cancer patients and allows more patients to be seen in less time.

TP Mechanical provided all of the prefabricated plumbing and HVAC piping in the new addition, which was brought in on racks to hang all in one piece. They also installed all air handling units and duct work through the new portion of the hospital. Every aspect of the project is precisely designed around the cancer treatment equipment for maximum efficiency and highest quality patient care. Throughout the project, an  Infection Control Risk Assessment (ICRA) barrier has kept the construction area from infiltrating the existing and operational hospital space which has eliminated treatment downtime. The project is nearing 80 percent completion, with an expected completion date of June 1.

Aside from the tremendous opportunity to contribute to Kentucky’s only NCI-designated cancer center, members of the TP Mechanical team have gained much from being on this project. Recently, an older gentleman rang the big silver bell and everyone in the room and in the adjacent construction area stopped to cheer and high five in celebration of this man and his family. Dennis Warren, superintendent on the project for TP Mechanical, said, “This is why we do what we do.”

Construction Manager:

Whiting-Turner

Other Team Members:

Marillia Design & Construction

JRA Architects

Baker Concrete

Davis H. Elliot Company

TP TEAM:

Rodney Bishop, Project Manager

Dennis Warren, Superintendent

Owners Representative:

David Lockhart, Chief Radiation Therapist at the University of Kentucky Medical Center

 

 

People Make the Difference in Our Quality-Driven Fabrication Process

Producing and assembling pre-fabricated items for construction requires a smooth, streamlined process.  Unlike other shops that rely on the sole use of machinery to build pre-fab materials, the TP Mechanical Fabrication Shop is automated by people.  We build every component of our systems in the controlled environment at our 45,000 square-foot and ISO 9001:2015 certified fabrication facility. The result is enhanced quality and consistency along with accelerated construction timelines.

Our 21-member team is organized into work groups spanning three types of positions—laborers, welders and plumbers. Each technician is highly trained in the production and assembly of a specialized unit or module, securing singular focus and attention to detail at every step of the process.

Specifically, laborers are responsible for cutting pipes, cleaning fittings and all other aspects of preparing materials for the plumbers. The welders join the parts together and the plumbers build the Carrier systems, including the frame, piping and connected fixtures. Together, the team produces high quality, pre-fab products to save time and money on complex projects.

A Streamlined Process

The pre-fab team is an important part of an overall process we employ to provide high-quality equipment. When a project kicks-off, Jerry Klein, manager of the pre-fab shop and distribution center, sits down with the CAD department and the project management team to come up with a fabrication plan with a comprehensive schedule. Once the CAD drawings are completed and approved for production, they are released to the purchasing group, who orders the necessary materials.

The ordered materials then arrive at one of our two distribution centers, located in Cincinnati and Columbus, where they are confirmed and prepared for the pre-fab shop. The pre-fab team members then begin producing the components, providing on-site vacuum testing for any leaks or other issues. Once the team is confident the product is the highest quality, the components are returned to the appropriate distribution center where they can be stored in a clean, controlled environment until the installation date.

When a product leaves one of our distribution centers it is fully ready to be installed. We check for quality upfront, ensuring orders are accurate, full and delivered on-time with little jobsite disruption. It’s all part of our innovative mechanical fabrication process to provide customized solutions to every project and saves time and money on construction.

The success of our unique pre-fab process means more demand, so TP Mechanical is looking to double its current pre-fab team. After all, a dedicated and talented pre-fab team is what makes it all possible. We are currently seeking team members who enjoy variety in the workplace and working on something new each day.

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.

 

 

Design Build and Design Assist Bring Comprehensive Mechanical Solutions Full Circle

At TP Mechanical, we understand that mechanical systems can be the cause of costly ongoing building operation expenditures if they’re not well-planned and properly configured.

As a customer-driven, solutions-oriented organization, our experienced team of mechanical designers and engineers are committed to more than just fulfilling the specifications and requirements of your project. We provide comprehensive, end-to-end solutions for you, from pre-construction expertise through contracting and fabrication to the service and maintenance of your mechanical systems.

The Design Build and Design Assist difference

When you choose to use our Design Build approach, TP Mechanical handles the mechanical engineering – HVAC, fire protection and plumbing – from start to finish. We provide budgeting, cost-estimating and proposal services, system design and expert construction. Combined with our state-of-the-art fabrication process and efficient installation services, we ensure that your project will be cost-effective and on-time.

If you’re already working with outside engineering and architecture firms, you can still get the TP Mechanical advantage by utilizing our Design Assist program. We provide services in both system designs and constructability by applying our experience and expertise in construction. The result: A completed project with a reduced budget and streamlined timeline.

Using Design Build and Design Assist means:

  • Faster delivery to market
  • Reduced costs via system design and constructability
  • Enhanced coordination of integrated teams of experienced mechanical system experts
  • Minimized project risk
  • More efficient installs with state-of-the-art fabrication capabilities
  • Energy-efficient systems incorporated into designs

Innovation, expertise and excellence

Our Design Build and Design Assist teams are comprised of engineers skilled at applying speed-to-market and cost-effective mechanical engineering principles to create custom, innovative project plans that protect your interests, optimize your budget, streamline your timeline, and overcome your challenges and obstacles to meet your specific business needs. Our engineers can also apply Leadership in Energy and Environmental Design (LEED) principles to improve the energy efficiency of the project.

“We deliver the whole package when we pair our Design Build and Design Assist services with state-of-the-art fabrication capabilities,” said Matt Anderson, business development leader for TP Mechanical. “The end result is that our clients have a building that delivers outstanding performance through the entire construction process and in day-to- day operations.”

To learn more about our Design Build and Design Assist Services visit:

http://www.tpmechanical.com/groups/designbuild/

Why Fabrication is Key to Providing Comprehensive Mechanical Solutions

The TP Mechanical advantage is innovation, pure and simple. We’ve taken the mechanical fabrication concept, expanded on its capabilities and used it in ground-breaking applications that have transformed the role of mechanical systems in the commercial construction industry.

TP Mechanical is different from other contractors out there because we house a team of experienced, creative engineers and state-of-the-art software, technology and equipment all under one roof – a 45,000 square-foot, ISO-certified fabrication facility built in 2009.

In this controlled environment, we build every component with unparalleled precision. Combine that with our three distribution centers in Cincinnati, Columbus and Lexington, and we can deliver quality, accurate orders of mechanical systems ready for installation. That means your project timeline is accelerated and your jobsite is cleaner, which gets your doors open faster.

“Our fabrication operations play a role in 90% of our projects,” said Steve Blust, TP Mechanical’s Vice President of Internal Operations. “Through fabrication, we are improving project efficiency by shortening timelines, reducing waste and pre-testing systems in our ISO-certified facilities before delivery.”

Our unique mechanical fabrication capabilities will revolutionize your project by:

  • Accelerating production and installation times
  • Shortening construction timelines
  • Eliminating delays due to inclement weather and schedule conflicts
  • Reducing material waste
  • Improving safety of workers and the jobsite
  • Ensuring pricing accuracy to help you stay within budget
  • Enhancing quality and consistency with specialized work groups
  • Ensuring local code compliance with pre-tested systems before delivery
  • Bundling materials and units to enable easier transport – saving time in the field
  • Customizing solutions to every project challenge

At TP Mechanical, we know the challenges of large-scale construction projects, and we’ve solved them with our market-leading, quality-driven fabrication process.

To learn more about our innovative fabrication process and capabilities, visit http://www.tpmechanical.com/fabrication/.

Prefabrication Answers the Challenge of a Tight Timeline

University of Cincinnati High Rise
Cincinnati, Ohio

This 14-story project offered unique challenges due to a strict schedule of just 12 months. To meet the timeline, TP Mechanical utilized prefabrication – building systems and connections offsite and delivering them to the job-site for installation.

This approach allowed us to maximize production with our on-site project team and prefabricate all materials being installed on this project. The coordination between our project management team, fabrication facility and distribution center helped to make us the premier contractor for this challenge.

Learn more about this project by visiting our portfolio page on our website.

How We Expect to Build on a Successful 2017

TP Mechanical has been a leader in providing contractor services for large-scale construction projects ranging from factories to schools to hospitals since 1953.

We’ve built on this successful tradition in 2016, and we expect an even more successful future because of our safety programs, innovative thinking and technology capabilities for plumbing, HVAC and fire protection service.

Safety First, Always First

TP Mechanical has performed, as of early August, more than 2 million man-hours of work without a lost-time accident – nearly one-third the industry average. We work closely with OSHA, participating in its safety training programs and Voluntary Protection Program to reduce accidents on the jobsite.

President and CEO Bill Riddle says safety drives the TP Mechanical culture, and due to all these efforts, our 2016 safety awards include:

  • ABC | Step Platinum Award
  • ABC Employer of the Year Safety Award
  • ABC Award of Excellence for The Christ Hospital Orthopedic & Spine Mechanical Commercial $2 to $10 million
  • ABC Award of Merit for the Summit Country Day Mechanical Commercial $2 to $10 million

Innovative Thinking

TP Mechanical’s innovation and forward-thinking problem-solving are major drivers for success. “I think we’re on the cutting edge with technology and processes,” Riddle says.

One of our biggest innovations is completing almost 30 percent of our project in the regulated environment of our fabrication shop before starting work on-site. More than 60 employees staff the shop for around-the-clock operations, incorporating advanced automation technology such as automated welding machines and tracking software to ensure workflow is managed smoothly.

A Bright Future

TP Mechanical will continue implementing technologies, such as BIM for rendering projects in a 3-D model. Riddle believes TP Mechanical will continue to find success with a focus on innovation and a dedication to safety, “I believe that over the next couple of years we should experience continuous growth in our industry.”

We look forward to sharing that success with you in 2017 and beyond; please Contact Us for your next project.

How Can ISO 9001:2008 Certification Benefit Your Company?

When you see that a company is certified as conforming to the ISO 9001:2008 Standards, you can count on this: The company’s production processes meet established international standards for quality. That may help you, as a customer, satisfy your legal or contractual requirements and ensures you’re working with an organization that places a high priority on quality.

To achieve certification of conformity to the ISO 9001:2008 Standards companies must demonstrate that they can meet regulatory requirements and apply a Quality Management System effectively. At TP Mechanical, we believe in reducing costs, increasing customer satisfaction – all of which are part of our Quality Management System.

TP Mechanical: ISO 9001:2008

TP Mechanical has a registered ISO 9001:2008 certification of conformity for our Quality Management System. We earned our registration for “prefabrication of components for the purpose of fast-track construction in the piping and mechanical plumbing fields.”

As a mechanical contractor specializing in large commercial construction projects, TP Mechanical utilizes prefabrication to reduce construction costs and shorten schedules while decreasing waste and scrap. By doing more work in the shop – in a controlled, dedicated facility – we also enhance safety d achieve higher quality for the projects we complete on the job site.

Benefits of ISO 9001:2008

TP Mechanical’s conformity to the ISO 9001:2008 Standards allows us to support your organization by delivering the results you want and expect. Our Quality Management System benefits your company by:

  • Improving quality and service
  • Reducing the amount of on-site work
  • Providing on-time delivery
  • Fostering a get it right the first time attitude
  • Reducing mistakes, change orders and defects

For more information

To learn more about what the TP Mechanical team can accomplish on your next project, click here.

TP MECHANICAL REDUCES JOB SITE WASTE WITH PREFABRICATION

The TP Mechanical Fabrication team is helping our customers gain significant benefits for their construction projects through prefabrication. With the aid of our innovative shop fabrication processes, we are able to substantially reduce job site waste.

It’s common to see the amount of unused material and scrap increase throughout a project during traditional construction and on-site fabrication. By moving as much of the construction process indoors into our 45,000 square-foot, ISO-certified fabrication facility, we remove a lot of that waste from the actual job site.

CADWith the aid of highly trained employees at each assembly station and our investment in automated equipment, we can ensure consistency and quality in every cut and weld. Additionally, with state-of-the-art BIM and CAD technologies, 2D and 3D highly customized designs are used to optimize waste reduction.

With these congruent factors, along with our fabrication process occurring in a controlled manufacturing environment, TP Mechanical produces higher quality units with fewer rejected assemblies while ensuring productivity is maximized and material waste is kept at a minimum.

At TP Mechanical, our recycling programs are designed to keep as much of the packaging and scrap raw material out of the landfill as possible – reusing what we can and properly recycling what we can’t.

According to a recent SmartMarket report released by McGraw-Hill Construction, more than 800 architecture, engineering and contracting professionals were surveyed and 77% said that construction site waste is decreased by utilizing new prefabrication construction techniques. More than 60% of the same professionals reported that prefabrication shortened project schedules and reduced budgets.

“These reported productivity benefits of prefabrication and modularization are particularly exciting in today’s economy, given the benefits of creating superior buildings while saving cost, time and waste,” said Harvey Bernstein, Vice President of Industry Insights and Alliances at McGraw-Hill Construction.

For project leaders looking to save cost, improve their schedule and reduce the impact to the environment, fabrication is a critical component to consider in any construction process, and TP Mechanical has invested in the resources and expertise to provide superior fabrication services for our customers.

More Information

Learn more about TP Mechanical’s Fabrication process on our website.