SMU technical presentation final to printer 04032015

Click to add title Department of Science & Technology

School of Construction April 8, 2015 Guest Lecture

Click to add title Click to add title Mark McSweeney

Born & raised in Cleveland, OH

Relocated to Columbus, OH in 1989

Cuyahoga Community College – AS Mechanical Engineering Technology

Cleveland State University – BS Mechanical Engineering

United Parcel Service (16 years): • PT Employee, Driver, Maintenance Mgr., Project Engineer

Mark of Excellence Builders – Owner (10 years)

Fabcon Precast – (11 years) • Project Manager, Regional Manager, Sales Engineer

Sales

Click to add title Click to add title

FABCON Precast Sale Organization

VP Sales & Marketing

National Accounts

Manager

National Accounts Sales Manager

Sales & Marketing Associate

Commercial Industrial Manager

Sales Engineers

Assistant Sales Engineers

Team Assistants

Institutional Sales

Assistant Sales Engineer

Corporate Marketing Manager

Block, Columns & Barrier Walls

Assistant Sales Engineer


Finding Out The - Who: – Identify the Owner & how the

building will be utilized.

– Architect/engineer

– Developer/investor

– End user/owner

– The General Contractor o In what territory/office is the GC

located?

o Design Build

o Construction Manager

o Project Manager

o Site Superintendent

o Subcontractors: Foundations, Steel Erector

• Who?

• What?

• Where?

• When?

FABCON Sales Opportunity to a Listing


New Building

– Product type

– Panel layout

– Finish

– Installation method

– Sequence

o Additional mobilizations necessary

What (New Construction)


Precast Design – Variable Widths & Thicknesses

Click to add title Click to add title Panel Sections

8” Panel Section 12” Sandwich panel section


Load bearing panels

eliminate the need for a

beam & column

structure

Panels can be free stood

prior to or set against

roof structure

Non-load bearing

panels connect to

framing system

Load Bearing or Non-Load Bearing

Click to add title Click to add title Freestanding Panels

Click to add title Click to add title Temporary Shored Panels

Click to add title Click to add title Footing Details

Click to add title Click to add title Grade Wall Connection

Click to add title Click to add title Panel-To-Panel Connections

Click to add title Click to add title Cast In Openings

Reduces field sawing &

scrap of material

Solid concrete edges

Structural support may

be required at blocked-

out openings to be

removed in the field.

Click to add title Click to add title Steel Formed Finish

Click to add title Click to add title Flat Exposed Aggregate

Click to add title Click to add title Raked – Exposed or Not Exposed

Click to add title Click to add title Uniform Ribbed

Click to add title Click to add title Random Ribbed

Click to add title Click to add title Imprinted

Click to add title Click to add title Cast in Brick

Click to add title Click to add title Sanblasted

Click to add title Click to add title Form Liner


What

Expansion on an existing

building

– Fabcon

– Other

Modification to the

existing building (Work to

Existing)

– Openings (new/infill),

panel removal

– Repair damaged panels

– Managed by designated

PM

Where

Project location

– Which production plant o Kansas o Minnesota o Ohio o Pennsylvania

Site Access

– Minimum working perimeter = 40’

– Require a surface that allows trucks, crane & lifts to operate under their own power

– Ideal traffic flow – ability to have delivery trucks drive through when bringing panels to the crane (avoid backing up)

What & Where

Click to add title Click to add title Hauling, Unloading & Lifting

Click to add title Click to add title BSA Summit Logistics Center Mt. New Hope, WV

Click to add title Click to add title CAC/LOW

Complexity Assessment Checklist

See folders

Layout Work Sheet

See folders

Click to add title Click to add title Proposal

Clearly define scope & price – Fabcon’s responsibilities

– GC’s responsibilities

– Specifics of the proposed project

– Current A&S information

o Drawing log

o Specifications

o Addenda

o Specific details


Letter of Intent

Reverse LOI

Contract

Purchase order

Information promise date

Proposal Acceptance, Project Listing Agreement


Develop opportunity, project cost & scope in an abbreviated timeframe.

– 3-day turnaround from receipt of LOW

Utilizes 3rd party resources

– Crane companies

– 3PL (hauling companies)

– Jessco – initial panel layout as basis for estimate

Consults with in-house Design Engineers to develop accurate details/design

Facilitates review of complex projects (CAC)

Estimating

Click to add title Click to add title Estimating

Custom developed the FabCost estimating program used to establish pricing/scope. – Summarizes costs:

o Production

o Installation labor

o Purchased materials

o Hauling

o Installation materials/equipment

o Crane

o Miscellaneous

FabCost = mega calculator – Maintains current costs for labor & materials

– Updates are implemented to keep costs current


Estimating

Click to add title Click to add title Questions


Hello Class…. My name is Morgan Denton

– Hometown of Minneapolis, MN

– I have lived in 15 different cities, 4 different states

touching both coasts & moved 16 times to bring me

to where I am today.

– Have an AAS in Architectural Design.

– Currently finishing up my Six Sigma Green Belt

certification.

– I am the Manager of Drafting Services for Fabcon

& have been with the company for 18 years.

Drafting/Engineering

Click to add title Click to add title FABCON Engineering Processes

Design Input

Generate Initial

Drawings

Engineering Calculations

Generating Details

Shop Drawing

Submittals

Approval Drawings Received

Incorporate Customer Changes

Final Review/Submit

Individual Production Drawings

Distribute Final Drawings

Order Materials Generate Individual

Production Drawings

Internal Drawing Review


Rolls of A&S drawings

Design Input

Gibberish on a napkin

Click to add title Click to add title Fabcon has developed

it’s own stand alone drafting software called FabCad that we use to generate our shop drawings.

The use of this software also enables Fabcon’s drawings to ‘talk’ to our Automation Systems within our plants, Inventory Control, Accounting, and many more.

Generating FABCON Shop Drawings

Click to add title Click to add title Design Calculations

Click to add title Click to add title The Details of a Project


Fabcon has hundreds of stock parts that we

use to generate our panels, some of which we

have developed & hold the patent for.

{Insert Photo for Guest Lecture}

Individual Product Materials

Click to add title Click to add title Every panel

that Fabcon produces gets it’s own drawing.

And every panel that we produce is for a specific place on a building.

Generating Production Drawings

Click to add title Click to add title To help other departments plan & increase communication,

Fabcon sends our drawings to internal contacts such as the

Plant Managers to be able to review the drawings & give any

input that they think might help in streamlining our casting

process.

Internal Drawing Review


Approved shop drawings, much like homework, never come back clean. – Changes

– Additions

– Corrections

Approved Shop Drawings


All of the Production

Drawings are double

checked & released

to the Plants for

Manufacturing.

The Number of panels

that can fit on a bed is

determined by

the length of the panels.

Submit Production Drawings

Click to add title Click to add title The final step in the Engineering & Drafting process is to

get out final shop drawings Distributed to our Field.

These are the instructions on how to take all of the parts

we are shipping to them & be able to assemble the

building.

Distribute Final Erection Drawings

Click to add title Click to add title Manufacturing


M

Casting One Pass Non-Sandwich Panels Casting Two Pass Non-Sandwich Panels Casting Sandwich Panels

Shipping

Resaw Panels

Prepare Panels for Resaw

Yarding of Panels

Stripping Panels from the Bed

Prepare Bed for Stripping

Washing Exposed

Programming the Bed

Hardware Tie-Down/Bed Inspection

Stressing Strand

Pulling Strand

Bed/Steel Preparation

Bed Layout

Prepare for Bed Layout

Patching

Click to add title Click to add title Manufacturing

Click to add title Click to add title Hallow Core vs VersaCore Technology

Click to add title Click to add title Old-New Panel

– In Fabcon’s previous manufacturing process, pea gravel occupied the panel’s interior. After the concrete cures, the panels were tilted up & emptied of gravel, which left a hollow core panel, shown on the top. The VersaCore process puts insulating Expanded Polystyrene (EPS) foam billets directly into the wet concrete, eliminating the cost of the gravel & equipment to remove it. The VersaCore™ panel, shown on the bottom, delivers the highest R-value ratings available from a concrete panel.

End Cut – VersaCore panels allow Fabcon to cast-in window & door

openings of any size. This saves time in the construction process, helps control costs & provides architects & engineers with a whole new range of aesthetic options & tools.

VersaCore


Steps 1A & 1B Steps 2A-2D Steps 3 & 4A, 4B Steps 5A-5D

VersaCore Panel Assembly


Step 1 Hollow Core

Panels allow cast-in

window & door

openings.

– Saves time

– Controls cost

– Reduces waste

– Range of aesthetic options

Step 2 Laying Concrete

Expanded Polystyrene

foam billets directly into

the wet concrete,

putting insulation in an

area traditionally left

hollow.

– Reduced shipping costs

– Flexibility of cast-in

openings.

VersaCore Assembly


Step 3

Fabcon engineers &

production supervisors

ensure location of

doors/windows match

specifications.

– VersaCore also

accommodates structural

design requests such as

pocketed connections.

Steps 4A-4B

American Concrete

Institute recommends

concrete strength of 5,000

psi for walls. Fabcon’s

significantly exceed this

with strengths of 8,000 –

11,000 psi.

Hand troweling finished

edges cure in the plant.

VersaCore Assembly


Steps 5A – 5B

Yard – since panels are custom

designed for a specific location

on the building perimeter, they

are stored in a matrix system

for easy retrieval & shipping.

Design finishes such as thin-

brick combine low

maintenance of concrete with

aesthetic appeal. Less then 1%

of the panel is caulked

compared to 20-30% of a brick

surface that is mortar.

5C-5D

Heating & cooling represent up

to 60% cost of building

operation. Fabcon’s panels

deliver an R-value up to 34.

Wide selection & combination

of finishes, textures & tints are

enhanced by architectural

forms which produce finishes

such as this 45-degree angle.

VersaCore Assembly


Brian Hamilton From Syracuse, NY – currently live in

Allentown, PA

BS in Business Management from

Clarkson University – Potsdam, NY

Marketing for United Technologies -

Carrier

Branch Rental Manager at Enterprise

Rent-A-Car

Project Manager at Ryan Homes

Project Manager at Fabcon ( 9 years in

November)

Project Management

Click to add title Click to add title Project Management

Paige, Colin & James Sully

Click to add title Click to add title Project Management

Project Management

Planning Strategy

Organization

Process

Monitoring Analysis

Development

Controls

Execution Schedule


Need a good rating (30/30)

Need an approved FAC file

– Perform FAC review

Kick-off meeting is scheduled

– PM, Drafter, Engineer, Sales Engineer, Plant

– Thank you packet is created

Customer is first contacted:

– Introduction, contact info, contract (2 weeks prior to

fabrication) shop drawing process, OFA & approved shops (2

weeks prior to delivery) FQF, delivery, caulking, sequence.

– Schedule a site meeting

The FABCON PM Process


While Shops are out: – “ABC’s”

Shops returned – Are they all approved? Do we have all stamps? R&R?

– Are there scope changes that I can get a CO for?

Sequence Field plan

– Enter field plan, adjust time per panel

– Leave out panels?

– Field plan check list

– Load list

The FABCON PM Process


Make site visit once installation has begun

Attend job site meetings

Work through any issues

– Access, field fixes, quality, fit & finish, customer

concerns, owner/architect concerns

10 & out

– The goal is to have our scope of work complete in

10 days past the last panel set

Field close out call – 10 days after last panel set

Project Management

Click to add title Click to add title Wash, Rinse, Repeat


We cannot perform our job without the help of many people:

Management + estimating

+ sales + drafting + engineering

+ production + yard + field

+ management + field crews

+ subcontractors, etc.

We all work together as a team & create some really cool buildings!

Team Collaboration

Click to add title Click to add title Progress is a Series of Small Steps

Click to add title Click to add title About Me….& About You

Professional background – 20+ years in commercial A/E/C

– Internal/External

– Integration

About you – Which program?

– What attracted you?

– Transition/skills development

S


External

Owner

Developer

End user

Architect

Engineer

Consultants

Contractor

Subcontractors

Community

stakeholders

Internal Estimators

Drafting/design

Contracting

Scheduling

Procurement

Field

Project managers

Sales/Business Development

Accounting

Quality

Safety

Who is Your Customer?

Click to add title

Developer

Owner

End-User

Building Operations Lighting/Acoustic

Designers

Logistics Consultants

Government Agencies

Fiscal Consultants

OEMs

Media

Interior Designers

Collaborators

City Officials

Fabricators

Safety Security

Industrial

Process

Engineers

Owner’s Representatives

Co-Workers BIM/REVIT

Technologists

MEP Engineers

Equipment Suppliers

Community Stakeholders

IT/Data-Comm

Lenders & Investors

Architects

Material Suppliers

Project Team Diversity & Dynamics

Click to add title Click to add title Customer Definition

A customer (sometimes known as a client, buyer, or purchaser) is the recipient of

a good, service, product, or idea, obtained from a seller, vendor, or supplier for a monetary or

other valuable consideration.

The person sitting next to you today may

be your customer tomorrow…..

And you may be theirs.

Really. Think about it.


Clients have more access to information; are more

sophisticated in their procurement process; are more

involved in overall planning & development of the project

& in some cases are becoming CMs & using multiple

prime contractors

Compressed margins

Litigious – adversarial by virtue of contractual language &

role definition

Increasing regulations

Risk of commoditization

Contractors neglecting the continuum of operational costs

& facility planning; only 8-10% of annual capital budget is

construction

Increasing Complexity & Demand

Click to add title Click to add title Increasing Complexity & Demand

“We should accept that planning, designing &

executing a building are complex processes that do

not follow strict rules & sequential procedures. On

the contrary, the processes are characterized by

unexpected zig-zags & many feed-back & feed-

forward loops.” Hans Rudolf Schalcher,

Swiss Federal Institute of Technology

Click to add title Click to add title Creating an Extraordinary Client Experience

LISTENING

Building rapport

Understanding project

goals

Setting & managing

expectations

Proactive problem solving

Celebrating milestones

Customer focus across

team

Act as an advocate &

resource for the client

Communication

Education

Responsiveness

Respect

Click to add title Click to add title Keys to Successful Team Building

Rapport with fellow team members

Understanding their skills/abilities

Mutual respect

Setting & managing expectations

Proactive problem solving

Open, fair, accepting of alternative points-of-view

Degree of experimentation & innovation

Celebrating milestones

Common courtesy

Dialogue should be constructive not divisive

Be available, accessible & responsive

Do not undermine position, skills or authority

Click to add title Click to add title Mitigating Conflict & Adversity

Remain objective

Do not personalize

Do not blame or shame

Do not triangulate

Do not take sides

Always try to solve at the immediate level without mediation from above or involving other parties

Acknowledge the view points of others

Determine/acknowledge whether there was a misunderstanding or whether there was a lack of information was given

Click to add title Click to add title Mitigating Conflict & Adversity

Confirm the goal/desired outcome going forward

Review facts

Discuss alternatives

Agree to a solution

Define action steps

Confirm parties understand outcome/action

Document & report as necessary

Do not try to solve using email & avoid telephone if possible

When discussions elevate walk away from an

argument – it will not bring resolution

Click to add title Click to add title Emerging Future Roles

If companies haven’t already, they will be….

Pre-fabrication, modularization of building components

Sophisticated field equipment

4-D real-time modeling on-site using tablets

Computer driven heavy equipment

Loss of experienced trade workers leave mentoring/training gap

Emerging materials technologies increase building efficiency

Emerging materials technologies increase building safety

Hand-held material/labor tracking devices

Developing IT as a profit center

Bridging skills gap in mathematics

LEAN construction delivery

These new roles/responsibilities require a new era of leadership. You are here

at USM to acquire technical & soft skills so that you can contribute at the level

expected & grow as business dynamics change.


Expectations – Requisite skill set

– Coachable

– Work cross-functionally

– Communication

– Group experience

– Critical thinking skills

– Ability to work toward solutions

autonomously & collaboratively

Construction the Profession

Professional is not a label you give yourself – it’s a description you hope others will apply to you. David Maister, Author


Characteristics – Humility

– Honesty

– Curiosity

– Genuine desire to achieve goals

– Customer centric

– Ability to ask for help, apologize & admit you were wrong or misjudged a situation.

– Cheer leader


People don’t care how much you know until they know how much you care. David Maister


Reality – In the trenches – a lot of responsibility &

starting out limited authority

– Monotonous/structured

– Thankless

– “Bad guy” (asking for money, telling people what to do)

– Deal with frequent controversy & discrepencies

– Many bosses



For what do you want to be remembered?

You are facing the beginning of your

career. This is an opportunity to learn not only the

skills to work in the A/E/C sector, but more

importantly who you are & what you stand for.

– Not just your skills & experience – 1/3

– How do your character, values & beliefs fit in? 1/3

– What is your style? How do you relate to others? 1/3

– What makes you stand-out?

– Why did you choose this career path?

Be Your Own Brand

SMU technical presentation final to printer 04032015

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