John Sealy Hospital Facade Modernization

Title: John Sealy Hospital Facade Modernization

Award Category: Exterior Wall

Project Address/Location

712 Texas Ave

Galveston, TX 77550
United States

Submitted By: Benjamin Scales

Company Info

Zero/Six Consulting

1027 Tremont Street

Galveston, TX 77550
United States

18582129243

[email protected]

Project Description and Background: The John Sealy Hospital Façade modernization project was a challenging project as we were retrofitting a new facade onto an existing 220,000 square foot concrete structure. The exterior skin replacement included removing the entire brick façade and replacing it with a new brick skin and replacement of all exterior windows. The facility remained serving the public as a hospital/medical School/ER and level 1 trauma center throughout the duration of the project. Throughout the construction process many unforeseen conditions were uncovered where the original 1970s construction was not up to today’s standards regarding quality and meeting the current construction codes. Additionally, significant variations in the existing construction tolerances made retrofitting the new façade onto the old concrete structure to be quite a challenge. Zero/Six provided a constant site presence which vastly assisted the contractor staff with prompt responses to unique building transitions that were uncovered during the demolition process. During the construction process a multitude of RFIs resulting in change orders, required extensive review to ensure conveyed costs were accurate, reasonable, and warranted. Unanticipated construction costs can certainly ignite conflict between the owner and construction contractors. Zero/Six acted as a mediator between the owner, contractors, and designers to verify the accuracy of envelope related change orders and offered a timely professional opinion to ensure a quick resolution. Lessons Learned: Mediation and Collaboration with verification, when conflicts arise, we facilitate a collaborative approach by involving both our project management team and the Contractor's representative in joint problem-solving sessions. Zero/Six verifies all information thoroughly to provide our clients with up to date, technically sound, proactive solutions.

Scope: Zero/Six Consulting provided a comprehensive drawing review, extensive onsite quality control and quality assurance inspections during the construction process. Our onsite field staff observed all aspects of the exterior renovation, beginning with the surgical removal of the existing problematic brick façade. Various repairs to the substrate were required as well as the installation of new HSS tube steel back up and cold formed metal framed walls, a new waterproofing system (and sheathing where applicable), and the exterior recladding with the new brick veneer, modern curtain wall systems, and sleek architectural metal panels. Daily reporting and daily deficiency log upkeep were shared with construction team. Zero/Six performed ANAB accredited field testing for air infiltration (per ASTM E783) and static pressure water infiltration testing (per ASTM E1105) during on site mobilizations. Offsite, a 20ft x 40ft performance assurance mock-up was constructed, consisting of the steel/concrete frame, curtain wall system, light gauge metal framing, gypsum sheathing and waterproofing system. The performance mock-up was vigorously tested to the ASTM-E331 standard. The journey through this project was not without its difficulties. Unanticipated construction costs often spark disputes between the property owner and construction contractors. In these situations, Zero/Six emerged as a crucial mediator. We bridged the gap between the owner and the contractor, validating the accuracy of the change orders and offering our timely, professional opinion to expedite resolutions. This role was pivotal in maintaining project momentum and ensuring all parties remained aligned with the project's goals. Our approach to conflict resolution is based on the consultant’s role of trusted advisor and is grounded in mediation and collaboration, backed by rigorous verification. When disputes arise, we champion a collaborative method, bringing together our project management team and the contractor's representatives for joint problem-solving sessions. This approach not only resolves conflicts efficiently but also fosters a spirit of teamwork and mutual understanding. At Zero/Six, we pride ourselves on our commitment to providing technically sound, proactive solutions. Our expertise lies in verifying all information thoroughly, thereby equipping our clients with the most current and reliable data to make informed decisions. Our experience with the John Sealy Hospital Facade modernization project highlights our dedication to navigating the complexities of building consultancy with skill, precision, and a collaborative spirit.

Solution: The John Sealy Hospital facade modernization is a shining example of how innovation and thorough planning can revolutionize construction management. This project, enriched with Building Enclosure Commissioning (BECx) activities, stands out for its systematic and advanced approach, spanning from the early planning stages to the final touches. During the pre-construction phase, our commitment to quality construction is evident in the meticulous review of the Owner's Project Requirements (OPR), ensuring everything is up to par with weather resistance and sustainable materials. During the pre-construction phase, the BECx consultant team meticulously went over every plan and specification, marking up (or 'red-lining') documents wherever necessary. This rigorous process played a crucial role in catching potential issues, saving time and money that might have been lost to unforeseen changes or delays later on. Advanced testing methods were another highlight of this project. Think of these as the construction world's equivalent of a thorough health check-up, involving ASTM tests for air infiltration, water penetration, and structural load. These tests weren't just for show; they ensured that every component of the building was performing up to the mark. Mock-up construction was a game-changer in our quality assurance strategy. By building and testing a scaled-down version of the construction, the team could identify and address any issues before they became costly problems. This step was key in guaranteeing the delivery of a high-quality facility. The BECx consultant team provided comprehensive field reports, complete with photos, sketches, and diagrams. These were indispensable in quickly spotting and addressing any construction hiccups. Teamwork was at the heart of this project. Whenever Zero/Six flagged an issue, the team logged it and collaboratively worked towards the solution. This approach was vital in keeping everything running smoothly and staying true to the original design vision. The project also included extensive functional performance testing in its acceptance phase. Testing included - curtain walls to air barriers - ensuring each part of the building enclosure was to standard. This assured the building's long-term performance and durability goals were being met. Aesthetics and functionality went hand in hand in this project. The project team struck the perfect balance, the completed facility not only adhered to the desired aesthetic but also performed at the highest level, meeting the Owner's Project Requirements (OPR). As the project evolved, solutions followed, the Zero/Six team consistently reviewed, tested, and observed, while making informed adjustments based on real-world/real-time insights. This adaptability significantly enhanced the project's effectiveness and the overall efficiency of the construction team. In summary, the BECx activities in the John Sealy Hospital facade modernization project set a new standard in construction. With its focus on sustainability, rigorous testing, teamwork, and a balanced approach to design and function, this project is a textbook example of how meticulous planning and execution can lead to exceptional outcomes in construction.

Value: The involvement of a consultant, specifically Zero/Six, in this project, played a crucial role in the success of the John Sealy Hospital Facade modernization project. Our contribution was significant in various aspects, particularly in handling the challenges that arose due to the discrepancies between the original 1970s construction and current construction codes. The following highlight some of our greatest contributions. 1. Mediation and Conflict Resolution: The project faced numerous unforeseen conditions that resulted in multiple change orders, which is a common source of conflict between the owner and construction contractors. Zero/Six acted as a mediator in these situations. Our ability to step in, verify the accuracy of change orders, and offer professional opinions expedited resolutions. This mediation was critical in maintaining a smooth workflow and preventing prolonged disputes, which could have led to delays and increased costs. 2. Expert Verification and Review: Zero/Six's involvement ensured that all additional costs and changes were thoroughly reviewed and justified. Our expertise in verifying the conveyed costs and the necessity of the change orders safeguarded the project from potential overcharging and unnecessary modifications. This level of scrutiny added a layer of financial security for the project, ensuring that every additional expense was essential and correctly priced. 3. Collaboration and Shared Problem-Solving: One of the key lessons learned from the project was the importance of collaboration and shared problem-solving. Zero/Six facilitated this by bringing together the Zero/Six project management team and the contractor's representatives. This collaborative approach not only helped in resolving conflicts but also fostered a more cohesive working environment. It ensured that solutions were reached with the consensus and understanding of all parties involved. 4. Providing Technically Sound, Proactive Solutions: Zero/Six's involvement was not just about managing conflicts; it was also about contributing technically sound and proactive solutions. By staying up to date and thoroughly verifying all information, we were able to provide the client with reliable advice and innovative solutions. This proactive approach helped in mitigating issues before they became major problems, saving time, budget, and resources. 5. Importance of IIBEC Member(s) Involvement: The involvement of IIBEC qualified members brought a high level of professionalism and industry-standard expertise to the project. IIBEC members are known for their specialized knowledge in building enclosures, which was particularly relevant in this facade modernization project. Our expertise ensures that the building enclosure work is up to the latest standards and best practices, which is crucial for the longevity and functionality of a facility. In conclusion, the involvement of Zero/Six, as a consultant and IIBEC member, added significant value to the John Sealy Hospital Facade modernization project. Our role in mediation, expert verification, collaboration, and providing sound solutions was instrumental in navigating the challenges of retrofitting a new facade onto an older structure and ensuring the project's success.

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Additional Info: This project had more than one contractor and architect. The submission form does not allow for multiple entries. If detailed information is required, a separate form with the contact information will be provided. This submission would not be possible without the help of Zach Johnson the onsite Zero/Six project manager and Zero/Six Senior Vice President Nicole Gavin