INOVA Fairfax Hospital – South Patient Tower
Fall Church, VA General Contractor: Turner Construction Company
Architect: Wilmont Sanz Architecture & Planning for Healthcare
Engineer: RMF Engineering
Contract Amount: $15,700,000
Contract Start Date: 12/22/2010
Contract Completion Date: 5/12/2012
Actual Completion Date: 7/12/2012
Two major challenges were involved in this project. First, re-engineering of the mechanical system, including the chilled water piping lines, had to be done in the existing Tower steam tunnel, which is only 8’9" wide and in which the temperature range is 105 – 120 degrees. Second, the new system had to be installed without disrupting domestic water service and other critical operating systems in the Heart Institute, Women’s and Children’s Center, and Pharmacy.
Assembly of the 24" piping took place under extremely difficult conditions, due to the limited 8’9" tunnel width and tunnel temperatures topping out at 120 degrees from the existing steam system. With the assistance of the Model T-9 WEBB Turning Rollers, the Shapiro & Duncan team was able to continually weld out three 24" joints at a time.
Once the piping was reassembled, it was rigged and hung in the newly-fabricated hanger system that had been manufactured at our Fabrication Shop. Then the piping was tied into the existing 20" supply and return chilled water lines. After more than half of the required system piping had been installed in the tunnel, a shutdown of the remaining chilled water system was coordinated with Hospital staff so that we could make the complex system tie-in to the existing 20" mains.
During this shutdown time, all of the fifth floor air handling units (AHUs) in the existing tower building were maintained until our tie-ins were complete. Meanwhile, demolition started on the chilled water piping in the tie-in area to remove approximately 290 feet of the existing 20" lines. That opened the door for us to start our installation of the most critical and complex part of the system tie-in. The piping was installed over the existing medical gas systems and sprinkler lines, and nested within and around the existing electrical lines.
Upon completion of this system, all piping was tested and insulated and the Tower’s existing chilled water system was brought back on line.
This project was just the start of our work on the South Patient Tower. Our team is continuing with next construction phase – mechanical rough-in of the rest of the 11-story structure.