Mace Group builds working on top of under-construction skyscrapers
The six-story factories eliminated the need for tower cranes, and increased productivity to the point where crews could complete 18 floors in 18 weeks.
U.K.-based general contractor Mace Group built working factories on top of two high rises while they were under construction in Stratford, England. The 47,355-cubic-meter factories allowed Mace to complete 18 stories in 18 weeks. Matt Gough, Mace’s Director of Innovation and Work Winning, says the factories were “cost neutral.” Photo: Mace Group
Mace Group is London’s largest contractor, and has been associated with some of that city’s signature projects, including its 95-story skyscraper The Shard; the 443-foot-high cantilevered observation wheel known as London Eye; and Heathrow Terminal 5, which at nearly four million sf on 640 acres is the largest freestanding structure in the United Kingdom.
Since its inception in 1990, Mace has explored where production and construction might intersect. That inquest is suddenly urgent today, as U.K. cities will need 10,500 new homes to be built per month every year through 2038. To meet that demand, the country’s construction industry must rev up its productivity by 30%.
Recently, Mace took a step toward shifting from construction to production when it literally built factories on top of two under-construction residential towers in Stratford. Workers within those factories poured concrete, and assembled and installed prefab MEP systems, bathroom pods, risers, and façade components. The firm showcased its factory during a presentation at Autodesk University in London in June.
SKYSCRAPERS RISE WITH SIX-STORY PREFAB FACTORIES
The six-story factories each weighed 510 tons and were 35 meters wide, 41 meters long, and 33 meters high. Some of their spaces were dedicated to materials delivery, façade installation, and assembling sub-assemblies. The structural engineer Davies Maguire helped Mace figure out how the building would manage that weight load.
Photo: Mace Group
Matt Gough, Mace’s Director of Innovation and Work Winning, tells BD+C that the factories were “cost neutral” in that they eliminated the need for tower cranes, and increased productivity to the point where crews could complete 18 floors in 18 weeks. The factories reduced the project’s transportation by 40%, and its waste by 75% compared to a more conventional construction site. This project’s “gross value added” per worker, at £80 ($101.41) per hour worked, was higher than the U.K.’s average for construction and manufacturing.
“We changed the process for delivering high rises,” says Gough, even as it struggled at first to get some trades to work “in a different way.”
In January, Mace handed over the two residential towers to their developer, a joint venture between Qatari Diar and Delancey. Stratford is Mace’s sole project with onsite factories. The contractor is open to doing more projects like it in the U.K. and elsewhere (it has a construction management office in New York). Mace’s goal is to be “manufacturing” 85% of its projects 50% faster by 2022 via just-in-time logistics and sharper site management abetted by technology.
The contractor is doing modular construction on some projects, and intends to rely more on offsite prefabrication, which could result in safer jobsites with fewer workers needed.
Mace
✔@MaceGroup
How do you construct one floor of a building in just 55 hours? At N08, our project at East Village in Stratford, Mace used the ‘rising factories’ – an #innovative new #construction method – to deliver a step change in productivity and efficiency. Watch our latest video:
Whether it’s your alma mater, a local team, or a family tradition, college football fans bleed their team’s colors and logos. There are 125 Division 1 football teams spread out across the United States. Some cheer to beat rivalries, some cheer for pride, and some cheer for national titles. Then, their favorite players move on to play in the most expensive professional stadiums in sports.
To honor the start of the college football season, here are the facts behind the stadiums of the top 5 teams from the Associated Press preseason rankings.
1. Clemson Tigers
Name: Memorial Stadium
Built: 1942
Capacity: 81,500
Details:
• It was designed by a Clemson graduate, Carl Lee, and Professor H.E. Glenn of the engineering facility. Originally 20,500 seats, the original stadium is now the lower south grandstand of the current stadium.
• Most of the original construction work was done by scholarship athletes. Two football team members, A.N. Cameron and Hugh Webb, staked out the stadium. The stadium has gone through renovations over the years and now seats 81,500.
• Clemson Memorial Stadium is often referred to as “Death Valley,” which is named after the Death Valley National Park in California and the Clemson University cemetery that used to overlook the field before the upper decks were built.
2. Alabama Crimson Tide
Name: Bryant-Denny Stadium
Built: 1929
Capacity: 101,821
Details:
• When completed in 1929, Bryant-Denny Stadium only had a capacity of 12,000. The original name is Denny Stadium in honor of the school’s president from 1912 to 1932, George H. Denny. In 1975, former coach Paul “Bear” Bryant’s name was added to the stadium.
• Since opening, Bryant-Denny Stadium has gone through renovations to increase the seating capacity 11 times. Today, at 101,821 seats, it’s the eighth-largest stadium in the world but only fourth-largest in the Southeastern Conference (SEC).
• Unlike most stadiums, Bryant-Denny Stadium didn’t have a logo at midfield until 2002. The school wanted to have a traditional field design with the only logos being “ALABAMA” in the end zone.
3. Georgia Bulldogs
Name: Sanford Stadium
Built: 1929
Capacity: 95,723
Details:
• Because the original Sanford Field was too small, the team had to travel to Georgia Tech’s Grant Field in every year to play its rivalry game. After a loss to their rival, Sanford vowed to “build a stadium bigger than Tech.”
• To fund the stadium, Sanford had members of the athletic association sign notes guaranteeing a bank loan. Whoever contributed would get lifetime seats. The stadium got funding in 1928 and cost $360,000 to build.
• With the open west end-zone view of the rolling hills, Sanford Stadium is referred to as the most beautiful on-campus stadium in college football. It’s also one of college football’s loudest and most intimidating stadiums.
4. Oklahoma Sooners
Name: Gaylord Family Oklahoma Memorial Stadium
Built: 1923
Capacity: 86,112
Details:
• Designed by architectural firm Layton & Hicks, Gaylord Family Oklahoma Stadium is the 23rd largest stadium in the world. It’s currently undergoing a two-phase, $160 million renovations to add a press box, club seats, new facade, offices, and training center.
• After 16,000 seats were built in 1925, the stadium was named Oklahoma Memorial Stadium in honor of the students and faculty that died during WWI.
• Coach Bennie Owen raised the money himself to build the stadium, which cost $293,000. The playing surface is named Owen Field, but the stadium itself is also commonly referred to as Owen Field.
5. Ohio State Buckeyes
Name: Ohio Stadium
Built: 1922
Capacity: 102,082
Details:
• The previous stadium, Ohio Field, became too small for the growing popularity of football in Ohio. The project to build a new stadium was funded by a public-subscription campaign, raising over $1.1 million.
• Designed by architect Howard Dwight Smith, the stadium was built with 66,210 seats, making it the largest concrete poured structure in the world at the time. After renovations over the years, it now has a seating capacity of 102,082.
• To build the stadium, Smith used revolutionary techniques. There is a slurry wall at the stadiums base to keep out water from the Olentangy River, the upper deck was designed to hang over part of the lower deck, and double columns to allow for more space between columns.
Working in a cold environment can cause various adverse effects on the human body and its ability to perform, and it can increase the risk of common hazards and cold-associated injuries. To maintain healthy temperatures in colder environments, the body is required to work harder, but when temperatures drop drastically and wind chill increases, heat is apt to leave the body more rapidly. The ability to quickly recognize the symptoms of cold stress is important for preventing cold-related injuries. According to OSHA, cold stress occurs by driving down the skin temperature and eventually the internal body temperature, or core temperature. Common risk factors for cold stress include but are not limited to wetness/dampness (e.g. sweating), dressing improperly, exhaustion and poor physical conditioning.
While it is important to be aware of your own physical conditions on the jobsite, it is also imperative that you pay close attention to your fellow coworkers’ well-being in order to best prevent any cold-related injuries on them as well.
2. Wear Appropriate Clothing
A main preventative of cold stress is dressing appropriately for the weather conditions. When low temperatures and adverse environmental surroundings cannot be avoided, there is apparel that will ensure you are properly equipped for the cold:
Multiple layers for better insulation and wind protection
Looser clothing that will not inhibit warm blood from circulating throughout the body
Mask to cover the face, mouth and neck
Warm hat to reduce the amount of heat released through the head
Insulated gloves
Insulated, waterproof boots for foot protection
When incorporating these items into your winter jobsite wardrobe, high visibility clothing and personal protective equipment (PPE) must still be worn. It is common this time of year that the day begins beautifully with sunny, warm temperatures but ends with a below-freezing snow. Therefore, it is important to remember that, as we add or remove clothing, jackets and coveralls throughout the day, we always maintain our high-visibility clothing on the outer-most layer.
Pro Tip: For cold stress prevention and added safety, keep extra clothing on hand in case you get wet on the jobsite and need a change.
3. Review worksites and Upcoming Weather Conditions
Actively monitoring weather conditions during the winter, having reliable means of communicating with other workers and being able to stop work or evacuate when necessary are safe work practices to protect from injuries, illnesses and fatalities, according to OSHA. It is important to also be aware of the specific public warnings provided by the community: sirens, radio alerts and television. If you are notified of a winter storm watch, advisory or warning, follow instructions from your local authorities. Take those warnings seriously and adjust your work schedule, transportation plans and clothing choices accordingly.
4. Be Prepared for Freezing and Thawing Effects
When temperatures vary on an hourly basis during this time of year, it is critical to be aware of the potential effects of freezing and thawing on a construction jobsite. The aforementioned temperature variations can make for very slippery conditions on both roofing and decking. Thermoplastic olefin (TPO) and polyvinyl chloride (PVC) roofs can be especially hazardous during cold weather. Unfortunately, there is very little that can be done to address this occurrence, because most ice-melt chemicals void a warranty when applied. As well, shoveling can tear and rip these thin membranes. In most cases, the only redress in this situation is to begin work later in the morning and give the snow/ice time to naturally melt. Walking on decking is also especially dangerous in the winter. Unlike with TPO/PVC roofing, we can typically clear the decks by shoveling. However, before applying any chemicals to melt the ice and snow, it is important to check with a supplier to inquire if certain melting chemicals are recommended.
5. Pay Special Attention to Walking and Working Surfaces
Walking around a jobsite can be extremely dangerous under even the best conditions. When freezing rain, snow and frozen ground are added to the mix, safety on the job site becomes increasingly challenging. OSHA’s General Industry Standard 1910.22(a)(3) requires that walking/working surfaces are maintained free of hazards such as sharp or protruding objects, loose boards, corrosion, leaks, spills, snow and ice. We encourage our site teams to develop site logistic plans that include clearly delineated travel paths around the site, early start times for snow removal and salt crews and later start times when bad roads could cause vehicle accidents. We also recommend adding line items to Job Safety Analyses (JSAs), equipment, tool and scaffold inspections to address possible accumulation of ice and snow.
Given these five ways for construction site teams to keep safety first this winter, this list is not exhaustive, nor can you ever be too cautious or too safe. For more comprehensive information on how to better prepare for and respond to severe winter weather, visit OSHA’s Winter Weather webpage
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Welcome to OSHA’s Fall Prevention Campaign
FALLS ARE THE LEADING CAUSE OF DEATH IN CONSTRUCTION. In 2017, there were 366 fatal falls to a lower level out of 971 construction fatalities (BLS data). These deaths are preventable.
Since 2012, OSHA has partnered with the National Institute for Occupational Safety and Health and National Occupational Research Agenda (NORA) – Construction Sector on the Fall Prevention Campaign to raise awareness among workers and employers about common fall hazards in construction, and how falls from ladders, scaffolds and roofs can be prevented.
PLAN ahead to get the job done safely
When working from heights, employers must plan projects to ensure that the job is done safely. Begin by deciding how the job will be done, what tasks will be involved, and what safety equipment may be needed to complete each task.
When estimating the cost of a job, employers should include safety equipment, and plan to have all the necessary equipment and tools available at the construction site. For example, in a roofing job, think about all of the different fall hazards, such as holes or skylights and leading edges, then plan and select fall protection suitable to that work, such as personal fall arrest systems (PFAS).
PROVIDE the right equipment
Workers who are six feet or more above lower levels are at risk for serious injury or death if they should fall. To protect these workers, employers must provide fall protection and the right equipment for the job, including the right kinds of ladders, scaffolds, and safety gear.
Use the right ladder or scaffold to get the job done safely. For roof work, if workers use personal fall arrest systems (PFAS), provide a harness for each worker who needs to tie off to the anchor. Make sure the PFAS fits, and regularly inspect it for safe use.
TRAIN everyone to use the equipment safely
Every worker should be trained on proper set-up and safe use of equipment they use on the job. Employers must train workers in recognizing hazards on the job
More than 90 million American spend their days on the job. As a nation, they are our most valuable resource. And surprisingly until 1970, no uniform and comprehensive requirements existed for workplace safety and their protection against health hazards.
How did OSHA Form?
In 1970, Congress considered annual figures such as these:
Job related accidents accounted for more than 14,000 worker deaths.
Nearly 2 1/2 million workers were disabled.
Ten times as many person-days were lost from job-related disabilities as from strikes.
Estimated new cases of occupational diseases totaled 300,000
In terms of lost production and wages, medical, expenses and disability compensation, the burden on the nation’s commerce was staggering. Human cost was beyond calculations. Therefore, the Occupational Safety and Health Act of 1979 (the Act) was passed by a bipartisan Congress “…to assure so far as possible every working man and woman in the Nation safe and healthful working conditions and to preserve our human resources.”
What does OSHA Stand For?
Under the Act, the Occupational Safety and Health administration (OSHA) was created within the Department of Labor.
Simply stated, OSHA is the Occupational Safety and Health Administration and is responsible for worker safety and health protection.
Since its inception in 1970, OSHA has cut the work-fatality rate by more than half, reduced the overall injury and illness rates in industries where OSHA has concentrated its attention, virtually eliminated brown lung disease in the textile industry and reduced trenching and excavation fatalities by 35 percent.
OSHA is administered through the Department of Labor (DOL). The DOL regulates and enforces more than 180 federal laws. These mandates and the regulations that implement them cover many workplace activities for about 10 million employers and 125 million workers.
Who Does OSHA Cover?
OSHA determines which standards apply to your workplace and requires you to follow these standards and requirements.
All employees and their employers under Federal Government authority are covered by OSHA. Coverage is provided either directly by federal OSHA or through state programs. OSHA does not cover the self-employed or immediate members of farm families that do not employ outside workers.
OSHA offers an extensive Web site at osha.gov that includes sections devoted to training, state programs, small businesses, construction, as well as interactive eTools to help employers and employees.
OSHA also offers training programs for employers and employees to get hazard recognition. Some states currently mandate training.
To adapt mortar to new building materials and industrial methods, the content in walls and plaster changed during the 20th century. The change meant that knowledge of historical materials and methods for producing mortar were lost. New research at the University of Gothenburg reveals that historical binding agents and mortar can be produced and used in present-day plaster restorations.
“We need to reclaim this knowledge to care for and preserve historic buildings constructed with other materials than those used today,” says Jonny Eriksson at the Department of Conservation at the University of Gothenburg, the author of the new thesis.
Millennial history
The production of plaster and mortar for buildings goes back thousands of years in Sweden. For a long time, builders made plaster and mortar using traditional techniques, but with industrialisation the process changed.
“The change involved using new materials and methods to make mortar. At the same time the knowledge of craftspeople on how to make binding agents and mortar for bricklaying and plastering in different situations was lost.”
The lack of knowledge first became apparent late in the 1960s because the new mortars were damaging historic buildings.
“For long-term and sustainable maintenance of historic buildings, we need to reclaim knowledge that has been lost,” Jonny Eriksson says. “And this requires collaboration among crafts and professions such as architects, engineers and antiquarians. More craftspeople also need to be trained in research on building conservation.”
Investigations in medieval church
For his thesis Eriksson investigated the formation of shrinkage cracks in plaster. He has studied the feasibility of using mortar mixed with the traditional proportions in use until the 19th century. He conducted his investigations will restoring plaster on a medieval church in Tanum municipality in northern Bohuslän.
“It became apparent that it is practical today to make and use the old-style of mortar. These mortars with a high content of binding agents need to be mixed with newly slaked lime, which is lime that has just been slaked with water,” says Eriksson.
During the 20th century, builders discouraged this particular production process. They thought it produced defects in the plaster. Instead they recommended preparing slaked lime one to four weeks before use.
“This was contrary to fundamental practices in the 19th century, when recommendations called for the use of newly slaked lime. The rationale was that this made the mortar more durable.”
The research results show that the older artisanal mortar with a high content of binding agents can also be made today. It also shows that the mortar can be used for plaster without unacceptable shrinkage cracks or blisters from unslaked lime.
“Our experiences with using these old-fashioned mortars in various construction projects indicates that the mortar has good durability. But the lime needs to be newly slaked when used and not stored after slaking nor processed to be packed in a bucket or barrel for later use, for example,” says Eriksson.
Facts
Slaked lime is produced by mixing lime and water. This releases energy in the form of heat, and slaked lime forms. Depending on how much water is introduced into the process, slaked lime forms as either dry powder or a wet paste. Slaked lime is used in the building materials industry and for water and flue gas treatment.
Wet slaked lime is quicklime that has been slaked with an excess of water so that it forms a lime paste. Normally this lime is stored for some time before it is mixed with sand to make mortar. Storage is done to avoid damage.
Newly slaked lime. Making mortar with newly slaked lime involves slaking the lime before mixing the lime with sand. In other words, the lime is used immediately and is not stored.
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Materials provided by University of Gothenburg. Note: Content may be edited for style and length.
Around 65% of the construction industry work on scaffolds and experience 4,500 injuries and 60 fatalities annually in the United States alone. To prevent these staggering statistics from reocurring better safety inspections, training and controls are needed.
There are three things to remember to ensure scaffolding safety:
The scaffold must be built under the supervision of a competent person;
Workers must be trained by a qualified person before they use the scaffold; and
The scaffold and its components should be checked by a competent person and properly tagged before the start of the shift to ensure its integrity and safety.
This article covers who are competent and qualified persons, the basic Do’s and Don’ts of scaffolding safety, usage of scaffold tags, and also includes free scaffold safety checklists to help you implement safety in your workplace using iAuditor – the world’s #1 inspection app.
Competent and Qualified Person
According to OSHA, a competent person is “one who is capable of identifying existing and predictable hazards in the surroundings or working conditions, which are unsanitary, hazardous to employees, and who has authorization to take prompt corrective measures to eliminate them.” This is typically someone who holds a scaffolding high-risk work license.
While a qualified person is one who “has successfully demonstrated his/her ability to solve or resolve problems related to the subject matter, the work, or the project.” A qualified person has the right background such as education or degree in designing safe scaffolding, for example this could be someone from the scaffold manufacturer or trained scaffold engineer.
The Bureau of Labor Statistics cites that 72% of scaffold injuries were due to scaffold planking or support giving way, slips, or falling objects. With regular inspections performed by a competent person, adequate scaffold safety training provided by a qualified person, and compliance with local regulatory standards, these dangers can be controlled.
Basic Scaffolding Safety Do’s and Don’ts
Here’s a simple guide you can follow to control the hazards when working on a scaffold:
DO’s:
Inspect the scaffold using a checklist or mobile inspection app before the work shift and ensure it is safe and in proper working order.
Provide proper training.
Have a toolbox talk before beginning work.
Wear appropriate PPE.
Always check inspection tags.
Know the weight capacity of the scaffold.
Have a handhold above the scaffold platform.
Level the scaffold after each move. Do not extend adjusting leg screws more than 12 inches.
Use your safety belts and lanyards when working on scaffolding at a height of 10 feet or more above ground level. Attach the lanyard to a secure member of the scaffold.
Safely use the ladder when climbing the cross braces for access to the scaffold.
Keep both feet on the decking.
Stay off scaffold during loading or unloading.
Ensure planking is overlapping or secured from movement.
Follow the manufacturer’s instructions when erecting the scaffold, under the direct supervision of a competent person.
Be mindful of coworkers working above and below you at all times, as well as others working on the scaffold.
Use the debris chutes or lower things by hoist or by hand.
Chock the wheels of the rolling scaffold, using the wheel blocks, and also lock the wheels by using your foot to depress the wheel-lock, before using the scaffold.
Always use netting to catch anything that falls.
DON’Ts:
Leave anything on the scaffold at the end of your shift.
Overload the scaffold.
Use unstable objects such as barrels, boxes, loose brick or concrete blocks to support scaffolds, increase your work height or planks.
Work on platforms or scaffolds unless they are fully planked.
Use a scaffold unless guardrails and all flooring are in place.
Stand on ties, guardrails, or extensions.
Use the scaffold if it appears damaged in any way, has been tampered with, or if there are components missing such as planking, guardrails, toeboards, debris nets or protective canopies.
Walk on scaffold planking covered in ice, snow or mud.
Avoid using a scaffold during adverse weather such as heavy rain, sleet, ice snow or strong winds.
Climb on any portion of the scaffold frame not intended for climbing.
Never climb with any materials or tools in your hand, they should be hoisted up to the scaffold separately.
Jump from, to, or between scaffolding.
Lean out or overreach outside the guardrails.
Rock the scaffold.
Throw anything “overboard” unless a spotter is available.
Move a mobile scaffold if anyone is on it.
Guidelines in Tagging Scaffolds
Scaffold tags are used to protect the lives of your workers. It identifies if a scaffold is safe or unsafe for use. Follow the guidelines below when tagging scaffolds.
Inspection and tagging of the scaffold are to be performed by a competent person experienced in the erection of scaffold.
A unique scaffold identification tag number must be clearly identified on all tags for tracking purposes.
All scaffolds shall be inspected after the erection per regulatory requirements.
All scaffold identification tags wlil be of a solid green, yellow, or red color with black lettering.
Front information displayed and completed for each tag.
It is common practice to use the following color schemes: Green, Yellow, Red
Green – tags will be hung on scaffolds that have been inspected and are safe for use. A green “SAFE FOR USE” tag(s), and should be attached to the scaffold at each access point after the initial inspection is complete.
Yellow – “CAUTION” tag(s), will replace all green “Safe Scaffold” tag(s) whenever the scaffold has been modified to meet work requirements, and as a result, could present a hazard to the user. This tag indicates special requirements for safe use. NOTE: Use of the “yellow tag” status is not intended to override the green tag system. All efforts should be made to return the scaffold to a “Green Tag” status as soon as possible.
Red – “DANGER – UNSAFE FOR USE” tag(s), will be used during erection or dismantling when the scaffold is left unattended and replace all green “Safe for Use ” tag(s) or yellow “Caution / Hazard “ tag(s) in the event a scaffold has been deemed unfit for use.
Protect Workers Operating and Working Near Forklifts
Forklifts are an essential piece of equipment in many workplaces, especially in warehousing and manufacturing. Although these vehicles make work more efficient, they can pose serious hazards to those operating or working near them. OSHA reminds employers and workers that these hazards can be prevented by following safe practices and ensuring that workers are properly trained.
Taking the following steps can protect workers from forklift hazards.
• Always wear seatbelts when operating a forklift. • Never exceed the rated load, and ensure loads are balanced. • Make sure you have enough clearance when raising and loading materials. • Watch for pedestrians and observe speed limits. • Keep a safe distance from platform and ramp edges.
For more information on ways to keep workers safe while working with or around forklifts, visit OSHA’s Powered Industrial Trucks – Forklifts page.
OSHA’s On-Site Consultation Program offers no-cost and confidential occupational safety and health compliance assistance to small- and medium-sized businesses. Consultation services are separate from enforcement and do not result in penalties or citations. The OSHA Training Institute Education Centers offer courses for workers, employers, and managers on hazard recognition and abatement at convenient locations nationwide.
OSHA alerts are issued on occasion to draw attention to worker safety and health issues and solutions.
• osha.gov/forklifts • 800-321-OSHA (6742) • @OSHA_DOL
Eliminating overproduction, unnecessary motion, and unneeded product transportation
At B&I Contractors’ job sites, workers aren’t perched on ladders, putting together intricate assemblies high above the ground. There are no tools or materials piled on the floor or stashed in the corner. That kind of work — the assembling, the preparing, the gathering of tools and supplies — has already been taken care of.
B&I, based in Fort Myers, Florida, is one of a growing number of contractors across the country to adopt “lean construction” techniques: a plug-and-play approach to construction that lets workers prefab a project off-site, section by section. Then, at the job site, all that remains is putting the pieces together.
B&I has been in business for 60 years, 30 of them as an employee-owned company. As a full-service mechanical contractor serving southern Florida, its 650 employees do everything from HVAC to piping, sheet metal, service work, plumbing, electrical, and special projects.
Although the term “lean construction” was coined in 1993, the “lean” concept itself can trace its origins several decades earlier to the Toyota Production System and its philosophy of eliminating waste: overproduction, unnecessary motion, and unneeded product transportation. Within the past several years, those same principles have started to gain popularity in the construction industry, with the two major focuses being prefabrication and preassembly (assembling components in a controlled environment, then transporting them to the construction site in “chunks” for assembly).
PORTABLE: Lean containers, like this lean pipe table, come in multiple sizes for various functions. “We have the lean cart and lean bin, which is 4 feet by 4 feet: you can put copper fittings in there, your sheet metal caps, adjustable elbows … so you’re no longer putting things on the ground and picking them up,” said Matt Davis, plumbing prefab superintendent.
B&I implemented lean procedures as a strategic initiative two years ago, although Jon Castro, sheet metal department manager, said they’ve been practicing it somewhat loosely for a few years before that.
“It’s part existential, part survival,” he said. “I really got into it because I saw that the culture and the construction world were shifting; I felt like we had to adapt if we wanted to maintain the size and profitability of the company we are, as well as the quality of work we put in. Everything’s getting more competitive.
“The lean approach really structures you to becoming more efficient, taking that leap ahead,” he added. “A lot of folks in the industry are, ‘I’ve always done it this way, and it’s good enough.’ If there’s someone who’s not as good as that guy but getting a little better and a little better, eventually the second one’s going to pass them by, and the first guy is going to stay the same.”
One recent B&I project that used both prefabrication and preassembly was at the six-story Cleveland Clinic Florida. In creating the clinic’s mechanical/engineering/plumbing system, B&I used a nearby off-site facility to design and put together 48 steel racks, each 20 feet long, 4 feet high, and 8 feet wide: the same width as the hospital corridor. This way, multi-trade installation could be performed at ground level, which allowed workers to build quickly, efficiently, and safely. Detailed shop drawings allowed the crew to maintain critical requirements for the location of system parts within the racks themselves.
On installation day, B&I used cranes to lift the racks to their respective floors, then removed the casters on the racks and rolled them to their proper locations.
“The racks were done months in advance, and we were able to build them off-site,” said Phil Murphey, sheet metal shop foreman. “When the structure got to where it needed to be, it was plug-and-play.”
Overall, B&I’s prefabrication and preassembly strategies resulted in minimal waste, reduced cost, and a significantly shortened installation time for the Cleveland Clinic project.
“Some of the guys were sitting in the warehouse putting things together; it’s safer than on a ladder,” Murphey explained. “Our customer and our clients are going to get better product, typically, when it’s prefab, because there’s no chance of products getting messed up in the field.”
It’s not about the company making more money and being more efficient — it’s really about better quality for the customer and the customer’s end user, according to Castro.
“When you’re improving your quality and reducing waste through lean, it’s a better product,” he said.
Racks, bins, and carts are a common sight on B&I job sites, where all the materials required for the job are delivered to the site pre-packed. When it’s time to start the day’s work, everything’s at hand.
“It’s eliminating wasteful movement, wasteful product, wasted energy,” said Matt Davis, plumbing prefab superintendent.
Lean containers come in different sizes for different uses.
PLUG AND PLAY: Racks, bins, and carts, like this lean cart with a table and trash can, are a common sight on B&I job sites, where all the materials required for the job are delivered to the site pre-packed. When it’s time to start the day’s work, everything’s at hand.
“We have a couple styles of baskets,” said Davis. “We have the lean cart and the lean bin, which is 4 feet by 4 feet: you can put copper fittings in there, your sheet metal caps, adjustable elbows … so you’re no longer putting things on the ground and picking them up. Then we have a basket that’s 30 inches wide and 5 feet tall. It’s designed to fit through a standard doorframe, so you can still put a bunch of trim fittings on that cart and get it through the corridor without damaging the work that’s been done.”
Behind the scenes, the same philosophy applies to work like creating project designs.
“The way that I used to get my work into the shop was the old-school way: The department would decide on a design, I would have to sit down with a piece of paper and a pencil, put it back into my computer, and spit it back out for the workers to work on,” said Murphey.
Now, they use software that converts that sketch into a usable design.
“In the past five years, it’s gotten faster and faster,” he said. “It eliminates hours and hours of handwriting, hours and hours of work.”
Going lean is a true team effort because it means anticipating the needs of employees whose jobs are several steps down the line.
“Lean really isn’t done in an office meeting. Lean is done by the guys in the field. We ask the guys for feedback all the time — survey, survey, survey… toolbox talks, iPhone surveys — and we implement what they tell us.”
— Jon Castro, sheet metal department manager, B&I Contractors Fort Meyers, Florida
“It’s a different approach,” said Murphey. “We’re trying to make it easier for the guys in the field, so I’m always thinking of not just myself but, even though it doesn’t affect me, the best way to ship [ductwork or other materials].”
B&I has complete and utter buy-in from upper management, Castro said. Company executives understand and see the value for the business as well as for customers. But lean is more than a company policy.
“Lean really isn’t done in an office meeting,” he said. “Lean is done by the guys in the field. We ask the guys for feedback all the time — survey, survey, survey… toolbox talks, iPhone surveys — and we implement what they tell us.”
And when someone comes up with a great idea, they’re given a shout-out — like a write-up in the company newsletter.
“Typically, it’s the apprentices, guys who haven’t been doing it forever, who come up with the most creative solutions,” Castro said. “You want to highlight your guys, make them feel proud for coming up with a great idea. And the more people that are involved in it, the more people see how useful it is and jump aboard.”
Lean processing has another side benefit: Less wasted time means technicians have more on-the-clock hours available, a major plus in an industry starved for workers.
“Everyone’s worried about the shortage of manpower,” said Castro. “We’ve been able to meet our scary project schedules with lean processing. Plus, the customer gets it on time and better quality.”
So far, just a handful of companies in Florida have implemented lean processing, but Castro said the business model is pushing forward in other parts of the country and among some of their larger competitors. It’s a trend B&I is excited to see taking hold.
“There’s a real open sharing of information with lean companies,” said Murphey. “Iron sharpens iron. And I want to see the cool thing some other company’s doing that will help push us to the next level.”
It’s Getting Hot, Hot, Hot. How to Work Safely in the Sweltering Summer Heat.
With summer in full swing, it’s that time of year again to talk about the very real and present dangers associated with working in the heat. As with all safety and health hazards, the best game plan is prevention. Knowing the dangers of working in the sun and what to do if you become ill are vital to your health and safety. Each year, more than 65,000 people seek medical treatment for extreme heat exposure. We’ll discuss the most common heat-related illnesses and what to do if you should suffer from any this summer.
When Are We at Greatest Risk for Heat-Related Sickness?
The sun has the greatest intensity between the hours of 10:00am and 3:00pm Standard Time, which is also when workers are in the middle of their workday and may be exposed to the sweltering heat. According to the Center for Disease Control and Prevention (CDC), a fair-skinned person can sunburn in as few as 10-15 minutes. Heat-related illnesses can occur more quickly than you may realize, and symptoms often tend to sneak up on you rather suddenly.
What Are the Dangers?
There are four common medical problems caused by heat exposure: heat rash, heat cramps, heat exhaustion and heat stroke.
Heat rash is just what it sounds like: a rash caused by too much heat. The skin becomes irritated by excessive sweating, particularly during humid times when it can’t evaporate well.
Symptoms & Treatment. It looks like a red cluster of pimples or small blisters and is most commonly found on the neck and upper chest, in the groin, under the breasts and in elbow creases. If possible, move to a cooler environment, at least temporarily. Keep the area dry — do not wash with water unless it is immediately toweled. You can also use a drying powder to soothe some of the feelings of irritation.
Heat cramps are pains felt in the muscles, often with spasms, and usually in conjunction with strenuous activity. They’re often caused by a depletion of the body’s salt and fluids through excessive sweating, and can also be a symptom of heat exhaustion.
Symptoms & Treatment. Symptoms include intermittent and involuntary spasms of larger muscles in the body. Stop activity and rest in a cool place. Drink juice or a sports beverage to replace the fluids and salts, but DO NOT take a salt pill unless directed by a doctor. If you are on a low-sodium diet, seek medical attention. Continue resting for several hours after the pain from the cramps goes away—returning to work too soon puts you at serious risk of heat exhaustion or heat stroke. If the heat cramps do not subside within one hour of resting, seek medical attention.
Heat exhaustion is the beginning of the body breaking down by being unable to regulate its internal temperature.
Symptoms & Treatment. Symptoms may include heavy and excessive sweating, paleness, muscle cramps, fatigue, weakness, dizziness, headache, nausea or vomiting, and fainting. Stop working immediately, get somewhere much cooler or even take a cool shower or bath, and drink cool beverages that are nonalcoholic. If clothing is heavy or tight, change into something lightweight and airy. As with heat cramps, wait several hours after the symptoms subside before returning to work. If the symptoms get worse during treatment, or if they last longer than one hour, seek medical attention. Not treating heat exhaustion can lead to the more severe heat stroke.
Heat stroke is the most serious of the heat-related illnesses. The body’s temperature regulation system breaks down entirely, and the body is unable to cool itself. Body temperature can rise to 106°F or higher in as little as 10-15 minutes. At that point, vital organs, including the brain, can become damaged. Heat stroke can cause death or permanent disability without emergency treatment.
Symptoms & Treatment. There are several warning signs of heat stroke, and not all of them need to be present: an extremely high body temperature (103°F or higher); skin that is red, hot, and dry, without sweating; a strong, fast pulse; a throbbing headache; dizziness; nausea, possibly with vomiting; confusion; and possibly unconsciousness. In the event of a heat stroke, call 911 immediately and do whatever you can to cool the victim’s temperature down as quickly as possible until help arrives.
Prevention is key. But How?
Drink water, water and more water. Plenty of fresh water will keep the body hydrated and cool during intense heat. Avoid sugary and caffeinated beverages as these can dehydrate the body. Employees exposed to the sun for prolonged periods of time should also take frequent breaks in the shade, rest, apply sunscreen with at least SPF 15, and wear protective gear when possible. Employers should make sure employees are aware of the threats posed by the heat and know in advance what the heat index is for the day to prepare. The heat index takes both temperature and humidity into account to give a more accurate account of how conditions will affect the body. Once the heat index gets into the 90s and above, threats start getting severe and precautions need to be raised.
Looking for a helpful tool to track the heat index? There’s an app for that.
Occupational Safety and Health Administration (OSHA) and The National Institute for Occupational Safety and Health (NIOSH) partnered to bring you the OSHA-NIOSH Heat Safety tool — a mobile application that gives you real-time heat index and hourly forecasts for your location. This app is helpful for planning outdoor work activities and keeps you in-the-know on the current temperatures and associated risk levels. Compatible with Android and iPhone.
Additional information
OSHA has a site dedicated to heat exposure with plenty of important information. It can be found here: http://www.osha.gov/SLTC/heatstress/
OSHA also provides small business with on-site consultations for free. This is available to businesses with fewer than 250 workers at a site, and with no more than 500 employees nationwide. This is not an enforcement visit, and it will not result in penalties or citations. It merely evaluates conditions and provides information on how to mitigate potential dangers. For more information, call 1-800-321-6742
Photo: Mace Group
Mace
Infographic: Mace Group
