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AE Senior Thesis: Research: Modular Construction Applied to Sullivan Trail Junior High Breadth 1: Structural Implications of Modular Construction Breadth 2: Modularizing Mechanical Systems. Goals of Presentation: Inform on state of modular construction in today's industry

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Presentation Transcript

  • AE Senior Thesis:

  • Research: Modular Construction Applied to Sullivan Trail Junior High

  • Breadth 1: Structural Implications of Modular Construction

  • Breadth 2: Modularizing Mechanical Systems


  • Goals of Presentation:

  • Inform on state of modular construction in today's industry

  • State advantages and disadvantages of modular construction

  • Apply a modular construction design to Sullivan Trail Junior High

  • Show minimal changes to floor plan

  • Show a schedule reduction of four months


  • Background information: Pocono Mountain School District

  • Over 11,200 students and 1,400 faculty members

  • 305 square mile coverage area

  • Increase in enrollment of about 4% or 400 students a year

  • Pocono Mountain West High school: Completed in 2002 is already 200 students over capacity.


  • Background information: Sullivan Trail Junior High

  • Features

    • 285,575 Sq. Ft.

    • 44.6 million dollars

    • 16 Prime Contractors

    • Built into the side of a hill and is two stories on each level

    • Auditorium

    • Multi Purpose Room

    • Cafeteria

    • Three Classroom Pods

    • Construction started in March 2004

    • Completion date December 2005


  • Background information: Sullivan Trail Junior High

  • Structure

    • Structural steel frame

    • Concrete spread footings and piers

    • 18 Foot high retaining wall

    • Combination of CMU and steel stud and drywall walls

    • Split-face CMU facade

  • Mechanical Systems

    • 3 boilers

    • 2 Chillers

    • 41 Single and Multi-Zone Air handling units

    • Fully Sprinkled


  • Modular Construction

  • Advantages

    • Requires little or no shake out area

    • Generally saves money

    • Reduces construction time by 1/3 because modules can be started while foundations are being dug

    • Reduced schedule leads to a faster payback period for the building

    • Minimizes schedule risks by having portions of the construction take place in a controlled environment and shortens critical path

    • Safety concerns are reduced because of controlled work environment

    • Portions of the building can easily be added or removed as needed


  • Modular Construction

  • Disadvantages

    • Requires substantial planning so front end of projects can be prolonged

    • Sometimes there will be an up cost

    • Works best on repetitive buildings such as jails and hotels

    • Increase in columns

    • Maximum clear span of 28 feet

    • Modular designers prefer to have very little or no CMU


  • Types of Modular Construction

    • Static Modular Construction

      • Modules are built similar to a conventional building

      • The modules are fully assembled them portions removed on match line

      • Typically are shipped on flat bed trucks

      • Adaptable to existing floor plans

      • NRB Incorporated

    • Assembly Line Modular Construction

      • Module moves to different stations

      • Modules are never fully assembled until on site

      • Typically have wheels attached to frame

      • Focuses on efficiency

      • Mark Line Industries







  • Sullivan Trail Junior High Modularization

  • Reduce schedule to have school completed by August 31, 2005

  • Use static built modularization

  • Modular design follows classroom pods

  • Auditorium, Gyms and Cafeteria would be conventionally built







  • Modularization Recommendations

    • Floor to floor heights would have to be lowered

    • Redesign of locker rooms to accommodate new columns

    • Flat roofs with roof top mechanical units

    • Modularize mechanical systems rather than mechanical room

    • Labor costs could be reduced by 1/3 because prevailing wage would not need to be used on off site construction

    • Save temporary modular classrooms and estimated cost of over $650,000


  • Special Thanks to..

    • Turner Construction: Bill Booth and Steve Miller

    • NRB Incorporated: John Crisp and Don Engle

    • AE Faculty

    • Gilbert Architects

    • Pocono Mountain School District


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