Plumbing Owners` Forum Presentation – June 2012

1350 Ala Moana
Pipe Replacement
Project
Owners Stack Forum
1350 Ala Moana
June 7, 2012
Allana Buick & Bers, Inc.
• Architectural-Engineering firm
• Established in 1987 25 Years
• Multi-disciplined
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Architects
Structural Engineers
Mechanical Engineers
Electrical Engineers
Civil Engineers
Building Envelope Experts
Solar Consultants
Construction Administrators
Project Managers
Palo Alto
• Over 110 Employees
• 9 Offices
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Palo Alto, Sacramento, Los Angeles,
San Diego
Las Vegas, Seattle, New York
Honolulu, Lahaina (Maui)
Ocean View Center, Honolulu
AFTER
1350 Ala Moana Project Team
ABB
Designers/Engineers
Construction Managers (Advisor)
Richard Furst, Assoc. AIA
Design Consultant / Project Construction Manager
Architectural and Construction Background New and
Remedial
Joe Higgins, P.E.
Licensed Mechanical Engineer
Years of plumbing and mechanical experience as a
designer and on the construction side.
3
Sagewater / Phoenix Renovation Corp.
• Plumbing specialty contractor
• Established in 1988 24 Years
• The nation's pipe replacement
experts
• Over 250 Employees
• One Call Repipe is a turnkey
solution, encompassing all the
work necessary to complete the
project, including precise
drywall cuts, plumbing, pipe
insulation, drywall/plaster
repair, painting and
professional project
management
• Licensed, insured and bonded
nationwide
AFTER
1350 Ala Moana Project Team
Sagewater
General Contractor / Plumbing Contractor
• Specializing in replacement of plumbing systems in
occupied buildings
Miguel Rentas
Hawaii Division Manager
Brendan Trail
Senior Project Manager
Ralph Nishimura
Master Plumber
Giovanni Camuso
Drywall / Finish RME
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Basic Overview of Plumbing System
Description of
Existing Systems:
• Drain / Waste / Vent
(DWV)
• Domestic Water
Supply
• Rain Leaders
All located within firerated plumbing shafts
that extend through
each apartment unit
in entire building
6
Typical Floor Plan & Chases
• Thirty-one plumbing shafts throughout the
building, extending from 3rd floor through roof
• Typically 2 - 3 per apartment unit
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Basic Project Objectives
• Replacement of existing plumbing
piping and defective components
• Plumbing chase repairs:
• Fire-rated drywall assembly
• Hazard removal / code deficiency correction
o
Damaged / defective wallboard
o
Dryer vents
o
Electrical components
8
Project Scope of Work
What is included in the repair scope?
• All DWV and rain leader piping in plumbing
chase
• DWV piping in unit up to, but not including,
fixtures
• Replacement of removed toilet with low-flow
fixture (as required by plumbing code)
• Plumbing accessories in unit (i.e. washer box,
tub/shower drain & overflow pipes, unit
isolation valves on bathroom stack only)
• Repair of fire-rated wall assembly
• Removal of electrical and fire hazards
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Aging plumbing
systems
• Building is approx.
44 years old
• Normal lifespan of
cast iron and
copper piping in
Hawaii is about 30
40 years
• Material is failing
due to normal
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Long terms costs
of continued
repairs and leak
mitigation is more
than replacement
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History of improper
repairs and
renovations have
resulted in
degradation of
plumbing chase firerated wall assembly
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• Deficiencies in fire-rated plumbing
chase wall assembly are more extensive
than originally anticipated
• Many defects due to individual unit owner
renovations
o
Costs of such work will be charged back to
individual unit owner
• Other related defects are still being evaluated
o
Engineer and Contractor are working to develop
effective solutions to these typical conditions
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Fire-rated Wall Deficiencies
Repairs to fire rated wall
assembly may include
installation of new fire
rated wall to enclose
defective conditions
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Fire hazards
that exist
within the
plumbing
chases need
to be
mitigated
• Unsafe
electrical
components
• Improper
wiring
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• Electrical hazards due to unit owner
renovations may extend outside of
plumbing project work areas
• Contractor does correct conditions within
project work areas
o
Costs of such work will be charged back to
individual unit owner
• Electrical defects that extend outside of project
work areas will be documented and unit owner
will be notified
o
Unit owner will be required to correct these
issues within an allotted amount of time
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Electrical Deficiencies
Improper wiring or
un-jacketed wiring
were found
associated with
individual unit
renovations
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Construction Process
• Pre-construction survey and preparation
o
Identify pre-existing damages
o
Same person must be present at post construction
inspection
• Protection of unit
o
Plastic, plastic, plastic!
• Hazardous materials abatement work
o
Must be performed by licensed environmental
subcontractor
o
Isolate work areas to contain friable material
o
Removal of all asbestos containing materials (ACM)
from unit prior to remaining work
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Construction Process
Unit Work Zone Map shows areas where work
will occur in your unit
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Construction Process
• Protection of
unit
o
Plastic, plastic,
plastic!
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Construction Process
• Asbestos
abatement
work
o
Isolate work
areas to contain
friable material
o
Removal of all
ACM from unit
prior to
remaining work
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Construction Process
Access to plumbing chases:
Kitchen:
•
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Through common hallway whenever possible
Contractor may have to remove and reinstall kitchen
counters and cabinets in one unit in each shared stack
location (in 05/07 and 09/11 unit types) as well as in 03
and 04 unit types
Bathroom / Laundry:
•
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Vanity sink and toilet will be removed and reinstalled in
one bathroom (same room as laundry)
Washer, dryer, and laundry sink will be removed and
reinstalled
Contractor will attempt to have one bathroom and kitchen
functional at the end of each work day
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Construction Process
• Kitchen
access
o
Through
common
hallway
whenever
possible
o
Will still have
to perform
some work
inside each unit
kitchen to make
connections
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Construction Process
• Kitchen access
o
Cabinets and
countertop at stove
area may be
removed in specific
units (in 05/07, 09/11,
03, and 04 unit
types)
o
All removed
cabinetry will be
reinstalled to preconstruction
condition
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Construction Process
• Bathroom access
o
Vanity sink and toilet will be removed in one bathroom
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Construction Process
• Laundry access
o
Washer, dryer, and laundry sink will be removed
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Construction Process
Plumbing Work
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Work in chases is hazardous
Fall protection and PPE must be used
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Construction Process
Plumbing Work
• New pipe supports are being installed to meet
revised seismic Code requirements, as well as to
prevent pipe from falling down the chase and
causing damage to persons or materials below
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Construction Process
Plumbing accessories
•
Unit isolation ball valves
to shut off service to
each unit (in bathroom)
o In
case of leak , system can be
isolated more quickly
o Individual unit renovations can
be made without affecting all
the units in a stack
•
New washer supply
and drain box
o
Replacement of defective
materials in supply system
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Construction Process
Firestopping Work
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Pipe penetrations
must be sealed
Various deficiencies
addressed by
firestopping
contractor
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Deficiencies from
original construction
Deficiencies from new
work
Deficiencies from unit
renovations
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Construction Process
Finish Repair Work
Drywall & Paint:
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Custom paint colors ok
•
Custom wall finishes not included
Cleanup:
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Daily cleanup in unit will be basic
o
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Vacuum & light dusting of work areas only
Cleanup at completion of work in unit will be more
thorough
o
Vacuum, dusting, wipe down of all surfaces in work areas
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Construction Process
Finish Repair Work
Drywall & Paint
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Construction Process
Closeout Procedures
Punchlist & correction of work:
• CM punchlist & corrections
o Architect / CM and Contractor attend
• Owner final walk and approvals
o Owner (or authorized agent), CM and Contractor attend
o One and only opportunity for correction of aesthetic
defects
o Once completed, repair team will not be returning to unit
• Warranty service
o Contract warranty is Five (5) years from date of Substantial
Completion for labor and materials installed
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Remember, it is a construction
• Noise
• Mess
• Some level of inconvenience
But the Contractor and CM will work
together with General Manager, Directors,
and staff to minimize these factors
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Critical Success Factors
Communication is the Key to a
Successful Project
• Communication between:
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Unit Owners BOD/1350 Management
BOD - CM
CM Contractor
Contractor Subcontractors
• Communication of:
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o
Schedule
Shutdowns
Progress
Changes
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Project Costs
The Project budget below includes all costs
incurred to date and projected through
completion of the work.
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Project Costs
The Project Cost Basis below indicates the costs
for the vairous scopes of work, approved
alternates, and allowances.
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Project Costs
Several unforeseen conditions were identified
during initial stages of construction that led to
increases in the overall cost of the project:
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Size of openings required to access plumbing was
larger than originally anticipated
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Presence of asbestos in walls and ceilings was
previously excluded from contractor pricing
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Existing pipe supports are insufficient and unusable
Washing machine boxes
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Additional cost for hazardous materials subcontractor
Additional cost for not being able to reuse existing drywall
Seismic pipe support bracing
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More drywall to be removed and replaced
Corrosion on valves likely cause for leaks
Firestopping and fire-wall deficiencies
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Much more widespread than originally anticipated
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Size of Openings to Access Plumbing
Entire wall required removal, rather than single
opening over toilet, to access plumbing shafts
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Asbestos Abatement Work
Asbestos
abatement work
requires licensed
specialty
subcontractor, as
well as
replacement with
approximately 500
square feet of new
drywall material
per unit
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Pipe Seismic Support / Bracing
New pipe supports are required to meet revised
seismic Code requirements, which were not
anticipated in preliminary construction budget
estimates from the contractor
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Corroded Washing Machine Supply
Fasteners used to attach the washer valve to the
drywall in the original construction appear to
have caused galvanic corrosion of the entire
washer valve and adjacent supply piping, which
must be replaced.
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Fire-rated Wall Deficiencies
Repairs to deficiencies in
fire rated wall assembly
were much more
extensive than originally
anticipated
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Project Costs
Original budget estimate from contractor did not
include costs for these unforeseen conditions:
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Size of openings required to access plumbing was
larger than originally anticipated
• ~ $600,000
Presence of asbestos in walls and ceilings
• ~ $850,000
Seismic pipe support bracing
• ~ $1,350,000
Washing machine boxes
• ~ $107,000
Firestopping and fire-wall deficiencies
• ~ $1,255,000
Estimated additional costs for unforeseen
conditions: ~ $4,162,000
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Project Costs
Owner vs. AOAO
According to the AOAO Bylaws, items located
within each individual apartment unit are
considered to be the responsibility of the unit
owner, while items located between adjacent
apartments are considered to be the
responsibility of the AOAO.
Owner Responsibility
AOAO Responsibility
• All plumbing work in bathroom /
laundry from riser to each fixture
• All plumbing, drywall, and
firestopping work in kitchen
• All drywall work in bathroom /
laundry including ACM abatement
and new drywall installation
• All work in common areas (i.e.
lobby, storage, roof, etc.)
• All firestopping work in bathroom /
laundry
• Architectural / Engineering /
Construction Manager fees
• Installation of new washer box
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Project Costs
Owner vs. AOAO
Below are the costs of the various Owner items:
Owner Responsibility
Costs
• All plumbing work in bathroom /
laundry from riser to each fixture
$637,165
• All drywall work in bathroom /
laundry including ACM abatement
and new drywall installation
$2,050,000
• All firestopping work in bathroom /
laundry
$653,050
• Installation of new washer box
$106,492
Total potential costs associated with Owner
expenses:
$3,446,707
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Project Costs
Unit Deficiencies
Unit Owners are also responsible for the costs of any
additional work required in their units as a result of
existing code deficiencies or hazards uncovered
during the process of completing the project scope of
work. These costs will be tracked per unit and
charged back to the unit owners at the conclusion of
work in each unit. Costs for such additional work so
far range from $80 - $5,000 per unit, depending on
the severity of the defects.
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MAHALO!