25,000SF Pre-Engineered Office Building Completed in 9 weeks for Holcim Cement & WGA

1. Holcim Cement
Pre-Engineered Office Building
Presented by:
Wes Villhard – Kozeny-Wagner
VP Commercial Construction
Tom Way – WGA
Senior Engineering Manager

2. Success Thru Best Practices
 Front End Planning
 Materials Management
 Team Building
 Partnering

3. Front End Planning
 Pre-Engineered Building
 Architecture & Engineering
 Mechanical / Electrical
 Interior Finish
 Project Team

4. Pre-Engineered Building
 Pre-Ordered American Metal Building
 Released without Door & Window Trim
 “In-Stock” Center Support Building
 Early Delivery in order to Build Frames During Slab Pour

5. Architecture & Engineering
 Completed Foundation Design from Pre-Engineered
Building Loads
 Ordered Rebar for Foundations before Slab Design was
Complete
 Pre-Approved Concrete Mix Design
 Allowed Two Weeks for Architectural Design

6. Mechanical / Electrical
 Ordered “In-Stock” Ground Mounted Split Systems
 Saved Engineering Time for Roof Frames
 Electrical Rough-in of Slab vs. Overhead
 Saved Two Weeks on Schedule

7. Mechanical / Electrical
 HighBay Lighting for Open Office Areas
 Reusable for Future Warehouse
 Duct Socks Reduced Field Labor
 Prefabed All Ductwork
 Installed Ductwork Prior to Roofing

8. Interior Finish
 Panelized Office Walls During Floor Slab Pours
 Install Studs Prior to Roofing
 Ordered only “In-Stock” Material
 Windows, Doors, Hardware, Toilet Partitions, Accessories, etc.
 Allowed Sealed Concrete Floors Rather than VCT or Other
Flooring
 Coordinated all Interior Work with Roof Installation
 One Side then the Other

9. Project Team
 Selected Only Subs with Available Manpower
 Past Performance “Can-do” Attitude
 Subcontractors- Foreman & Project Manager
 Kozeny-Wagner - Foreman & Project Manager
 Teamwork, Find Solutions
 Overcome Obstacles
 Go the Extra Mile

10. Week 1 – Prefab Foundation Rebar
During Building Layout

11. Week 1 – Bad Soils & Rock
Encountered

12. Week 1 – Rock Encountered

13. Week 1 – Foundations Started

14. Week 1 – PreFabed Rebar in Perimeter
Foundations

15. Week 2 – Foundation Complete and
Backfilled

16. Week 2 – Slab Rough-in, Electrical &
Plumbing

17. Week 2 – Rebar For Heavy Duty Slab,
Delivered & Installed

18. Week 3 – Slab Pour, Steel Material Deck
Delivered in the Background

19. Week 3 – Rain Pushed First Slab Pour
Late Into the Night

20. Week 3 – Second Slab Pour

21. Week 4 – Plumbing Rough-in Started
Immediately with Wall Layout

22. Week 4 – Steel Erection in Progress
Using Pre-Assembled Frames

23. Week 4 – Center Support vs Clear-Span
Steel Used for Early Delivery

24. Week 4 – Building Frame Complete

25. Week 5 – Roof Perlins Complete and
Duct Hangers In Progress

26. Week 5 – Ductwork Delivered

27. Week 5 – Plumbing Rough-In
In Progress

28. Week 5 – Ductwork & West End & Side
Wall

29. Week 5 – Exterior HVAC Units Set, Roof
Insulation & Roof Panels In Progress

30. Week 5 – Roof Insulation, Roof Panels,
Widows & Exterior Framing In Progress

31. Week 5 – Exterior View of Roof Insulation,
Window Framing & Ductwork / AC Units

32. Week 6 – Close-up of Roof Panels
In Progress

33. Week 6 – Ceiling Grid-Continuous,
Prior to Perimeter Offices

34. Week 6 – First Panelized Office

35. Week 6 – Exterior Office Framing,
Acoustical Grid, Prior to Roof Panels

36. Week 6 – Roof Insulation & Roof Panels
Continue to the Far End of the Building

37. Week 6 – One Side of Roof Complete,
Framing / MEP Rough-in In Progress

38. Week 7 – High Bay Lights Above Open
Office Areas

39. Week 7 – Roof Deck Delayed by High
Winds 1- 2 Weeks, Nearly Complete

40. Week 7 – Exterior Panes / Windows
Nearly Complete

41. Week 7 – Exterior Wall Panels Complete

42. Week 7 – Exterior Duct Work Complete,
Power On! Test & Balanced Started.

43. Week 7 – Duct Socks Installed to
Reduce Field Labor

44. Week 7 – Sheetrock and Restrooms
In Progress

45. Week 7 – Drywall / Doors / Hardware In
Progress, Preparing for Work Stations

46. Week 8 – Work Stations In Progress, Flex
Duct / Diffusers Installed, Lights / HVAC On

47. Week 8 – Painting Nearly Complete

48. Week 9 – Project Complete

49. COMPLETED IN
9 WEEKS!

50. Project Summary
 Design-Build Delivery
 Half the Time of a Typical Schedule
 32 Private Offices, 5 Conference Rooms and
90 Workstations
 Critical Path – “Fast-Track” Mode
 10-12 Hour Days
 7 Days / Week

51. Project Summary
 $240,000 in Change Orders
 $79 / Square Foot Total
 45 Normal Working Days (9 Weeks M-F)
 Less 16 Weather Days

52. Safety Award
 “On the Spot” WGA Safety
Award Given to Dan Fox of
Kozeny-Wagner.
 MSHA Award – Recognized by
the South Central Region of the
Federal Mine Safety & Health
Administration for Outstanding
Safety Compliance &
Accomplishment.

53. Success Thru Best Practices
 Front End Planning
 Materials Management
 Team Building
 Partnering

54. Thank You Project Team!
 Aschinger Electric  Zumwalt Corporation
 Bieg Plumbing Company  Wedemeyer/Cernik/Corrubia, Inc.
 Fenix Construction Company  Zahner Surveying
 Frontenac Painting, Inc.  A.F. Becker
 Grau Contracting, Inc.  CKC Woodworks, Inc.
 Jarrell Contracting  H&G Sales
 Paul Abt Flooring  St. Louis Steel Buildings
 Rednour Steel Erectors, Inc.

55. A Special Thanks to
Holcim Cement
&
WGA

56. We Build A Better Quality of Life