JavaScript isn't enabled in your browser, so this file can't be opened. Enable and reload.

1 of 68

Case Study 1:

The Haynor Construction Company

Group 5: William Bennett - Othul Hock - Jemal Sadvakassov

ISE 311 B52

Professor Ning

2 of 68

Agenda

Background
Objective
Assumptions
Timeline
Plans
Recommendations
Conclusion

3 of 68

Background

Haynor Construction Company awarded contract to build indoor college stadium of 15,000 seats

Team of 15 year-round employees and 30 during construction season

Starting date of August 28th and deadline exactly one year from then

Few months available to discuss execution

President of company Don Haynor expects profits of $450,000

4 of 68

Objectives

Research various steps required to finish stadium on time including:

Preparation of site
Structural support and frame
Building various parts of stadium including surface and roofing
Seating
Electronics

Create timeline to execute project with minimal loss of profits
Materials and realistic budget of project
Factors that can delay project completion

5 of 68

Assumptions

Time taken to complete stadium sections already factors in the added number of employees during construction season
Different sections of the actual structure can be built simultaneously
Stadium will take up 4.5 acres based on Kibbie Dome Stadium
Coldest temperatures happen during December and January
Strike can happen at any time
Eliminate painting time for seats (painting/color included with the order)

6 of 68

Factors to Consider

Size of project along with partial public funding requires use of unionized employees

Expiration of construction industry labor agreements on November 30th could lead to possibility of a strike

Schedule calls for pouring of concrete in December and January, increasing chances of exposure to extreme/harsh cold which could also cause delays
Intensity of labor, type of materials needed and how much money these factors will cost

7 of 68

Site Preparation (8 weeks)

Excavation required for approximately 4.5 acres of land for 15,000 person stadium
Water, sewage, electricity, and gas systems will need to be rerouted for the stadium
Roads must be built for delivery trucks

8 of 68

Excavation Process

4 acres of land must be cleared, which can range from $2,000 - $22,000 depending on conditions

Forests
Clearing Permits
Soil Erosion
Asbestos Removal
Existing architecture

9 of 68

Drainage System

Sewage and water drainage systems are essential for large structure like a stadium

Combined sewers for storm and waste can be installed instead of separate systems
Average of $40,000 per acre

$160,000 for stadium

10 of 68

Footings (4 weeks)

Distributing weight over a larger area helps ensure ground or soil underneath does not reach load-bearing capacity, which could lead to unequal settling, rotation, sliding, or overturning
Have a professional to accurately assess soil conditions beforehand and decide proper depth/width and placement of footings needed
Process is typically completed by pouring concrete (sometimes rebar reinforced) into an excavated trench, and once finished curing, temporary braces that kept footing in place can be removed

11 of 68

Curing (3 weeks)

Process of continuously wetting exposed surface of concrete to control rate at which it loses moisture
This is essential as preventing loss of moisture for as long as needed will maximize concrete’s potential strength and durability
Temperature and relative humidity are important factors to consider
It only takes a week of curing for concrete to reach 75% of strength it would achieve in 180 days, in this case, 3 weeks of curing time will allow concrete to reach around 85-90% of its potential strength

12 of 68

Curing (con’t)

Concrete that is allowed to dry quickly undergoes considerable early-age shrinkage, contributing to weak, powdery surfaces w/ low abrasion resistance
There are several different processes of curing, among most popular include spraying with water, ponding, and utilizing formwork
Other less common examples:

Membrane
Pipe Water Cooling
Hot Mixing
Electrical
Infrared
Covering w/ sand or soil

13 of 68

Field: Subsurface Drainage (4 weeks)

Used in preventing a field from becoming a muddy mess by managing water that makes its way underground and helping field dry quicker
Most traditional way is utilizing pipe drains where perforated pipes are laid in trenches dug in subgrade and surrounded by coarse sand or stone, allowing water to drain down through rootzone and into trenches so it can leave through pipes

14 of 68

Field: Subsurface Drainage (con’t)

Another method is digging flat (strip) drains, typically 6-18 in wide and 1-2 in thick, they can be placed horizontally in subgrade during construction or trenched in vertically following installation of rootzone
A less common but least expensive option, and still effective is utilizing sand vein systems
Important factors to consider when deciding on type of drainage system include weather conditions, type of soil, and how much use field will see

15 of 68

Building Field (4 weeks)

Have option of using soil or sand to replace native soil, a sand-based system involves placing pea-sized gravel for drainage and laying a sand-based rootzone on top
Using soil on the other hand, starts with rototilling the material so it is thoroughly mixed, then carefully compacting and reworking it around any structural footings until at the proper elevation (measured with laser grader)

16 of 68

Artificial Surface Installation (7 weeks)

Once base for field is sufficiently compacted and leveled, process starts with laying a couple inches of granite and shock absorption pad (if needed) under where turf is going to be placed
Sections of the artificial turf are then rolled out and either sewn or glued together, then nailed into the ground in appropriate spots
Followed by infill installation, which is spread out in layers between the turf fibers, increasing the lifespan as well as providing other benefits

17 of 68

Structure: Concrete Pillars (4 weeks)

Pouring and forming process is paramount considering weight of entire building rests on these pillars
Layout Work: Location of pillars are arranged practically within construction site, usually done by laying rope in same location as grids in structural drawings and marking their location relative to rope.
Reinforcement: Steel rods are placed as reinforcement w/ careful reference to structural drawings, it’s important to consider what diameter for the rods is appropriate.

18 of 68

Structure: Concrete Pillars (con’t)

Formwork: Mold for pillar is built around steel reinforcement. All sides except for 1 should be height of the pillar, leaving one at 5 ft or less or a small window at 5 ft mark allows concrete to be poured from a sufficient height without it segregating. Once 5 ft of pillar is cast, remainder of formwork can be built up.

Pouring: It’s suggested that pillars are poured using machine-mix concrete from a pump or tremie pipe, minimizing initial setting time and preserving more quality compared to doing it manually. It’s essential that it compacts adequately in layers in order to reach desired quality and strength. This is also achieved with use of form vibrators, which are used to remove any air bubbles from concrete during compaction process

19 of 68

Seat Gallery Supports (10 weeks)

Best option for supporting seats is a grandstand design combining angled and horizontal steel beams with concrete columns, as it can accommodate any number of seats and offers most amount of customization
Provides the cleanest and most open understructure, allowing space for restrooms, concessions, storage, or locker rooms

20 of 68

Precast Galleries (11 weeks)

Works in conjunction with steel frames to keep various stresses and forces to a minimum

Can also work with in-situ concrete to reduce concrete used

Fire resistant
Two types:

Precast Hollow Core
Composites

21 of 68

In-situ Concrete

Final placement of concrete that is laid down
Acts as reinforcement for the precast concrete laid down and any steel support systems in place

22 of 68

Precast Hollow Core

Mainly used for flooring and roofing of multi-family units
Reduces materials needed and cost of project because of hollow core

23 of 68

Precast Concrete

Greater efficiency of installation, durability, cost-effectiveness, and maintenance
Has significant design freedom of architectural and structural shapes
Mass-manufactured in controlled factory conditions year-round, resulting in higher quality at lower cost and option to install in almost weather
Less need for on-site labor allows fewer delays

24 of 68

Composites

Both in-situ and precast are used so final concrete placement can be determined
Strong support for seats against various forces
Best choice for supporting seats as it is most structurally sound

25 of 68

Seating (4 weeks)

Choosing type of seat comes down to comfort vs fitting the most number of people in a stadium
3 types of seating:

Bleacher seating
Fixed seating
Beam seating

26 of 68

Bleacher Seating

Raised seats with stairs built in
Seats on every other step so each individual has leg room
Prioritizes number of seats over comfort

27 of 68

Fixed Seating

Seats come with a backrest
Fixed so seats are unable to be moved

Structurally sound but difficult to clean

Most comfortable but not very practical for a stadium scenario

28 of 68

Beam Seating

Also known as bench seating
Multiple seats attached to a support beams under the seats
Ideal combination of comfort, durability, and easiest to maintain

Best option for a stadium

29 of 68

Installation

Beam seats come fully assembled so labor costs are very low
Can include ventilation for heating and cooling
Beam holds majority of weight so material costs for seats are low as well
Purchasing price of $500,000 for 15,000 seats

30 of 68

Painting Seats

Beam seats come assembled when delivered
Color of seats can be requested for order so no additional painting will be required

Polypropylene seats whose color can be selected pre-manufacturing

31 of 68

Steel Work (6 weeks)

Create supporting structure that can withstand various types of stresses on stadium and seats

Plan includes combination of:

Reinforced Concrete Shear Walls
Steel Moment Frames
Steel Concentrically Braced Frames

32 of 68

Reinforced Concrete Shear Wall

Protects structure from lateral forces

Most common forces includes wind, earthquakes, and uneven land
About $100,000 for materials and installation

33 of 68

Steel Moment Frame

Protects structure from vertical and lateral forces through welded structures

Consists of beams and columns that are joined rigidly
Special retrofitted moment frames will be needed which can cost between $70,000 - $110,000

34 of 68

Steel Concentrically Braced Frame

Prevents lateral forces from harming structure through a vertical truss system that utilizes beams, columns, and braces

Helpful with dissipating earthquake forces
Uses multi-tiered systems to most effectively protect structures at various weak points

35 of 68

Roof (8 weeks)

Must be able to bear heavy loads of snow and rain
Allow sunlight into stadium with translucent material
Ideally be able to open and close small section of roof for air flow

36 of 68

Support for Roof

Steel columns put up to support facade and roof of stadium

Combination of cables and steel truss used
Approximately 2500 tons of steel will be needed, which equates to $1 million

37 of 68

Scoreboard (4 weeks)

Multipurpose for keeping score of various field sports such as soccer and football
Viewing size large enough for everyone in stadium to see
LED for long display time and brightness
Durable material, such as aluminum, for harsh weather conditions

Average size of scoreboard is 8 ft x 18 ft costing up to $10,000

38 of 68

Display Screens

Bright LCD or LED displays that can be read in the sunlight and darkness
Waterproof and durable using material like stainless steel or aluminium
Aspect ratio at 16:9 or higher for smaller screens for advertising

Prices can range from $300 - $500

Jumbotrons can be installed for highlights, advertising, and following the game

Ideally rented for big games which will cost about $5,000 per day

39 of 68

Speaker System

Speakers should be waterproof, clear, and loud

Good nominal power: power that can be put out over a long period of time

350 Watt speaker will be able to allow 1,000 listeners to hear clearly

The stadium will need about 16 350 Watt speakers, which costs $3,200

40 of 68

Lighting (5 weeks)

Powerful LED lights that are high in the air and angled peculiarly to cover as much of the field as possible

Prevents shadows and dim areas
Angle is exact to prevent blinding as well

500 watt light at 40 degree angle and 45 ft high can cover 60 ft x 60 ft

Required 50 lights to cover 4 acres, costing $30,000

41 of 68

Painting

OSHA standards must be followed

Ventilation, precautions taken for certain types of flammable paint, and proper equipment

Proper preparation needs to be taken for paint to last a long time
Industrial paint used to prevent rusting and corrosion, as well as applying fireproofing material

42 of 68

Prep for Painting

Surface needs to be cleaned of grease and non-rust coating is applied
Old paint will need to be removed along with any rust
Dents and small holes have to be repaired
Primer is applied so paint has good surface to dry onto

Must use special primer for metal so moisture cannot penetrate paint and cause rusting

43 of 68

TIMELINE

Site Prep, 8 wks

Sep, Oct

Pillars,

4 wks,

Nov

Footings,

4 wks,

Nov

Drainage,

4 wks,

Nov.

Seat Supports,

10 wks,

Dec, Jan, ½ Feb

Precast Galleries,

11 wks,

½ Feb, Mar, Apr, ¼ May

Seats,

4 wks,

¾ May, ¼ June

Electronics,

4 wks,

¾ May, ¼ June

Painting & Lights,

5 wks,

¾ May, ½ June

Curing,

3 wks,

¾ Dec

Steelwork,

6 wks,

¼ Dec, Jan, ¼ Feb

Roofing,

8 wks,

¾ Feb, Mar, ¼ Apr

Interior,

4 wks,

¾ Apr, ¼ May

Field,

4 wks,

Dec.

Artificial Surface,

7 wks,

Jan, ¾ Feb

44 of 68

Timeline Analysis

Strike and extreme cold weather could both happen on Dec. & Jan.
Parts of structure can be built simultaneously
No need for painting seats due to color being included with the order
Construction scheduled to finish by second week of June without delays
2 possibilities created:

Strike and cold months happen at the same time
Strike happens at separate time

45 of 68

Weather Analysis

Concrete’s ability to bind together worsens at temperatures below 50°F
Average temperatures for Binghamton were all below 50° during December and January over a 30 year period
Can assume that every week within the 2 months will require a $1,640 cost
This creates 2 options:

Pour during the cold months and incur $1,640 every week for 8 weeks ($13,120)
Do not pour during the cold months and lose 8 weeks but with no cost incurred

46 of 68

Strike Analysis

Strikes happen due to employee grievances
PLAs (project labor agreements) are a contract stating that the company will work with a union, and prohibit strikes during the period that the contract is active for
Strikes usually occur after that agreement has expired
In this case, strike could happen immediately after contract expiration or sometime later or before
Has a 50/50 chance of happening

47 of 68

1st Outcomes

Strike happens during December and January:

Cost, Weeks Lost, Project Completion Time

48 of 68

1st Outcome Analysis

3 outcomes if strike happens within Dec. & Jan.
If strike occurs, eliminates need for pouring since Dec. and Jan. preoccupied by strike, $0 lost and finish on time
Lack of a strike creates option to pour or not pour. Not pouring should be chosen due to finishing on time regardless of missing 2 months
2nd outcome entirely unnecessary

49 of 68

2nd Outcomes

Strike happens outside December and January:

Cost, Weeks Lost, Project Completion Time

50 of 68

2nd Outcome Analysis

The occurrence of a strike does not affect cost (-$13,120) if pouring is done since work continues during winter, and project is done on time regardless of strike’s occurrence
If pouring is not done and winter months are left inactive, occurrence of a strike could mean a cost of $144,000

$144,000 cost derived from a 16 week setback, where along with the cost of pouring the project is not done on time and $18,000 is incurred per week for 8 weeks
A $0 cost is derived from pouring not being done, and no time setback due to the strike. Project still completes by deadline

51 of 68

Best Options

Strike December and January:

No pour:

Strike outside Dec and Jan:

Pour:

-$13,120

50/50 risk is too great to not pour

52 of 68

Plan 1

Have more confidence in the original contract
Choice comes down to pouring and not pouring

If strike begins right after November 30th, pouring is not needed
If strike begins at any other time, pouring is needed to cut out risk

If choosing only one option, always pour. Unforeseen circumstances may result when leaving 2 months inactive

Minimizes risk and only expense comes out to $13,120

53 of 68

Plan 2

Expediting seat pouring:

Only one subsection finished faster
Project completion time stays the same

Does not change any of the outcomes, only adds a cost of $22,000

54 of 68

Plan 3

Double shift on field

2 week time reduction
Added cost of $10,000
Field finished by first week of February

Structure takes longer than field to finish
Unnecessary cost of $10,000 added

55 of 68

Plan 4 (Alternative)

Contract can not be changed to prevent strike
Have to increase chances of strike not happening in order to net no losses
Options outside of agreement:

Hire replacement workers during strike
Take human resources approach

56 of 68

Replacement Workers

Hiring temporary replacement workers during duration of strike
Strike is assumed to be economic (i.e. wages, benefits, work rules)
Reinstatement of striking employees is NOT required, but recommended to avoid complications
Approximate salary for 15 workers for a period of 8 weeks:

$5,440 based on a 40 hour work week with $17/hr pay rate

Not necessary if outcome 1
Moreso countermeasure rather than preventive measure

57 of 68

Result of Replacement Workers

A cost of of $5,440 is incurred for replacement workers’ salary during strike

15 workers at $17/hr

If strike happens, best option would be to not pour and spend $5,440 for replacement employees
Cost minimized by more than half

58 of 68

Human Resources Approach

Implement employee meetings to talk about safety issues
Bridge worker-management divide through better organizational structures
Be more involved with the employees
Provide feedback
Relationship closeness depends on management control mechanism (accountability, supervision, etc.)
Leads to overall increase of morale