Boiler Replacement Design

Confidential Client - Data Center

New York

SSM prepared construction documents for the installation of a dual fuel 1,200 HP boiler to replace a 67 year old water tube boiler. The new boiler will provide a better energy efficiency and turndown ratio for off-peak conditions. The project included replacement of two 75,000 lb/hr deaerators with custom deaerators that could be modified to fit the available space.

SSM utilized high definition laser scanning to document existing conditions in the 3 level boiler building. SSM mechanical engineers prepared a detailed flow diagram of existing piping and instrumentation.

The structural scope included design of a boiler access platform, roof modifications for the new stack, and structural support of the economizer located on the third floor. The existing steel was detailed using 3D laser scanning and field measurements to identify scope of removal and replacement of deaerators located on the third floor.

The electrical design included power, instrumentation, and controls. SSM electrical engineers provided a short circuit analysis and breaker coordination study for replacement power systems. The instrumentation and controls was designed to integrate with owners legacy building management system while maintaining owners preferred boiler combustion controls, boiler water level controller, valves, and sensors.

Energy Audit and Systems Design

Children’s Beach House

Delaware

The Children’s Beach House is an approximate 20,000 square foot, two story facility that holds summer and weekend camps for children with communicative disabilities and other special needs.

SSM conducted a survey and performed an energy audit of the existing facility in 2010 and suggested several no cost and low cost strategies for saving energy as well as some capital improvement project that would have an impact on energy efficiency. In 2011 SSM expanded the energy audit to further investigate other energy saving strategies such as converting the existing heat pump system to a geothermal heat pump system, installing a wind turbine power generator, and installing a PV solar array.

After implementation of several energy conservation measures, SSM again was asked to evaluate more energy saving strategies for the facility with the consideration that the existing mechanical equipment was reaching the end of its useful life. SSM performed a life cycle cost analysis of the HVAC systems to compare replacement in kind with a geothermal heat pump system and a variable refrigerant system (VRF). The VRF system offered the lowest overall lifecycle cost and was recommended to the client. SSM is assisting the Children’s Beach house in completion of grant applications to fund the project and will design the HVAC renovation.

Building Conversion | Mansfield University

Foor and Associates Architects

Mansfield, PA

Mansfield University

Study and preliminary design for the conversion of a 2,400 square foot lecture hall into three separate functional spaces by the installation of moveable partitions. HVAC and electrical systems needed to be reconfigured to function as three individual zones. SSM performed a survey of existing HVAC and electrical systems, determined how to modify these system to support the new architectural layout for the space, and estimated the cost of construction for the renovations. SSM also evaluated the existing structure to determine if it could support the proposed moveable partitions.

Structural Assessment for Coal Breaker Reconstruction/Stabilization

ECKLEY MINER'S VILLAGE

Pennsylvania Historical and Museum Commission

Eckley Miner’s Village, Weatherly, PA

SSM's structural engineers assessed the existing condition of the timber-framed structure and provided engineering analysis and design to replace or reconstruct a portion of the coal breaker, called the tipple. (A tipple is a structure used at a mine to load the extracted product (e.g., coal, ores) for transport, typically into railroad hopper cars). SSM provided detailed structural designs, technical specifications, STAAD models for the tipple frame for the breaker and for the pole structure. In addition we provided construction services.

Founded in 1854, Eckley is an example of a planned nineteenth century coal mining town. It is a community, or coal “patch town,” which provided mining families with the basic necessities such as housing and medical care, as well as basic amenities like a store, a school and churches. Companies often designed and constructed industrial communities to house their employees in close proximity to the collieries, or mining operations, for which they worked. Such mining towns were built to attract other mining families to live and work among the coal fields of northeastern Pennsylvania. While the company greatly influenced the lives of its village residents, and each family member faced challenges and difficulties every day. The way in which they faced these challenges is the history of the region that is studied, preserved and interpreted.

Since 1970, Eckley has been owned and operated as a museum by the Pennsylvania Historical and Museum Commission. The Molly Maguires a 1970 film was filmed in Eckley in 1969. The wooden "coal breaker" featured heavily in the film. The filming of the movie resulted in the town's being saved from demolition, and it was afterward turned into a mining museum under the control of the Pennsylvania Historical and Museum Commission.

High Definition Scanning and AutoCAD Modeling

BRYN MAWR PRESBYTERIAN CHURCH | EXTERIOR SCAN

CVM Engineers

Bryn Mawr, Pennsylvania

SSM utilized high definition laser scanning equipment and software to quickly and accurately capture the existing facade conditions of the church’s 150-foot bell tower. These services were employed to enable the project team to understand the design the displacements of the masonry elements in a 3‑D environment to ascertain structural conditions. The AutoCad elevations and sections and accompanying point cloud allows the team and owner to design and then view the existing conditions and effects of any proposed repairs.

SSM delivered the following:

• Elevation of each side of the tower portion of the church delivered as a 2D Autocad drawing. The portion of the tower, from the parapet base to the top of highest point was highly detailed to show cast stone ornamentation and the location of each of the stones in the aforementioned portion and include general geometry for the balance of the tower (to ground level). SSM documented planar distortion to indicate how far the top portion of the tower as well as the parapet walls may be leaning.

• Leica Tru-View of each scanner position. Leica Tru-View is a free web-based tool allowing the user to view the point cloud and field photography together, to easily and quickly “re-visit” the scanned areas of the building. Tasks such as panning, zooming, acquiring measurements and mark-up tools are all functions of the Leica Tru-View Software.

HIGHLIGHT: The 11 scans were performed in 1 day.  

Structural Engineering for Adaptive Residential Reuse of Former School

AFTER: DUFFY SCHOOL APARTMENTS ADDITION

Kramer Marks Architects | Duffy School Apartments

Florence, New Jersey

When the Marcella L. Duffy School was established as Florence School No. 1 in the 1870s, the four-classroom building was the first public school in the community.  Located in Florence, New Jersey, this project involved the development of 53 units of affordable, senior housing.  The original 1870s school building required substantial on-site inspection during construction.  A three-story wood framed addition extended the building.

The project emphasized the adaptive reuse and rehabilitation of the Duffy School into an apartment building featuring historic renovation / revitalization of the former school, completed in 1924, plus new amenities for today's lifestyle.  The sustainable design features of this project satisfy the standards of New Jersey’s ENERGY Efficient Homes and USGBC LEED© for Homes programs.

BEFORE: DUFFY SCHOOL APARTMENTS

AFTER: DUFFY SCHOOL APARTMENTS

Structural Engineering for Adaptive Residential Reuse of Factory

BEFORE | Union Pants Mfg. Co.

Kramer Marks Architects | Mission First Housing

Bordentown, New Jersey

This project involved the development of 48 units of affordable, senior housing. The project features the adaptive reuse and rehabilitation of the former Eagle Shirt Company factory (aka Union Pants Mfg. Co.) into 21 one-bedroom apartments, and the new construction of an addition for 27 one-bedroom aparments. The building required substantial repairs due to fire damage and foundation subsidence. The three-story wood framed addition nearly doubled the footprint of the original building.Five of the 48 units will provide supportive housing or veterans. The sustainable design features of this project satisfy the standards of New Jersey's ENERGY Efficient homes and USGBC LEED for Homes programs.

BEFORE | Union Pants Mfg. Co.

Structural Engineering for Adaptive Residential Reuse of Social Center

AFTER: ALICIAN SENIOR APARTMENTS

Alician Senior Apartments

Kramer Marks Architects

Upper Darby, Pennsylvania

Assessment of a 1950s Social Center for re-use as apartments. Extensive documentation and evaluation of the existing clear-span steel and concrete structure required for addition of new level.  New construction included the added wood-framed floor and roof, infill of the original mezzanine level and full height elevator core.  In addition to structural engineering, the project included preparation of drawings, specifications, submittal reviews and construction oversight.

Originally utilized by the adjacent school as a gymnasium and hall, St. Alice’s was a popular gathering place for teens and young adults for dancing, roller skating, bingo and big band nights.  Located in Upper Darby, Pennsylvania, this project involved the development of 53 units of affordable, senior housing.  The project features the adaptive reuse and rehabilitation of the original ground floor and original second floor. The original first floor mezzanine overlooking the gymnasium was filled in to complete the level.  The original roof structure was reinforced and repurposed to become the new fifth floor, while adding a new roof structure.

BEFORE: St. Alice's

Multi-Discipline Engineering for New Fitness Center

GATEWAY MOTION AND FITNESS

Gateway Motion and Fitness

Lewes, Delaware

Spotts, Stevens and McCoy has been engaged with the Owners of Midway Fitness since 2012, performing a building energy audit, expansion feasibility projects for their existing facility located in Rehoboth DE. After their decision to relocate, SSM was engaged to provide due diligence and concept planning for alternate sites with existing structures and ultimately, the greenfield site selected for development of a new facility, Gateway Motion and Fitness. Due diligence and concept planning included site and civil engineering, and multi-disciplinary building systems.

SSM is partnered with Ambit Architecture to provide professional services to develop new building design from Programming through Construction Documentation and has been further engaged as the Owner’s representative and Project Manager. The project is currently in Design Development Phase. Basis of Design calls for a 48,000 square foot multi-level facility with diverse programmatic needs for fitness, aquatics, physical therapy and administration.

SSM technical services include: structural design, mechanical, plumbing, fire protection and electrical design and Project Management services to coordinate the efforts of the architectural design work of Ambit Architecture, the engineering design teams and the pre-construction services of Wohlsen Construction.

Structural and Building for New Manufacturing and Warehouse Building

First Quality Non Wovens, Inc.

Quandel Construction

Hazleton, Pennsylvania

SSM provided structural engineering and building engineering for four major buildings for First Quality Nonwovens, Inc. as the structural engineering member of the Design Build team for Quandel Construction services. These projects included a Major warehouse addition in McEhlattan, Pennsylvania, two manufacturing plants in Hazelton, Pennsylvania and a paper Mill in Lock Haven, Pennsylvania. The buildings included a 70,000 square foot manufacturing plant and a 200,000 square foot warehouse and a 70,000 square foot manufacturing and warehouse building.

Ventilation Study

UNIVERSITY OF PENNSYLVANIA

UNIVERSITY OF PENNSYLVANIA

Philadelphia PA

SSM completed a study to provide options to ventilate the “attic” spaceof Weightman Hall. The space contained two air conditioners discharging hot condenser air into the space. The existing ventilation of this space was not sufficient to remove the heat leading to an increased load on the air conditioners and decrease in performance of the units which are rated at ambient temperatures of 95 deg. F. Temperatures in the attic space were believedtoexceed 120 deg. F.

SSM explored options to ventilate the space housing the air conditioners to provide a satisfactory ambient condition or modify the installation to mitigate the impact of being installed in an interior space.  SSM mechanical engineers surveyed the site and documented existing conditions including several existing and apparently abandoned duct systems in the vicinity of the air conditioners and the space in which the units are housed and the surrounding areas in sufficient detail to develop ventilation options. The final report included three options for creating a satisfactory environment for the operation of the air conditioning units and budgetary construction costs for each scenario.

Ventilation Study

QUADRANT EPP USA, INC.

Ventilation Study

Reading PA

Quadrant EPP USA, Inc. is a wholly owned subsidiary of Quadrant Plastics of Lenzburg, Switzerland.  Quadrant was founded in 1996 and has become the standard bearer for innovation with many key developments in the formulation and manufacturing of plastic materials to their credit.  Quadrant, along with its strategic partner Mitsubishi Plastics of Japan, is the global leader in the manufacturing of high performance, machinable, thermoplastic materials. In addition to being the corporate headquarters for Quadrant EPP USA, Inc; the Reading, PA facility manufactures ultra high molecular weight polyethylene, nylon, and acetal polymer finished parts and shapes. The products manufactured in Reading are used in the food processing & packaging, semiconductor, aerospace, chemical processing, life sciences, and power generation industries.

A manufacturing process used at Quadrant creates off-gassing of Caprolactam which was not captured or controlled resulting in blood level concentrations exceeding OSHA guidelines. SSM was retained by Quadrant EPP to evaluate the processes being used and recommend modifications to bring the facility into compliance. SSM documented the performance of the ventilation systems and the capture capabilities of the exhaust hoods at the process points. SSM also observed the manufacturing process and operator procedures. The outcome was recommendations for modifications to the ventilation systems and modifications to the fume capture hoods to move the fumes away from personnel and intoexhaust systems for removal. SSM then provided the design of those modifications resulting in a compliant environment.

Structural Assessment of Historical Building

Wernersville Historical Society | Wernersville Train Station

Wernersville, PA

SSM conducted a comprehensive structural condition survey of this existing historic building that has been abandoned for almost 40 years.  In addition to identifying the building components that required repairs or replacement, SSM provided a prioritized, cost-itemized list of recommendations for the ultimate restoration.

Adaptive Re-Use

KUTZTOWN TRAIN STATION

Borough of Kutztown

Train Station

Kutztown PA

SSM provided engineering for upgrades to train station that was built in approximately 1870.  The upgrades include installation of restrooms, closets, new HVAC system, as well as insulation of walls, floor, and roof.  The project also included improving the lighting, providing ADA compliant access to the building, and relocating the boarding platform.  The large freight room in one section of the structure will become a meeting room for the Borough Council.

Master Plan, Phase I Restoration and Phase II Construction Documentation

WHITE HAVEN COMMUNITY LIBRARY

FRENS & FRENS, LLC RESTORATION ARCHITECTS

White Haven Community Library

White Haven PA

The West Chester-based architectural firm of Frens and Frens, LLC was initially engaged to prepare a Master Plan to identify the feasibility of the adaptive re-use of the 1864 Lehigh Railroad Engine House for the White Haven Area Community Library. As SSM has done with several projects with the firm, we were responsible for land surveying; the assessment of the building systems including mechanical, electrical, plumbing and structural; site design issues related to zoning, stormwater management and; evaluation potential site environmental concerns.  At this stage, schematic plans were prepared to identify budget and gain community support for the conversion.

SSM continued to support the team on subsequent phases. Phase 1 has been completed and was undertaken to stabilize and improve the building’s masonry envelope and steel structure. 

Phase 2 is currently underway and includes the design for site improvements and documentation for the new building mechanical, electrical and plumbing systems. A significant effort was undertaken to identify the feasibility of utilizing alternative energy opportunities, including geothermal systems.  After identifying potential geothermal systems appropriate for the specific site geology, site design constraints and permitting our mechanical design staff worked in concert with SSM’s environmental staff to conduct a well boring and thermal conductivity testing.  SSM prepared probably cost estimates and payback.  The outcome of these efforts has led to funding of the system installation, and the project is currently out for bidding.

Ventilation Studies

NESTLE WATERS NORTH AMERICA

Nestle Waters North America

Poland Springs ME, Breinigsville PA, Zephyr Hills Florida

NWNA is a business unit of Nestlé Nestle Waters North America (NWNA) S.A. The Nestlé Waters business represents 10% of Nestlé, S.A. global sales and holds the number one leadership position for bottled water brands in the world. Nestlé Waters North America represented 36.4% ($)of the bottled water market in 2010 producing water under the brand names of Perrier, Aqua Panna, S. Pellegrino, Deer Park, Arrowhead, Ice Mountain, Ozarka, Zephyrhills, Poland Spring, re-source, and Nestle Pure Life.  SSM has worked with NWNA at several sites throughout the United States including Poland Springs ME, Breinigsville PA, and Zephyr Hills FL.

Our services have included providing ventilation studies at these three facilities to evaluate airflow, contaminant migration, and temperature control.

A key element and driver of the study at two of the facilities involved area carbon monoxide levels above the OSHA guideline. SSM performed both spot and time-history testing of carbon monoxide levels as well as space temperature and observed operating procedures within the facility.  The studies provided recommendations for modifications and additions to the ventilation systems including recommendations for ventilation control systems to achieve the desired results while minimizing energy consumption.

Subsequent projects included the design of those ventilation systems and the design of the ventilation control systems including heat recovery. 

Other projects have included the design of new ammonia chiller cooling systems, HVAC design for clean manufacturing areas, ventilation system validation, and arc flash studies and training.