O&C Low Bay View Looking West Before Start of Construction
ATM CRANE REMOVED 7/5/07 Apollo Telescope Mount Building Demolition ATM 7/2/07 ATM 7/5/07 ATM 7/9/07 ATM 7/10/07 ATM 7/24/07
South Offline Area Construction Vendor Support Area Electrical Installation Vendor Support Area Floor Preparation Proof Pressure Test Room Re-Bar West Mech. Room Systems Installation
Basement Demolition In Progress Demolition Complete Basement Construction Complete Basement Transition
IOZ Systems Installation Electrical Substation Installation Electrical Distribution In Basement Air Handler Connections West Mech. Room Chilled Water Line Fabrication
At Construction Peak 22 Man-Lifts Were In Use Within The Building
Before and After View Looking East
Completed Low Bay Area Looking West
Integrated emergency lighting into high bay / low bay ceiling fixtures vs. separate fixtures on building column surfaces.
Trade revealed integrated lighting into ceiling fixtures was lowest cost, lowest contamination risk, and aesthetically best solution however column mounted fixtures were commercially available.
Integrated emergency lighting into ceiling fixtures was selected.
Added Quartz Restrike Emergency Light
Reuse existing HVAC ductwork vs. new ductwork.
Trade revealed reuse of existing ductwork was lowest cost but risk was high to clean the ductwork, adapt to modern clean room air flow protocol and energy efficiency due to ductwork location above ceiling.
New ductwork was selected even though higher in cost risk was the over-riding factor. Retrospect – Correct decision was made as existing ductwork was grossly contaminated and contained asbestos mastic.
New Duct Section Inspection Old Duct Work Removal
Two Bridge Cranes vs. relocation of planned crane from High Bay rails to Low Bay rails.
Crane originally baselined to be installed on High Bay rails to support altitude chamber access.
Crane design for high rails was 80% +.
Crane on low rails provided usability full length of building rather than high bay area. Manufacturing concept of operations required crane full length of factory. Second crane was requirement.
Evaluated vehicle clearance to install on K-Mag transporter – hook height if crane was on low rails was acceptable.
Altitude Chamber requirement not mature for crane support at chambers.
Trade revealed best cost and schedule result was to move planned crane to low rails.
New Bridge Crane on Low Rails
Refurbishment Room vs. Air Lock
Baseline concept has separate “building” within the low bay area to host post launch vehicle tear down and preparation for refurbishment.
Evaluation of manufacturing area revealed an air-lock area that could be used as large item receiving and refurbishment was a better use of building space.
Trade revealed air lock was substantially lower in cost than the separate refurbishment building and greatly enhanced production operations.
Air Lock Wall Installation complete Air Lock Wall Steel Erection
HVAC Air Handlers Redundancy
Facility requirement to have “plus one” air handler to support down time on any air handler
Baseline requirement required four recirculating air handlers and two outside air handlers.
Detailed study revealed minimal risk to facility and spacecraft should one recirculating air handler go down and not have redundant backup.
Decision as a cost savings measure to not procure / install the fourth recirculation air handler however location for the unit to be reserved and systems to be adaptable to a later addition.
Commissioning of the HVAC system which included failure modes confirmed no need for the redundant air handler.
HVAC Air Handlers
Design specified HVAC air handler model and vendor. Quotes from vendor revealed cost over $1.4M for the five required units.
Team optimized design to generic performance specification to promote competition between suppliers for cost reduction.
Cost savings exceeded $800K by competing and selecting other qualified vendor.
New Trane Outside Air Handler New Trane Recirculation Air Handler
Electrical and Communications Systems Distribution
Design had all power and communication distribution in conduit. Design limited future expandability, had complex conduit routing, high cost.
Team optimized power and communications to install in cable trays.
Installation time and material significantly reduced but cable for tray use was more expensive; net reduction in cost revealed. Future growth capability greatly enhanced.
Basement Power And Comm. Distribution Power Distribution In Substation Room
Substation Primary Transformers
Design requirements specified oil filled transformers. Vendor quotes revealed higher cost and longer lead time than dry wound transformers. Dry wound transformers operate at higher temperatures, and have lower output ratings.
Load study revealed dry transformers will adequately support IOZ and have suitable reserve with cooling fan option installed.
Cost savings exceeded $100K by selecting dry wound transformers.
Completed substation Installation New Dry Wound Transformers
Craft 4 Day Work Week
Establishing Craft 4 day work week enabled flexibility at non-overtime rates to accommodate astronaut quiet times, weekend required work and other external limiting influences.
Cost estimates for ESD flooring greatly exceeded budget allocated for floor.
Team challenged requirement for ESD flooring and revealed no vehicle or program requirement existed for the capability. Revised FDC requirement and specifications to delete the ESD capability. Estimated cost avoidance is $300K
Proof Pressure Test Room Design
Initial design revealed Pressure Test Room to fully contain pressure and shock wave. Wall, ceiling, and door size was very large and exceeded budget allocation.
Team conceptualized a pressure relief capability by having a frangible wall to the building exterior. Concept was analyzed and deemed an acceptable solution.
The optimized design maintained budget allocation for the structure.
Proof Pressure Test Room Installation
Concrete placement for the Pressure Test Room using standard mixes required removal of the existing building’s roof.
Team researched, tested, and approved a special concrete mix that could flow into confined areas without personnel access and settling vibration.
The material selection allowed placement with removal of the roof structure revealing a cost savings of over $100K and schedule mitigation of over two months.
High Bay and Low Bay Ceiling Material
Design required standard gypsum board 5/8 inch thick. Roof water leakage was apparent and occurring when schedule mandated installation of the ceiling material. Questions on table as to the suitability of existing ceiling suspension system for holding weight of the gypsum board.
Team revised gypsum board to ½ inch thick and water resistant fiberglass backing rather than paper backing.
Water leaks continued for a year after ceiling installation; due to the revised material selection no gypsum board was required to be replaced.
Reduction of material thickness reduced overall ceiling weight and enabled utilization of existing suspension system without modification.
Building Automation System (BAS)
Design established sole source procurement to match SSPF, MPPF, and other building Andover based HVAC control systems. Andover based system cost higher than anticipated and budgeted.
Team revised specification to generic requirements enabling competition between vendors. Revised requirements included interface to existing Andover based infrastructure.
Acquisition of the BAS came within budget limitations.
System Control and Monitor Console Andover Interface
Fire Detection System
Design established 23 Advanced Smoke Detection System (ASDS) zones throughout the IOZ. Budget would be exceeded implementing 23 ASDS systems.
Team challenged design and established operational logic to reduce to 8 zones. AHJ concurred with the 8 zone concept. Design was revised to the desired 8 zones.
Installed Fire Detection system came within budget limitations and will reveal substantially lower recurring cost.
ASDS Monitor Console ASDS Sense Tubes ASDS Sensor Modules
Design required elevators 9 (West) and 11(integration cell) to be rated for personnel use. Elevator 9 was to be rated for a 30K pound lifting capability. Significant cost and infrastructure is added when elevators are “man rated” rather than used only for material.
Team challenged requirement to man rate and found no need for personnel to ride on the elevators. Orion had no requirement to maintain a 30K pound lifting capability. Specification was revised to delete the man rating and reduce lifting capability to 15K pounds.
Original specification pricing greatly exceeded available budget; revised requirements enabled installation within budget limitiation.
West Material Lift East Material Lift
HVAC Ductwork installation and insulating.
Design required rectangular ductwork for supply air with field installed insulation. Duct work cost, field application of insulation, and validation did not support cost and schedule model.
Team revised engineering to provide prefabricated dual wall insulated round ductwork. Field work was offset to factory work allowing benefits in cost and schedule. Savings of $60K.
Duct Penetration From West East Room Supply Duct Along North Wall
GN2 / GHE high pressure gas storage
Original concept and baseline reutilized existing O&C tank farm for high pressure gas storage. Evaluation of the existing tanks revealed in poor condition and out of certification. Cost and risk was elevated.
Performed commodity use study which revealed the validation vehicle manufacturing and testing could be completed using portable tube bank supplies.
Revised engineering to provide connections to tube banks yet maintain growth capability to reconnect to refurbished tank farm in future.
Handrails for Integration Cell
Team located useable aluminum hand rails at the LC-40 MST. MST was being taken down and hand rail became available.
Recovered Aluminum hand rail salvaged from the Titan IV program was used for railing at the O&C IOZ integration cell saving approximately $20K.
O&C Salvage Management
Team established and implemented a program to reinvest scrap recovery value. And minimize impact on landfill
359 Dumpster Loads
1,550 Tons of Material
238 Tons of Hazardous Materials
660 Tons of Recycled Material
43% of dispositioned material diverted from local landfills
Recycled material earned $300,000 that was re-invested into the project .
Asbestos in Ceiling Gypsum
IOZ ceilings were in poor shape. Sampling prior to repair revealed asbestos in taping compound used during original installation.
Could not qualify drywall contractor to work on asbestos containing materials and could not find asbestos mitigating contractor to work on drywall.
Resolved to remove entire 50,000 square feet of ceiling material and replace with new. Retrospect – ended up being the right decision as continuing roof water leaks would have demanded significant additional removal and replacement. New material used was resistant to water.
Use of Mobile Platform and Aerial Lift to perform Asbestos Ceiling Demolition New Ceiling Gypsum Installation Ceiling Installed Ceiling Access
Wall Paint Did Not Adhere to Wall Substrate
Existing paint installed in 1960’s changed chemically and would not allow overcoat to adhere.
Coatings required removal and were classified as Health Hazard.
Access to remove was at heights and awkward locations
Removed coatings required controlled containment and disposal as Hazardous Waste
Utilized high pressure water blast system for removal in general areas and needle gun mechanical removal in tight places.
Provided on site used water containment.
Equipment provided 30,000 psig water for blasting.
Performed work on second shift to minimize hazards and impact to other ongoing efforts.
Approximately 62,000 Square feet required removal on main floor
Approximately 24,000 Square feet required removal on basement walls.
“ Spaghetti Pot” Tool Used for Main Floor Walls Blast Wand Used for Basement Walls
2007 – 2008 Holiday Outage
Outage required to retrofit and tie in IOZ water and power systems; complex scope of work.
Much of O&C building would be affected including Astronaut Crew Quarters
STS-122 launch preparations planned during outage period. Many coordinating meeting held with NASA Sr. Management.
Used alternant methods to safe systems so work could advance before the outage window.
Outage completed one day ahead of schedule; no issues.
Line Stops Medium Voltage Pot Heads Terminated with New Conductor IOZ Isolation Pipe Spools Installed in Main Chilled Water Lines
High Bay Light fixtures
Specified high bay and low bay light fixtures were not UL compliant.
Further research into the fixture revealed significant manufacturing defects (wiring, glass lens installation)
Manufacturer was not responsive to provide corrective action
HPCC, MilCon, and LM provided all corrective action and obtained third party UL certification.
LM maintained AHJ current with all information and status.
Effort was accomplished within budget limitations and implemented without impact to ongoing manufacturing operations.
Refurbishment of Fixtures Staged Ready for Reinstallation UL Compliance Notification
All concrete anchors required to be cut minimum ½” below surface.
Visible concrete anchors (priced and scheduled in baseline) ended up being only 25% of total found when existing flooring was ground off; over 5000 concrete anchors needed removal.
Integrated removal effort as off shift activity during flooring removal activities.
Effort was accomplished without impact to overall project schedule and within budget limitations.
Locating Concrete Anchors Removing Anchors Anchors in South Offline Areas
Floor leakage in basement
Significant effort required to seal cracks in building concrete below ground water level.
New crack appeared after work was complete allowing ground water leakage into basement.
Crack location ends up being coincident with the building’s expansion joint.
Engaged A&E’s to establish corrective action as an expansion joint.
Implemented joint design. No further leakage evident.
Effort was accomplished within budget and schedule limitations.
Column Line 9 Crack Expansion Joint Placement
Vertical Bay Doors
Minimal work baselined on East and West vertical bay doors.
Deeper investigation revealed significant defects and degeneration in the doors and supporting systems. Substantial effort required to replace pneumatics, control system, seals, counterweights, cables, and drive systems.
Overall door retrofit effort split between baseline and follow-on scopes.
Door retrofit effort completed within schedule and budget limitations.
Counterweight Corrosion Repair Door Operator Drive Shives Cable Reels
Emergency Lighting system compatibility with emergency generator.
Existing O&C emergency power generator’s grounding system not compliant with current code requirements.
To be compliant with IOZ electrical effort isolating transformer and supporting equipment required.
Additional equipment, installation, and testing accommodated within budget and schedule baseline.
Tropical Storm Fay (August 2008)
Halted construction activity 5 days
Significant water leakage into building
4 week recovery to nominal construction activities
Delayed project baseline completion 4 weeks.
Schedule impacts did not affect Orion manufacturing effort
Cost impacts were within budget limitations.
Rainwater drain piping
Investigation revealed most of roof water leakage was from the rain water drain piping above the high bay and low bay ceilings.
NASA Orion program provided additional funding to replace all of the rain water drain leaders.
Effort was accomplished within schedule limitations. Minor issue with scupper liners requiring replacement twice.