Modular Passenger Station Buildings on the LIRR

Paul Johnson, Engineer – Structural Projects Long Island Rail Road 610 Hicksville Road

Bethpage, New York 11714 Tel: 516 827 4400 Fax: 516 576 3322

Modular Station Buildings on the LIRR

1. Introduction (abstract) 2. Typical LIRR Station Building Construction 3. The Modular Station Design 4. Modular Station Design Review Process 5. Modular Station Construction

• LIRR Forces • Downing Corporation

6. Modular Station Costs 7. Conclusions

8. Appendix (photos)

Abstract

The Long Island Rail Road (LIRR) is the largest commuter railroad in North America serving

275,000 customers daily. The LIRR maintains 124 stations across Long Island stretching from Penn

Station in Manhattan to Montauk on the eastern tip of Long Island.

In an effort to replace obsolete station facilities cost effectively, the concept of installing modular or

prefabricated passenger station buildings was evaluated. Utilizing LIRR Architects and Engineers and

input from manufacturers of modular buildings, the LIRR developed design drawings for the modular

station buildings. A contract plans, specifications and bid documents were put together for three (3)

modular passenger station buildings. Each station building was to be virtually identical to each other in

regard to physical size and to the features contained within each structure. The project utilized both

LIRR Engineering Department forces and third party forces to construct each modular station building.

The LIRR was responsible for the installation of the new building foundation, all building utility

connections, all station site work (curbs, sidewalks, signage). The modular building contractor was

responsible for station building fabrication, building delivery, building installation and the station

building roof installation. An abatement contractor was retained for the demolition and removal of the

existing station building that contained lead paint and asbestos. Typically each station was completed

in six (6) months; witch included all existing station building demolition. This was a significant

improvement over the old way we reconstructed stations, resulting in a saving of many months of

disruption to our valued customers. The project proved to be an ideal way to replace a passenger

station building cost effectively and expeditiously.

Typical LIRR Station Building Construction

The LIRR has been aggressively renovating and replacing station buildings throughout our system. Over

the past ten years approximately 30 station buildings have been renovated or replaced. The projects

typically fall into one of two categories: total replacement or renovation. Station buildings with

historical characteristics and/or buildings that are structurally sound are typically slated for renovation.

Structures that are structurally deficient and/or buildings that do not meet current ADA and other

building codes are typically demolished and a new station designed and constructed.

Typical station building features include: a customer waiting room with ADA compliant unisex rest

room, ticket office with ADA compliant unisex rest room & ADA ticket counter and utility rooms

(communications/information services, electrical, mechanical, passenger services). To streamline

construction and to minimize service disruptions to our valued customers, LIRR forces have

successfully utilized generic building components to standardize design and construction features. Due

to the high traffic volume in our stations and occasional vandalism, standardized station building

materials allows the LIRR to repair or replace damaged areas quickly and efficiently.

Modular Station Building Design

Following an engineering feasibility study to consider whether replacement or rehabilitation of the

Oceanside & Hewlett Stations was required, the LIRR Engineering Department determined that these

existing station buildings should be demolished and replaced with new facilities. It was concluded that

utilizing a prefabricated structure would provide the LIRR with a cost effective, high quality station

facility. The concept for the station design was to provide a passenger station that evoked a classic

railroad design with architectural features that blended with the surrounding community. The design of

the three station buildings was virtually identical to each other, and all focused on the following; cost

efficient construction, short duration, scheduled to minimize service disruption, low future maintenance

costs and a minimum 50 year useful life.

Outlined below are some of the attributes of the modular station buildings:

Station Building Rooms

• Customer waiting room

• Manned ticket office

• Unisex ADA customer restroom

• Unsex ADA ticket agent restroom

• Utility closet (stations cleaners closet)

• Electrical room

• Communications room

• Information services room (computer room)

• Boiler room

Building Components

• Building dimensions: 20 ft. x 50 ft.

• Steel stud framing

• Steel stud truss roof frames

• Structural steel framed flooring system

• 4 inch thick concrete sub floor

• 3 phase 200 amp electrical service

• HVAC system (Heating capacity: 100,000 BTUH; Cooling capacity: 60,000 BTUH)

Interior Building Finishes

• Porcelain tile flooring

• Oak wainscoting (customer waiting room)

• Corian ticket counter surface (ADA accessible)

• Bullet-Resistant ticket window glazing

• Stainless steel motorized security screens (all ticket office windows)

• Infrared controlled toilet fixtures

• Best locking system (door hardware/lock cylinders)

• Acoustical panel ceilings

• Oak benches

• Alarm system

Exterior Building Features

• Fiber-Cement lap siding (stained)

• Anderson windows (fine line w/ tilt sashes)

• Solid douglas fir doors

• Vinyl soffits

• Standing seam roofing

• High-Hat lighting

• Vinyl Shutters

• Decorative station signage

Exterior Site Features

• Concrete curbs

• Brick pavers and/or concrete sidewalks

• Basement access hatch

• Ornamental fencing and railings

• Decorative bollards

• Ticket vending machines

• Subsurface storm water runoff facilities

• Customer bulletin boards

• Perimeter lighting

Modular station Design Review Process

Our goal for the modular station building contract was to deliver a completed building that would require

little or no modifications after delivery and, more importantly, no schedule delaying change orders during

the construction phase. In order to insure that all LIRR Departments approved of all features in the

proposed station buildings, very detailed design review meetings were held at the 30, 60 & 100 percent

design level submissions. All details of each room were discussed. At each meeting all departments

(Passenger Services, Transportation, Police, Safety & Engineering) were required to sign off on every

sheet in the design drawing package and contract specifications. This process ensured that we were

getting maximum input form all LIRR user departments, which insured that the individuals working at

the station would be satisfied with the end product. More importantly, these extensive reviews avoided

potential costly change orders during the construction phase of the project.

Modular Station Construction

As stated previously, the construction of each station was a joint venture between the LIRR and the

contractor who was awarded the contract. The Downing Corporation of Rochester, New York was the

low bidder for the construction three (3) modular station buildings. The Downing Corporation had

extensive experience building several types of modular buildings, most notably classrooms, banks and

prison cells. This was the first complete railroad station building facility that The Downing Corporation

has built for any railroad.

The construction responsibilities of each partner in this project are outlined below:

LIRR Responsibilities

• Temporary station facility (trailer) set up

• Existing station building abatement (lead & asbestos)

• Existing building demolition

• Foundation installation

• Installation of all new utilities (gas, water, sewer, electric, communications)

• Foundation waterproofing

• Utility tie-ins after modular station delivery

• Installation of curbs, sidewalks, brick pavers, asphalt pavement and fencing around station building

• Installation of miscellaneous interior station components (benches, bulletin boards, timetable racks)

The Downing Corporation Responsibilities

• Fabrication of the modular station buildings

• Delivery of stations to site

• Erection/Installation of the modular station components

• Mating of the modular station components

• Roof installation

LIRR Construction Activities

Construction staging was carefully planned by the LIRR Engineering Department to cause as little

disruption as possible to commuters. All understood that in order to insure the success of the project, all

activities between the LIRR and Downing had to be closely coordinated. Prior to starting the foundation

construction at each site the LIRR reviewed and approved foundation shop drawings supplied by The

Downing Corporation.

The LIRR Bridges and Buildings Department (B&B) handled the bulk of the LIRR construction activities

associated with this project. B&B gangs set up temporary station facilities, constructed the poured –in-

place building foundations, and installed gas, water and sewer lines to the new stations. After the

modular buildings were installed, B&B completed all site work around the buildings in order to open the

stations to our customers. The LIRR Power Department installed a new 200 amp electrical service to the

stations while the LIRR Communications Department installed all communications that would be needed

in the new facility (phone, fax, intranet, P.A. system, alarms, etc.).

The Downing Corporation Construction Activities

The Downing Corporation commenced construction upon approval of their shop drawings by the LIRR.

Each station was built in two halves: one measuring eight feet by fifty feet, the other half measuring

twelve feet by 50 feet. These dimensions facilitated delivery of the units over local roadways and

allowed The Downing Corporation to quickly connect the buildings on site. The Downing Corporation’s

facility in Rochester, New York was the fabrication site for the modular sections. This indoor facility

was ideal to insure the high construction quality the LIRR was demanding on this project. LIRR

Engineers, Architects and Quality Assurance Managers visited the facility several times during the

fabrication phase to inspect all facets of the project for conformance to the plans and specifications.

Regularly scheduled progress meetings were held both in Rochester and on Long Island during the course

of the project. On site inspections were very beneficial for both the LIRR and The Downing Corporation.

Design/Construction issues were resolved quickly due to the close working relationships of both parties.

Work progressed on each station very quickly and with a high quality of workmanship. The project

schedule required that the delivery of the three stations be staggered. The first station (New Hyde Park)

was delivered in September 2002, followed by Oceanside in November 2002 and finally Hewlett in

March 2003. This staging allowed ample time for LIRR forces to complete work at the preceding station

.

Upon delivery of each station, the Downing Corporation hired a local subcontractor to install the roof

system. The roof system was comprised of galvanized steel stud trusses, plywood sheathing and standing

seam roofing. This subcontractor was also responsible for the installation of leaders and gutters.

Modular Station Costs

Each modular station was estimated to cost $1,000,000 to complete. This estimate included all costs for:

design, project management, existing station abatement and demolition, temporary station facilities,

modular building, foundation installation, utilities and all site work. Actual project costs were slightly

below the estimated costs. Outlined below are the costs for various components of the project.

Item Description Costs

Design Costs $40,000

Project Management Costs $40,000

Abatement/Demolition $30,000

Modular Building

(Downing Corporation)

$400,000

LIRR Construction Costs $490,000

Total Costs $1,000,000

Conclusions

This modular station building project succeeded in providing a state of the art passenger station for

approximately half the cost of a typical station replacement on the LIRR. Intensive planning and

coordination during the design phase resulted in a project that was completed on schedule and on budget.

This project proved that replacing existing passenger stations with prefabricated passenger stations could

be a cost-effective, time saving alternative to replace line stations on the Long Island Rail Road.

Appendix

Existing New Hyde Park Station – March 2002

Foundation at New Hyde Park – August 2002

New Hyde Park Modular Station Under Construction

At The Downing Corporation Plant in Rochester, NY

New Hyde Park Station Installation – Sept 2002

New Hyde Park Station Installation – Sept 2002

New Hyde Park Modular Station – October 2002

New Hyde Park Modular Station: Customer Waiting Room

October 2002

Oceanside Modular Station – May 2003