/in /by

The client, a silicon wafer and digital memory manufacturer, hired SSOE to provide detailed design for a new bulk silane system at their facility in Idaho. The proposed area for the system was constrained by existing campus structures, and required careful planning for both the finished design and the construction phases to ensure constructability. The project faced two major challenges from the beginning:

  • Silane storage was on the opposite side of a road from the use area, requiring an over-road trestle system to safely deliver the hazardous material.
  • Final equipment selection would not be made until week six of the project, posing an immediate delay to traditional design approaches.

Over-Road Trestle Solution
Silane gas is a flammable and pyrophoric gas that requires special storage and handling. It is also the source of silicon for high tech manufacturing processes. In addition to designing the storage, containment, and mitigation measures for the Silane storage, SSOE’s team designed a robust trestle system that would safely move the gas from the point of storage to the point of use over a public roadway running through the client’s site.

Flexible Scheduling
In a typical project, civil and architectural disciplines lead by establishing the preliminary building shell, with mechanical, electrical, and process design following. Structural is involved at every stage, but performs the bulk of their work after the mechanical and process mechanical systems are in place, and the structural and seismic support needs of the equipment is better understood. For this project, SSOE delayed the civil, structural, and architectural work related to the shell to focus on mechanical and process designs, like for the silane distribution loops, which would not be majorly impacted by the final equipment selection. Once the crucial selections were made, SSOE was prepared to continue with the remainder of the design, and there was no wasted time in the client’s project schedule.

/in /by

A major supplier of semiconductor manufacturing tools wanted to expand their research and development facilities, but had extremely limited available space on their existing campus. With existing structures, adjacent bay lands, and a challenging soil composition, SSOE engineered a phased delivery of a vertical solution that accommodated all constraints.

Sandy Soil Mitigation
The combination of sandy soil and a seismically sensitive area made structural engineering for a vertically stacked building very challenging. The traditional approach to piles and platforms would have suffered from settling and vibration issues almost immediately. Instead, SSOE’s team developed an approach using micro piles and platforms. By using smaller and more numerous piles and platforms we were able to distribute the building loads more uniformly and protect against both seismic shifts and settling.

Design Precision and Specification Development
The existing production could not be shut down during construction, which required timely and precise tie-in locations via hot-taps on many of the wet systems, and closely coordinated tie-ins for air-side during short shutdown windows. The vertical nature of the utility areas required precise routing and coordination through existing yard. As a result of this need for precision, SSOE developed highly accurate project standards and specifications for the client.

Phased Execution
Existing structures in the project space required repeated demolition-construction cycles. This required SSOE to work closely with the General Contractor (GC) to develop a complex project phasing. SSOE developed modeling baselines and a BIM environment in order to manage and coordinate between trades, the GC, and the design team. The result allowed construction partners to seamlessly integrate each new building segment with the one before, while keeping the project on time and within budget.

/in /by

SSOE was selected by a leading semiconductor manufacturer to scope and design a new flagship high-rise office and research facility at one of their campuses. The project included the design of state-of-the-art research and development (R&D) laboratory spaces to develop new technologies.

At 19,850 SF, the labs are overall not clean spaces, though they will house select semiconductor manufacturing tools. The spaces needed to meet material delivery, vibration, and interference requirements similar to a Fab; attention to detail was paramount. A vibration subconsultant was engaged to ensure the designed structure would meet the exacting standards necessary for semiconductor design. Likewise, electromagnetic interference (EMI) was a critical consideration, dictating the strategic placement of the lab within the building to protect the equipment from WiFi or other EMI sources located in other areas. Telecom restrictions also played a significant role, with careful planning and material selection to provide needed connectivity without compromising sensitive equipment.

To meet ongoing needs, the client wanted a space that could be reconfigured with new tools as needed. SSOE delivered a design with access, structure, and move in / move out pads needed for easy movement of tools and equipment. This adaptability is further enhanced by the management of liquids and gases, including equipment feeds equipped with monitored drip trays and bottle-fed gas systems fed from the main Fab laterals.

The project’s Design-Build approach leveraged early collaboration between the design team and the contractor. Combined with comprehensive project communication processes, this partnership ensured efficiency and constructability across project changes.

/in , /by

Integrated design of complex liquid and gas delivery systems broken into manageable pieces for repeatable off-site manufacturing and expedited design and construction.

Getting liquid and gas materials to and from semiconductor manufacturing tools is essential, and it involves a large amount of piping. SSOE is a go-to designer of subfab laterals for a leading semiconductor
manufacturer, and for good reason. When we were asked to provide lateral piping designs for twin semiconductor fabs, one in the Southwest U.S. and the other overseas on a tight timeline, we knew we had to change how we did things. On a typical project, SSOE would provide design documents which are transferred to a fabricator to develop the spool drawings for manufacturing. For these facilities, we modeled the piping to a fabrication-level of detail, and provided the fabrication drawings.

By embedding these details into the design, we put constructability at the forefront of the project and eliminated a series of RFI back-and-forth, thus providing the client with great savings to budget and schedule. We also delivered innovative time and cost savings by designing the pipe support racks and piping to be built off-site, transported to the site, and installed in large modular sections. And, in order to facilitate inventory tracking and installation of these units between off-site manufacturing and on-site installation, we developed an asset tracking system that is integrated within our design models. Using barcodes on each spool, we were able to track whether a particular module was in fabrication, storage, or already installed with up-to-the-minute accuracy.

We further multiplied the savings created by applying our industry and client-specific knowledge to identify “building block” modules which can be assembled in various configurations. By using these building blocks, our lateral designs could be adapted for new site locations with minimal adjustments, allowing us to effectively perform detailed design work for two facilities in parallel. And for projects where off-site manufacturing was feasible, like this one, we improved construction efficiency and safety by limiting on-site materials and minimizing the manpower and logistics needed to install the lateral racks and piping.

/in , /by

SSOE was contracted by a major semiconductor manufacturer to design a 1,425,000 SF greenfield fabrication facility (Fab). The Fab would be a new addition to the client’s existing campus. Having recently completed the campus-wide master planning, SSOE was well-positioned to resolve the challenges posed during the Conceptual Design phase, including:

  • Greenfield “ground-up” Fab design planning for a 341,000 SF building with five levels.
  • Routing site utilities through, around, or over an existing Fab without disrupting production or causing excessive vibration.
  • Client requirements to keep the Fab level of the new facility at the same elevation as the Fab levels of neighboring existing buildings, complicated by grade changes in the site, and limitations from an adjacent wetland.
  • Vehicle access to the new Fab had to be strategically routed around existing structures and wetlands.
  • Full Fab development including: sub-utility levels, utility level, Subfab and laterals, 264,450 SF cleanroom manufacturing space, gowning, storage, and connections with adjacent structures.
  • Expansion planning for future chemical utility and process utility buildings.
  • Detailed analysis for utility requirements to ensure both expanded and new systems would support the intended use for the new Fab.

SSOE provided project leadership, cleanroom, and Subfab expertise while guiding a subconsultant firm through the overall facility design. This Conceptual Design phase was completed within the proposed 12-week time frame, and rolled seamlessly into the Detailed Design phase.

/in /by

When a client’s capital spending grew significantly, they needed to outsource some of their work. SSOE was a top choice when they set out to find engineering firms to manage their projects.

The first project was the installation of a new process moulding line for one of the client’s most popular candies. SSOE served as Engineer of Record for the original construction of this facility in 2009. Replacing the first production line that was installed during the original construction, this new process line has a much higher capacity and utilizes state-of-art technology to obtain improved efficiency. Project features include the moulding line, a 10,000 SF packaging mezzanine with a two-floor packaging operation, modifications to the peanut processing area and peanut butter kitchen, and additional utility infrastructure to support the operation.

What started as an FEL to confirm scope and refine the cost estimate in January 2022, quickly grew into a full, detailed design effort, then followed by a request to provide a field team to serve as the Owner’s Representative in support of the plant during construction.

One of the key components to the project’s success was the SSOE’s site team, composed of employees from SSOE’s León office, who worked with both the client and SSOE U.S.-based Subject Matter Experts, to help eliminate language and cultural barriers.

SSOE encountered challenges during the construction process. However, the team worked tirelessly to overcome these challenges and ensured the client remained satisfied. The client applauded our design and procurement processes, as well as our responsiveness and knowledge of the site. Even with delays, SSOE managed to make sure everything was delivered to the site and installed properly.

We built a partnership with the client and they viewed our field employees as an extension of their team, trusting us to drive results. This allowed the client’s engineering team to focus on other projects, saving time and money for the client. SSOE saved the client over $3 million. Of that, $2.5 million was realized in the FEL process and an additional $500,000 was saved through process improvements.

/in , , , , , /by

SSOE’s design of vehicle and powertrain manufacturing facilities returned more than the total fee in construction savings when compared to the competition’s design for the same facility.

Toyota has utilized SSOE as their trusted A/E partner of choice since 1999. SSOE’s structural department has consistently designed facilities for Toyota that could be constructed for less than any of their competition in the market place, regularly designing much closer to the actual service factor. SSOE consistently delivers on schedule for Toyota, and the number of errors and omissions experiences is much lower than what they had seen with their previous engineering services providers.

With these factors in mind, it was an easy decision for Toyota to select SSOE to provide the design to double the size of their automobile manufacturing plant in Princeton, Indiana and for their greenfield facilities in San Antonio, Texas and Tupelo, Mississippi.

In Indiana, having gained an understanding of Toyota’s goals and needs from previous projects in France, SSOE provided architectural / engineering services for an addition to the existing factory space to double the assembly plant.

In Texas, SSOE provided the facility design for a greenfield truck assembly plant on a 2,000-acre site that included suppliers. SSOE also provided on-site engineering staff to Toyota’s Owner’s Representative Office (ORO) to support the construction efforts and coordinate the design documents during construction phases.

In Mississippi, SSOE performed the master planning and design of the plant, as well as provided on-site engineering staff to Toyota’s Owner’s Representative Office (ORO) to support the construction efforts and coordinate the design documents during construction phases.

/in , , /by

The first EDGE radiosurgery LINAC of its kind in North America—second in the world.

Henry Ford Health System chose SSOE Group to provide architectural and engineering services, which included the removal of a linear accelerator (LINAC) and installation of a new Varian EDGE radiosurgery system in an existing vault in the basement of Henry Ford Hospital. Initially, the vault was not adequately shielded for the radiation output of the new equipment, as determined by the client’s on-staff physicist. SSOE worked closely with the physicist, shielding contractor, and construction manager to creatively solve this problem and ultimately provided a fully-shielded treatment room to house the first EDGE radiosurgery LINAC of its kind in North America—second in the world.

SSOE has become a trusted partner of Henry Ford Health System over the years, often called upon to provide our expertise in some of the most challenging of circumstances. We pride ourselves on providing the finest solutions in architectural, structural, mechanical, and engineering services to allow our customers to provide their patients with unparalleled healthcare. The EDGE radiosurgery system allows doctors to minimize treatment time and provide more accurate treatment of cancerous tumors, while minimizing radiation damage to normal tissue surrounding the tumor.

/in , , , , /by

ProMedica Health System, a locally owned, non-profit healthcare organization serving Northwest Ohio and Southeast Michigan established in 1986, has completed the renovation and construction of their new corporate headquarters in downtown Toledo, Ohio. The move to downtown’s waterfront entailed the renovation of the vacant historical Edison Steam Plant, renovation of the adjacent former Key Bank building, and construction of a new multi-level parking structure.

In cooperation with HKS, SSOE was the firm of choice to provide full mechanical, electrical, plumbing, technology, and fire protection (MEPT / FP) design services for the two large commercial office structures. Our team of experts carefully evaluated the existing buildings and the historic aspect of each building that needed to be maintained, and provided detailed engineering design for the HVAC and plumbing systems, the Data / Fire / Security systems, the fire suppression systems, and the electrical system, including site lighting.

The existing Key Bank building will house a new YMCA space in the basement level, the Chop House restaurant on the lobby level, and office spaces on floors two, three, and four. The large variety of mixed building use is unique to this type of project but was successfully handled by the design team. SSOE is proud to be a part of this local project that promotes economic growth and urban revitalization. The project was completed in August 2017.

/in , /by

Through innovative design concepts, benchmarking common practices, and scheduling, SSOE has saved the client more than $7.3 million to date.

Nimble and resourceful, SSOE quickly increased personnel for a critical tool installation design project when a semiconductor client accelerated release of a new technology. This project, part of an ongoing program for the client, included the installation of 250 tools over the course of a year.

Initially, the project required all design work to be performed in Oregon. However, due to the quick ramp up needed on this project, the client determined that design work could be completed remotely. SSOE quickly responded, engaging tool installation design teams in New Mexico and Arizona to support the Oregon team. In addition—for the first time in SSOE’s tool installation design program history—SSOE’s Mumbai, India, and Leon, Mexico, teams were engaged to provide critical support to meet project demands. Getting these international team members on board allowed for greater agility and flexibility on this project. In addition, it allows for a trained workforce to be available on short notice for burst capacity as well as subsequent easing off the project as workload diminishes. This approach keeps SSOE’s project budgets and schedules healthy and, in turn, enables our clients to get their products to market on-time to meet demand at a competitive price point.

In addition to providing a high level of service on this project, SSOE implemented a number of efficiencies that have saved the client more than $7.3 million to date. A utilization-based resource staffing model and a workshare agreement form, as well as innovative design concepts, have all contributed to these significant project savings.

/in , , /by

The scope of this project involved the conversion of an existing 500,000 SF pet food facility from a textile manufacturing facility to a wet pet food facility and distribution warehouse. The site, idle for nearly a decade, required extensive refurbishment, site improvements, and building modifications to make it ready for the new processes. The project included site development, construction, design, equipment procurement, installation, and start-up of two canning lines.

The initial project phase included the civil site design, with additional parking, new roadways, laydown areas for construction, Stormwater Pollution Prevention Plan (SWPPP); lighting, and a completely new medium voltage site electrical distribution system. Interior work included the definition and design of new rooms, new floor slab, industrial waste drain system, design and specification of new utilities (HVAC, boilers, compressed air, bio-filter odor control, and others), process and packaging design, and overall modeling / BIM/VDC.

Due to the complexity of the project and condensed schedule, multiple entities were engaged across a wide variety of tasks, requiring a high level of collaboration. For example, separate design / build efforts were needed for the freezer, empty can building, compactor area, wastewater treatment, and employee center. Coordination was also extensive between the multiple layers of the client’s project management and engineering disciplines. Lastly there were multiple vendor supplied “modules” (dries, meat bins, gravy, and packaging), which were integrated into the design and installation.

/in , , , , /by

SSOE was selected to provide architectural and engineering design for the Sandusky County Courthouse’s interior renovation project. With the main part of the building dating back to 1844 and an expansion in the 1930’s, the courthouse’s interior was in need of significant modernization. Mindful of the building’s original Grecian design, SSOE was able to complement its 19th century style, while giving it 21st century functionality.

The age of the facility provided many obstacles that had to be overcome to ensure the design was feasible with the building’s current architecture and the schedule could be realized. The courthouse’s architectural improvements included ADA upgrades, enhancements to both public and staff areas, and department layout improvements to provide increased efficiency—marrying contemporary and traditional finishes throughout for a uniform appearance. Project savings were realized by preserving existing corridor marble walls with the removal of 100+ years of build-up.

The courthouse’s technology and security systems received a complete overhaul as well, which included installing a single point of entry with metal detectors, securing all remaining access doors with card reader access control. A complete lock down security system was installed with alert buttons placed in each department for use as needed. By better defining public and staff areas, we were able to improve workflow from one department to the next. Most importantly, employee safety was significantly enhanced through the security and mass notification measures put in place by SSOE’s data / fire / security experts.

/in , , /by

This well-known automotive client set an aggressive goal of producing mostly electric and autonomous vehicles by 2035. To achieve this, the client developed a plan that centers around converting multiple Internal Combustion Engine (ICE) manufacturing and assembly facilities to all-electric vehicle plants and spans several locations throughout North America.

Partnering with multiple general contractors, SSOE provided the engineering and design of substantial renovations and expansions for two facilities. To drive efficiency, the collaborative team leveraged Lean project delivery methods on every project.

The team and client stakeholders used the Big Room concept and remote collaboration to review the proposed facility additions, connections to existing buildings, concepts for new program elements, and stand-alone greenfield manufacturing construction. All sites employed a fast-track schedule, relying on innovation and technology to quickly move the projects from planning and design to construction.

The team’s first project focused on engine, body, paint, and general assembly shops, in addition to process buildings, a commercial kitchen, and an employee cafeteria. SSOE and its partners kicked off the project with an in-person Big Room collaboration meeting. However, three months later, all team members were forced to work remotely due to COVID-19. To keep the project on track, SSOE implemented an on-site construction administrator and daily virtual huddles.

At the second site, SSOE designed major plant additions, including new body and paint shops. The project included a nine-bay dock addition to the general assembly shop and a three-bay addition to the current body shop, with a connector trestle spanning over a road. Our team also designed the structural reinforcement of many existing buildings to accommodate the heavier electric vehicles. Additionally, we relocated the facility’s main access road to provide space for the paint shop addition and other utility tie-ins within the existing plant.

Throughout these projects, SSOE gained significant knowledge and insight into the process of converting ICE facilities to EV producing plants, which we will leverage as we continue to assist this client with its program.

/in , , , /by

Continuing our partnership with the Anthony Wayne Local Schools district, SSOE transformed the priorities established during the master planning phase into design solutions across the district’s four campuses. The main campus, which includes Anthony Wayne High School, Anthony Wayne Junior High School, and Fallen Timbers Middle School, received overall facility improvements, upgraded security vestibules and visitor entries, a new high school office addition to make room for three new science rooms, and a media center addition at the junior high. The new high school auxiliary gym and cafeteria addition are adjacent to a new commons area that incorporates storefront windows that allow interior access to daylight. This space will be used by students daily as well as for public events.

The elementary schools also received upgrades. Monclova Elementary School received a new security vestibule and office addition, classroom modifications, and infrastructure improvements for energy efficiency. Waterville Elementary School upgrades included a new security vestibule / office renovation, new four-classroom addition for kindergarten students, and renovation of the daycare program’s office space. Whitehouse Elementary School received a new 70,000 SF facility on the same site as the existing elementary school. The architectural design included repurposing stone elements from the original building into the new facility to carry forward the community’s history. This facility also includes a storm shelter and new playground.

All upgrades focused on student and staff safety, including the site designs, which were updated for bus circulation, parent / visitor and student parking, and parent drop-off to reduce congestion and increase student safety. SSOE also worked closely with the district’s operations personnel to increase energy efficiency with the improvements.

Classroom designs included learning communities, active learning spaces with grade-specific media materials and collaborative areas for teachers and students. The science labs were designed and laid out for 21st-century teaching and learning. Existing education spaces were updated with new technology, and traditional classrooms were opened up into multipurpose student-centered learning spaces.

/in /by

SSOE delivered more than $8 million in documented project savings through our team’s focus on due diligence, in addition to its approach to pipe routing design and other process and facility modifications.

When this globally recognized beverage manufacturer began to experience sanitation and quality issues related to one of the facility’s cellars, it enlisted SSOE to provide the design of a major brewing process addition to replace it.

SSOE’s team provided complete engineering and design for site and facility modifications and additions to house the new tanks, pumps, valve arrays, CIP systems, and associated equipment. Significant piping routes and structural modifications were required to accommodate the new tanks and piping distribution systems. Project execution was carefully planned to minimize the impact of construction efforts on plant production operations, while allowing for required personnel access and material flows.

True to SSOE’s commitment to driving value into every project we deliver, our design and engineering team members were diligent in identifying and implementing cost saving measures throughout the project. The team’s focus on due diligence, in addition to its approach to pipe routing design and other process and facility modifications generated more than $8 million in client savings on this project.

/in , , , , , , /by

SSOE’s complete steel prefab structural building drawing ultimately saved La-Z-Boy over $500,000.

La-Z-Boy desired a research and development center that reflected the importance of innovation and technology to their company. Their vision was to create a new state-of-the-art R&D facility with larger, modern work spaces that would aid in improving staff recruiting and retention.

The SSOE team, with construction manager Rudolph Libbe, worked closely with La-Z-Boy on this design / build project, utilizing 3D modeling reviews to communicate clearly with the client’s project team to assure they fully visualized the design concepts. This allowed the client to understand the design at each phase and see how their design requirements were being incorporated. The final design included a combination of a 50,000 SF pre-engineered research building and a 20,000 SF conventional building designed with flexibility for the office spaces.

The research / testing area includes shops, wood working, and engineering spaces. The office space has an open floor plan incorporating the flexible workplace strategy, with only one walled office for the vice president. This floor plan, along with the café and outdoor seating areas, follow La-Z-Boy’s overall strategy to have office neighborhoods where people aren’t tied to the same work space on a daily basis, providing employees with a choice of where to work. There are also movable furnishings with electrical outlets located throughout for device charging.

The Innovation Center’s corridor is lined with windows that provide a view into the research and engineering brainstorming “garages” where they refine pieces of furniture and collaborate on design innovations. SSOE’s engineering team designed a special dust collection system used in the facility.

SSOE was pleased to offer architecture, MEP and structural engineering, dust collection, data / fire / security design, steel detailing, and interior design services for this facility that met the client’s goal and vision for a modern and flexible workplace for their employees.

/in , , /by

Over the past 6 years, we’ve managed to save a leading consumer products client more than $8.8 million on SSOE projects demonstrating the ever-increasing value of our partnership. They’ve utilized SSOE as their preferred A/E partner since we began providing our services to them in 2012.

The client had seldom worked with outside firms and was initially apprehensive about working with a new team. Our multidisciplinary team worked diligently and consistently to build trust within the client’s team, while providing world-class service, which has resulted in us delivering 48 projects at the client’s various processing facilities. Here are some of the highlights:

Production Capacity Increase

In order to increase the production capacity of plastic storage bags, the client entrusted SSOE with the conversion of two production lines. As this conversion involved a new product, time to market was crucial and an aggressive schedule was required. The project included the design of a vacuum and reclaim system to feed waste to the front of the production line, along with an exhaust system for new production equipment. We also provided the design of a mezzanine for the support of additional production equipment, an upgrade to the plant power supply, additional process equipment, and various building upgrades that included fire protection systems.

Instrument specification support and electrical upgrades consisting of a new transformer, switchgear, and electrical panels were also required. Our team was able to save the client $58,500 on this project by repositioning hangers to align with existing steel floor beams, reusing an existing roof girder to hang the bridge crane runway beams rather than installing new, and leaving the existing switchgear connected to its transformer to avoid swapping feeds with the new equipment. Additionally, we provided procurement services, construction management support, and package delivery for all SSOE-designed systems.

Innovation Solutions with Technical Know-How

Impressed by the value SSOE brought on previous projects, the client asked SSOE to design or modify various mechanical processes for multiple unique lines across several processing facilities to add new features to its plastic storage bags. Functioning as an extension of the client’s team, we worked directly with their R&D staff to design several prototype subassemblies, which were installed in a pilot line to verify functionality before full-scale design.

Based on the client’s aggressive schedule and launch date, it was evident that a traditional design / bid / build delivery method would not be effective for this project. In addition, there was a requirement to minimize downtime for all lines. We worked with the client to develop a project execution strategy that reduced the amount of downtime from 3 weeks to 2 weeks per line, providing the client more than $3 million in savings. Contractors were pre-selected and participated in review meetings early on to not only collaborate more effectively, but improve external coordination and ultimately the outcome of the project.

One challenge was incorporating more than 10 unique equipment layouts that we designed to fit into different locations within the client’s various facilities. Additionally, the layout for new equipment needed to be installed within the previously mentioned 2-week window—no small feat. We also attained a temporary project license in the location of one of the client’s facilities in order to seal required drawings and keep the project on schedule, which ended up saving the client a projected $2 million in construction package redesign fees.

Expanding Production to Enter New Markets, with More Options

The client was looking to add three additional lines at an existing manufacturing facility to increase production capacity, expand into new retail markets, and create fresh packaging options. Our multidisciplinary team was selected to provide both facility and process support on this $25 million project—performing architectural, civil, structural, and MEP engineering on the project as well as machine design, packaging, controls and instrumentation, and process design for utilities. We were also responsible for purchasing all equipment.

During the project, we worked with the client to install temporary walls to prevent contamination and disruption of other production lines. SSOE’s in-house construction capabilities were also put to use as we helped optimize the construction bidding process for the client, assisted with procurement and cash flow management, and provided on-site field support for the duration of construction. At the peak of the project, the team consisted of more than 25 people.

The project was not without its challenges. At this particular facility, the client was implementing two very large capital projects with aggressive schedules at the same time, creating several obstacles along the way—including a contractor that was new, not only to the site, but also the client, and a modified purchasing procedure that required detailed bid packages be divided by discipline. To keep the project on track, our team assumed leading start-up and commissioning activities and was tenacious in providing the higher level of detail needed for construction documentation, meeting all budget, schedule, and staffing requirements while maintaining a level of quality the client had come to expect from SSOE. We were able to reduce the number of planned packaging lines without negatively impacting production, thus saving them more than $2 million.

Increasing Production Output by Maximizing Technology

When the client set a goal of increasing its production of plastic film storage products within a multi-year period, they again reached out to SSOE for assistance. By this time, our team had worked to seamlessly integrate themselves into the client’s engineering team, assisting them with multiple key capital projects in addition to supporting a number of routine activities. Our on-site team solidified their relationship with the client, leaving them confident in our ability to help them meet their ambitious goal. Due to our positive track record and knowledge of both the client and the site, SSOE was selected to deliver this $65 million capital expansion project, providing conceptual engineering through start-up and commissioning.

The project—designed to cGMP standards—included the design of a new facility on the client’s existing site and two identical packaging lines within: one for carton and case packing, and the other for shrink wrap and bulk packing. The process included new and innovative packaging concepts. In order to address space constraints and operator access issues, the process was designed into a Lean configuration, allowing the system to fit into the designated area while reducing overall operator travel and increasing efficiency. Notably, the SSOE-designed facility qualified the client for a local energy efficiency
program, which equated to an $170,000 credit. Our design optimizations also allowed us to eliminate confined spaces in the new facility and reduce work at heights, helping us achieve more than 180,000 working hours of injury-free construction.

An industry leader in leveraging technology, SSOE employed reality capture, or laser scanning, to significantly improve the speed and accuracy of capturing existing field conditions. By using a long-range scanner—one of three types of scans we have the ability to perform—we not only reduced time spent conducting on-site walk-downs, we were able to create a point cloud that was referenced into a detailed 3D model, which helped avoid costly rework in the field. The resulting 3D model served as the basis for all design reviews, bringing project stakeholders together early on to eliminate hand-offs, reduce waste and cost, and compress the schedule. The approach also allowed for design changes on the fly while providing ongoing clash detection.

Giving the client a lot of credit: the SSOE-designed facility qualified the client for a local energy efficiency program for one of two packaging lines, which equated to an $170,000+ credit.

/in , /by

Often, the most difficult part of a job is pulling together consultants working on various pieces of the project. While the task of coordinating numerous suppliers is vital for project success, it is not the most valuable use of one’s time. This global consumer products client recognized this, and enlisted the assistance of SSOE to act as the coordinator of three design firms for this time-sensitive project. This included coordinating the fast-track schedule and budget for the three firms.

This project involved process line additions required to add two new perfumes to the client’s laundry product line. Technical components included installing two new 3,000 gallon tanks, piping to tie the new tanks into the mixing skids, and an extension to the Motor Control Center (MCC) room.

SSOE’s engineering expertise, combined with our familiarity working as an extension of the client on numerous projects at this facility, made coordinating this project a seamless effort.

/in , , /by

In the world of consumer products, it is well known that speed to market is of utmost important when it comes to new products. When this well-known, global consumer products manufacturer sought to launch it’s new 2-in-1 laundry product line, it was critical they be the first to market in order to reap the first-mover advantage.

In an effort to capitalize on the strengths of multiple engineering providers, the client decided to award the project to a consortium of competing firms. SSOE and its partners were charged with providing all engineering and design services to allow for the production of the new laundry product. This included the design of new tanks and piping, as well as tying them into to the existing mixing skids. In addition to this technical role, SSOE was also tasked with coordinating the efforts of all design and construction firms involved in this project.

The project was successfully completed within its fast-track schedule. This allowed the client to get the new product on store shelves before its competitors, resulting in increased revenue, profitability, and higher return on investment.

/in , , /by

A well-known food manufacturer hired SSOE to design, install, and start-up the process and packaging lines for their newly upgraded facility in North Carolina to allow the production of its new brand. To accommodate an aggressive schedule, the team held an interactive planning (IAP) session at 60% design development to consider alternative methods to ensure successful delivery of this complex project—ultimately enlisting the help of SSOE Systems, our construction management division.

By using a criteria package instead of a more traditional bid document, we were able to start installation before design was completed, resulting in significant time savings. The team only had a small window of time to move the equipment and get the repurposed facility up and running. One team member provided on-site assistance at our client’s west coast facility where the equipment was removed and another in the facility in North Carolina where a combination of both repurposed and new process and packaging equipment was being installed. Moving into the installation phase the team realized many of the 2D installation drawings were incomplete and quickly decided to use the 3D model as the construction guide for installation. This minimized rework and ensured the team was working from the most current design, providing the ability to confirm dimensions in real time as equipment was being installed and maintain a high level of activity at each site to achieve our client’s tight timeframe.

On-site in North Carolina, we held daily reviews around the model with the contractors. With more than 30 different systems interacting together, a visual tool became necessary to keep the trades moving. Contractors were able to show 3D renderings to the trades below them to provide a better idea of how everything would go together. There were a couple of very specific cases with pipes at two to three different angles, making it difficult for contractors to lay out at ground level. We were able to measure spool pieces, or certain sections of the pipe, directly through the model, and the contractor fabricated to our dimensions seamlessly, which was especially beneficial on the more complicated runs.

Late in construction, a permitting issue was discovered for the process equipment. We negotiated with the county, who ultimately agreed to us running the equipment while documentation was being created for the permit as we were nearing the checkout phase of the project—and allowed equipment training without an occupancy permit.

/in , , , /by

Direction Credit Union selected SSOE as their A/E firm to assist with the design of a new headquarters location in downtown Toledo. Working closely with JLL and SSOE for site selection, Directions chose to move their headquarters in to the Tower on the Maumee, a building on the Ohio Historical Registry. This move involved merging two existing suburban office locations into the headquarters on the 15th, 16th, and 17th floors in the newly redeveloped Tower.

The Direction leadership team’s vision was for a cultural change and creation of a more open and collaborative workplace. The space was planned to create multiple teaming, conference, and collaboration zones, with the elimination of most private offices. They desired spaces that would respond to changing workforce demographics, and one that would allow them to continue to be innovators within their industry. We worked closely with the furniture / change manager, providing employees options and personal choices in their areas, such as varied work spaces, adjustable height work surfaces, adjustable computer monitor arms, personalized user tools, and various types of furnishings to support different employee work and conferencing styles.

The headquarters design includes the renovation of three floor plates. Design features include 360 degree views of downtown, multiple team and collaboration spaces, two work cafés, and a large multi-use boardroom. The interior color scheme reinforces Direction’s branding and interior vision for their new space. This new, cutting edge workplace has the latest technology, wi-fi, and plug and play flexibility for employees and visitors to access. The new Direction’s Credit Union Headquarters will become a workplace destination with an atmosphere of high energy, excitement, and amenities that attracts and retains employees.

/in /by

SSOE’s design eliminated two underground tie-points and piping and saved $60,000 in engineering and construction.

TransCanada sought to update its aging 9,000+ mile ANR natural gas pipeline system to maintain its reliability, preventing any potential system failures. As a part of this process, the company’s engineers documented system issues at their compressor stations and then contracted SSOE to start upgrades at six compressor stations.

In a two-phase approach, we performed field analysis, defined a preliminary scope (Phase I), created detailed design packages, and provided construction support (Phase II). Maintaining a strict schedule, one site visit was conducted per station. Field investigation time was maximized by utilizing hand held laser scanners. Upon field analysis completion, design differences were discovered in each stations’ systems.

Customizing a system design for each compressor station doubled our scope of work, and the outdated drawings from ANR impeded the process. Despite these obstacles, the schedule could not change, and we coordinated efforts among multiple offices in the U.S. and India to work on the design packages.

Creating almost 1,000 preliminary drawings during the scope definition phase, we finalized the work scopes and launched into Phase II. The final construction packages consisted of scope drawings and demolitions drawings (538 total), design documents, equipment submittals, and work scopes.

During Phase II, SSOE provided construction support and modified the old ANR drawings to bring them up to TransCanada’s current CAD standards. The entire project was completed on schedule.

/in , , /by

The SSOE team documented more than $500,000 in cost savings through innovative approaches on the project.

SSOE was selected to provide architectural, structural, mechanical, and electrical engineering design services for a 150,000 SF tire manufacturing facility expansion in the Southeast U.S. The area for expansion included wire winding, tire build, and tire curing areas which included utility routing to the curing presses through the pit and trench system.

Cooling water and electrical upgrades were required to support the expansion along with the relocation of a main drainage swale and the reconstruction of the fore-bay / detention pond system.

During the initial design meetings, SSOE was given design parameters for a 100’-0” addition. Bay sizes were then discussed as (2) 50’-0” bays +/- and how bay sizes would match with the curing trench locations. SSOE proposed to clear span the entire 100’-0” distance in the curing area and within the ASRS, tire build, and wire wind areas to allow for maximum flexibility within the space. The idea was accepted with a single stipulation of minimum clear heights within the building. The main girders were designed with specific clearance openings to accommodate the utilities so that the clear height could be maintained. While there was a premium in the steel framing for long span members, larger columns and footings, the cost was partially offset by reduced column quantity and foundations / excavations.

SSOE’s scope also included steel detailing services, eliminating the need for steel shop drawing generation and review—resulting in a 10-12 week reduction in project schedule.

/in , /by

When Miami University needed assistance with an indoor Distributed Antenna System (DAS) to support data needs, the SSOE team responded with unique design solutions. SSOE gained familiarity with the campus and its many unique architectural elements while consulting on outdoor DAS facilities. Now, the team needed to provide high data throughput within the buildings themselves.

Placing antennas in the many iconic spaces on campus provided a challenge to which SSOE’s team was able to meet with imaginative stealth designs allowing inconspicuous antennas where a stronger signal was needed. Photo renderings were created to ensure University aesthetics were a priority. Upon completion, students will have seamless coverage with high data rates throughout the entire campus.

Close collaboration between SSOE and the University ensured all work could be completed in short breaks between semesters—requiring a high degree of communication and coordination before and during construction. SSOE has professionals ready to be on-site within hours as required to achieve this. With disciplines ranging from architectural to structural on hand, SSOE is able to respond to any challenge from stealth antennas to cable routing without the need for outside resources or consulting.

/in , , /by

Despite setbacks, the schedule for this complex project was met through creative sequencing and quick thinking.

When this project for a major consumer products client went to bid, SSOE was not the lowest bidder and lost the job opportunity. The successful bidder was new to the site and their lack of familiarity caused delays in schedule. They struggled to meet the strict timeline and, in the end, were removed from the project. SSOE was asked to take over the large project, complete with compromised time-critical schedule, and get it back on track.

To ensure deadlines were met effectively, SSOE utilized offshore resources; an Indian-based engineering firm. This afforded round-the-clock development of over 300 drawings.

The project goal was to realign the filling lines with palletizers of a similar speed to avoid bottlenecks and under-utilized capacity. While a typical project would reroute only one line, this project rerouted seven lines to different palletizers, making this project especially complex.

SSOE’s on-site construction assistance proved especially helpful when our extensive in-plant experience allowed us to efficiently act as the project’s scheduler, coordinator, and supervisor. Through strategic sequencing of construction, the team was able to get this project back on schedule and avoid any costly down time.

/in , , , , /by

Through the design and implementation of a number of efficiency improvements such as equipment placement and repurposing to reduce process demands, SSOE was able to save the client $1.2 million in project costs.

Betco Corporation, a manufacturer of cleaning products, purchased a brownfield site in order to consolidate equipment and processes housed in three separate facilities into one central location. SSOE was selected to provide architectural and engineering services in support of the renovation and expansion efforts necessary to prepare the facility for operation. The expansion involved the renovation of 242,000 SF of manufacturing space and the addition of 54,640 SF to the facility.

SSOE drew from its extensive bench of engineers and architects to form an experienced team to work closely with Betco throughout the project. The team met with the client’s staff on a weekly basis to communicate progress and discuss any issues that may have arisen during the previous week. SSOE also assigned a chemical process engineer to work in the existing Betco facilities and assist in the evaluation and classification of the chemicals used in manufacturing their products.

Working together with Betco’s staff, the SSOE team completed front-end loading (FEL) for the project. During the FEL process, a conceptual layout of the site was developed, along with a 30% cost estimate and milestone schedule. As is the case with many small businesses, Betco did not have the internal staff to create P&IDs for the new operations, which led to SSOE creating a complete set of P&IDs for the new facility. In order to maintain operations in the existing facilities, a blend of new and existing equipment was included in the final layouts. Several processes were also analyzed and updated to significantly increase efficiency.

The code evaluation for this facility proved to be very complex. SSOE provided support in preliminary meetings with the county plans examiner and throughout the building permitting process. Fire walls were incorporated in the design to provide separation, with steel fireproofing for added protection and explosion relief. To effectively accommodate the large amounts of hazardous materials on-site, two additions were designed to isolate them from each other and the rest of the facility. This design was based on SSOE’s site evaluation and included minimizing piping lengths, considering truck deliveries, and minimizing the impact to existing utilities.

 

/in , /by

SSOE has been performing design engineering for tool installation packages for MOK (Multiple of Kind) and FOK (First of Kind) tools for multiple functional areas of this world-leading semiconductor client’s development manufacturing facility. This project launched the client’s new business methodology of designing engineered packages from one location for projects around the world, with part of the team on the ground for design review and fieldwork and the remainder of the team in other U.S. locations. This enabled the client’s internal engineering design staff to exert more control over the design process for standardization throughout the entire corporation.

Because of our success, SSOE was able to be highly efficient, leveraging the skills of SSOE team members operating in multiple locations including Santa Clara, Oregon, New Mexico, and Arizona.

Schedule was a significant challenge for this program, as rapidly evolving technologies and developmental fine-tuning resulted in the needs changing throughout. SSOE’s flexibility and skill at managing scope change has been key to the success of this project—enabling the achievement of client productivity goals. In recognition of SSOE’s ability to keep pace while maintaining a high level of quality, the client consistently allocates additional scope above and beyond the standard tool installation design.

The team’s exceptional attention to detail extends to our cost management systems. Through lean management and continuous process improvements, SSOE continuously returns savings to the client. This culture and focus has given the client confidence in SSOE’s abilities, as evidenced in additional project awards.

/in , /by

SSOE saved the client $7 million in installation costs by leveraging PPMOF and BIM.

A global semiconductor client had plans to fit out an empty manufacturing building with process tools for a new technology. They selected SSOE to design the build-out of the sub fab laterals because of our extensive BIM capabilities. SSOE led the work for the subfab process laterals—an extension of utilities that would facilitate process tool installation on the level above. The 1300 process laterals included chemicals, gases, waste, waters, exhaust, telecom, and life safety systems. The team facilitated an early construction start date and saved the client money by leveraging several unique work approaches:

PPMOF: Prefabrication, Preassembly, Modularization, and Off-site Fabrication

SSOE approached the design with the client’s goal of PPMOF in mind. This strategy allowed installation coordination to take place early, providing schedule and labor savings. The team designed the strut racks to be fabricated off-site, then lifted into position in modules. All water, gas, and waste lines were fabricated with valves off-site in the longest lengths possible to rig onto the rack.

BIM2Fab

SSOE team members transitioned BIM design models into construction models to aid in the execution of PPMOF and eliminate project waste by removing the need to create a construction model from scratch. The construction models were then used to produce fabrication (spool) drawings for the trade partner to fabricate off-site. The team saved additional time by eliminating the typical contractor redline process used to develop record drawings. Since the model was used for fabrication there were no deviations from design. Such tight alignment resulted in the achievement of zero-redline designs due in part to SSOE opening up our office to enable the trade partners to co-locate with SSOE during the project.

Kanban

Kanban, a scheduling system for lean manufacturing and “just-in-time manufacturing,” was used to coordinate design efforts and streamline communication. This was the team’s first time using this software across companies—between SSOE and the trade contractors. It provided visibility of hand-offs between each company resulting in zero lost time and minimal email communication.

International Workshare

By collaborating with counterparts in India to achieve day and night design effort, the team was able to ramp up production to help meet the aggressive schedule set for this project. The use of Kanban for hand-offs between the two teams was crucial in meeting many of the project milestones. This method provided an estimated 50% increase in productivity.

/in , /by

In a multi-billion dollar industry where companies feel pressure to continually innovate and increase efficiency, semiconductor manufacturers cannot afford to have anything stop production in their fabrication facilities. This global semiconductor client discovered that the cleanroom in their aging mask operations facility was at risk of going out of compliance due to the state of the mechanical systems. The client chose SSOE, through our Joint Venture Design / Build partnership with JE Dunn, to embark on a nearly 2-year, $150 million project to modernize the facility, bringing it up to specification and into compliance with current standards for code, reliability, and safety.

Upgrading of the facility’s mechanical and process systems was a large undertaking. The work included: 

Hazardous chemical storage space. SSOE addressed the need by expanding the chemical storage space and necessary support systems including exhaust fans and scrubbers, and safety treatment systems for chemical storage areas.

Acid waste neutralization system. SSOE upgraded this system by adding a caustic storage and distribution system and reaction tank modifications.

Additional mechanical and process system upgrades. These included chilled water, heating water, system cross-ties to provide redundancy, process vacuum, house vacuum, and process chilled water supplying the process tools in the fab.

BIM2Fab. SSOE performed detailing of the heating water and chilled water piping to produce fabrication drawings of the piping for the system crossties.

Clean-up. To create adequate space for all new systems, the team demolished and removed obsolete equipment.

A small team on the ground at the client’s facility received support from a remote design team residing in multiple SSOE offices. The project team made extensive use of BIM and Point Cloud software, eliminating the need to locate an entire team on the client’s site. This resulted in significant project savings and allowed the team to make the most of the resources available to them.

/in , /by

Facing ever-increasing industrywide pressure to reduce cost and time to market, a world-leading semiconductor manufacturer needed to increase efficiencies on its 300-acre technology development campus. This project involved the design and construction of a 43,000 SF structure, known as a “cleanlink,” to connect the chip maker’s primary research facilities—allowing for the seamless integration of manufacturing.

Prior to this structure’s completion, cleanroom staff had been forced to use complex and time-consuming measures in order to fully utilize the separate fab buildings. With the cleanlink in place, wafers can now move to the other fabs on campus without leaving a clean environment and risking damage to the product.

Moving wafers within the link and fabs is accomplished by an Automated Material Handling System (AMHS). More than 2.5 miles of overhead track connect the AMHS wafer conveyance systems of multiple buildings, allowing for direct tool-to-tool WIP movement without human intervention.

The cleanlink consists of three structures:

A Transition Building. A two-story Transition Building with H5 occupancy was designed to enable the AMHS to overcome the elevation difference between two of the buildings. It contains multiple catwalks and interstitial levels, providing access for maintenance for both the transition devices and the AMHS. Wafers are moved both horizontally and vertically within this space.

An AMHS Link. The AMHS Link was designed to accommodate pedestrian traffic, but its primary function is to support and enclose the AMHS track system. An interstitial level provides access and maintenance points for servicing the AMHS.

A reconstructed utility bridge and pedestrian walkway. SSOE and JE Dunn removed and reconstructed 80% of an existing pedestrian walkway to more effectively handle the upgraded AMHS system and to create a more efficient walkway used by people every day.

/in , /by

Following the client’s success in a high-volume manufacturing facility using a new design methodology—providing design engineering for tool installation packages from one location for projects around the world—SSOE was requested to mobilize for a new project in a second high-volume manufacturing facility. SSOE augmented a small team of local staff in Arizona with design staff in Oregon, New Mexico, and Ohio to perform MOK (Multiple of Kind) tool installation designs for the most complex functional area of this world-leading semiconductor client’s high-volume manufacturing facility.

Two A/E firms were already on-site performing design work locally but were unable to meet the steep demand curve of this new technology transfer project. Integrating into the site where existing BKMs and stakeholder expectations differed significantly from contracted deliverables proved a significant challenge. SSOE was recognized for leadership in promoting the new program to client stakeholders and guiding other A/E firms on the program parameters including code compliance issues, project reporting, and quality program implementation.

SSOE started 79 and completed 31 tool design packages in its first quarter on-site and closed a backlog of highly complex tool conversion designs within 8 weeks. While mobilizing from 0 to 28 staff across 4 sites and with significant schedule and stakeholder availability issues, SSOE maintained a 100% performance against schedule rate and a 98% positive quality scorecard rate.

/in , , , , /by

When faced with the need for new elementary schools, Fremont City Schools selected the team of SSOE / Munger for design. The seven existing elementary schools will be demolished and consolidated onto the four existing sites of Atkinson, Croghan, Lutz, and Otis. Each new Pre-K through 5th grade building will be constructed while the existing elementary schools are occupied with classes. The new facilities will be 58,460 SF in size and were designed to meet LEED Silver certification requirements.

Led by SSOE, the four elementary projects have the exact same floor plan, with two of the schools mirrored on their sites to better facilitate parking and bus lanes. The duplication of floor plans provides each student in the district with the same experience, allows staff to transfer from one building to another easily, and provides ease for facility maintenance and First Responders. The designs are focused on student centered learning environments, with first through fifth grades each having their classrooms surrounded by a learning studio. Pre-K and Kindergarten areas are connected with internal doorways to enable team teaching and access within classroom areas. These spaces are sized to accommodate artistic, small group reading, and other early development learning. The studio will be utilized for shared learning, special activities, and house the students’ storage cubbies, freeing the classrooms for dedicated learning spaces.

Another key facility feature is the Learning Commons, positioned on the second level as an open extension of the corridor. This colorful area will provide students various options for learning and includes soft, tiered seating for group discussions or individual study, a teaming area with table top outlets for tablet / device charging, a Makerspace, active movement seating, in addition to books and other learning resources for the students. Services provided by SSOE for this project include project management, programming, architecture, interior design, landscape architecture, and construction administration. During the interviewing process, the SSOE team proposed an accelerated design schedule that allowed construction on the elementary schools to begin a year earlier than originally planned by the district. Construction is currently underway and the new elementary schools will be open for classes for the start of the 2020-2021 school year. This $58 million project is the single largest one-time project in the history of Sandusky County.

/in , , , , , /by

SSOE worked with Youngstown State University for the creation of a living / learning R&D Excellence Training Center (ETC) that serves as an advanced manufacturing education, workforce training facility, and incubator factory. It houses a welding, machining CNC, automation and fluids training labs, high-bay workspace, metals and 3D printing, secure group project space, classrooms, and a workroom space. The ETC opened in Fall 2021 and houses approximately $5.5 million worth of advanced manufacturing equipment. The development of the ETC required the renovation of an existing building and addition to the facility on a downtown campus while maintaining project specific and ITAR security regulations.

SSOE worked with YSU faculty and staff, MVICC members, and Eastern Gateway Community College to develop detailed bid documents for repairs, renovation, and new construction. The project site is located both on the edge of YSU’s campus and in Youngstown’s downtown area. This location provides access to the varied groups that will utilize the facility including Youngstown’s downtown community. The building’s architecture takes inspiration from the existing urban context and neighboring campus buildings to create a common aesthetic statement. This project is also partially funded with an EDA Grant, for which SSOE provided the necessary documents. SSOE’s design also included provisions and concepts for future expansion(s) to the facility, as this is Phase I of a multi-Phase 100,000+ SF master plan created as part of the project’s planning and design.

Utilization of our significant manufacturing industry experience allowed our design team to lead the YSU design committee through the design process by helping them create a real-life simulated advanced manufacturing environment. We were able to utilize our knowledge of plant and process design and apply it into the manufacturing educational design, which will ultimately allow students to be completely prepared to enter real manufacturing environments upon program completion.

/in , , , /by

Northwest State Community College selected SSOE as the preferred design team to complete the renovations to “C” Building on its main campus. The project encompassed the complete renovation of a two-story building and adding a new addition, which included all student services departments: admissions, registrar, dean’s offices, student services, financial aid office, copy center, and business office; plus relocation of the fitness area, and renovations of the student cafeteria and kitchen.

With an expedited project schedule, SSOE was asked to create an overall project schedule that incorporated department moves and construction phases to minimize impact on operations. The process included creating a logical and orderly relocation of the departments involved, and creating a construction schedule that will complete the project on time, while adjacent areas are being occupied or in use.

The following items are included in the renovation:

  • Relocation of the fitness center, locker rooms, and restrooms
  • Building code upgrades, including mechanical, electrical, plumbing, ADA, fire protection, and fire alarm systems
  • Technology upgrades
  • Office renovations and re-location of offices
  • Construction of new two-story addition to house the University Center and conference rooms (approximately 1500 SF)
  • Exterior window replacement
  • New student cafeteria and kitchen
  • Copy center relocation
/in , , /by

The project consisted of phased demolition, renovation, and construction of a new 1600 student comprehensive high school complex to accommodate grades nine through twelve at the existing Columbia Central High School site location. Core elements are designed for an enrollment of 1800 students to allow for future expansion.

Being the only operational high school serving Columbia, TN, the Central High School project posed a unique challenge. The school needed to be replaced in place, while students remained in session during the entirety of construction activity. The existing main school buildings were demolished with the exception of the existing ROTC building / auxiliary gymnasium, the classroom building (1997 metal building), and the vocational building. The portable storage and classroom buildings were removed and the existing vocational building was renovated to accommodate the modified career-technical program (26,500 SF).

New construction consisted of a two-story building of approximately 147,265 SF for academic core and shared career-technical program. Auxiliary spaces, which include auditorium, cafeteria / kitchen, music program, and gymnasiums, were connected to the main academic building via corridor extension. The auxiliary portion of the new school complex is single level, totaling approximately 96,746 SF. Site design included separate drop-off areas for school buses and cars, walkways, pedestrian courtyards, landscaping, and off-street parking.

Design intent was to reference the original 1939 Central High School (traditional aesthetic). The main two-story academic building at the front of the site reflects this style through proportion and material selection. As you move around the building, technology and modern design become apparent, representing the future (use of metal panel and modern rectilinear profiles). The proposed design incorporated passive security measures through controlled entry / egress, controlled public access, limiting travel distances and visual observation.

/in , , /by

SSOE was tasked with renovating the existing football team facility (the Larimer Athletic Complex is a two-story, 32,000 GSF facility that was constructed in 1990) to create a more functional facility for the coaches and players alike. SSOE’s approach was to carefully place additions around the facility that would not only increase the size of the facility but aid in creating a new aesthetic. This aesthetic would enrich the facility from its two halves – athletic and academic, and assist in recruiting efforts.

The new weight room and office spaces required additional HVAC design. Heating and cooling of the existing and new areas were not from the existing chiller and boiler systems in the building, but rather from the campus site utilities. Therefore, the mechanical room became the point of interface of the campus chilled water primary / secondary system, tying into the building tertiary chilled water system. Additionally, the campus steam and condensate system fed a new steam to hot water heat exchange, utilizing a condensate receiver and motive (steam pressure-powered) pump.

Entry to the facility is through a new arched stone tower and display lobby with a grand staircase and memorabilia displays. History walls, graphics, and physical memorabilia are displayed throughout the renovated facility. The displays are architectural features with rich materials and interesting lighting that present recruits, families of recruits, and current players with a rich heritage of Rocket Football highlights.

/in , , , /by

The Metropolitan Government of Nashville and Davidson County Public Schools (MNPS) selected SSOE to lead the $20 million renovation of Stratford STEM High School, which can house up to 1200 full time students in grades 9-12. This school is a 236,653 SF building located on a 30 acre site. The site includes a baseball field, football field with a practice area, and ample parking.

MNPS’s goals for this project are for it to be an energy efficient, healthy environment for its students, and to be a high performance structure, both inside and out, with an achievement of LEED® Silver certification. The project was designed in Revit as a 3D model with a focus on a modern and functional learning environment, updating it from its late 1960’s design. MNPS sought a design that creates a warm and inviting setting that is open to the students and community, yet has a modern approach to a 21st Century Learning Environment. Openness and flexibility are maximized for current and future educational needs. The project was a complete renovation, including replacement of all mechanical and electrical systems, windows, finishes, alteration of the main entry, kitchen, band room, and the addition of a connecting corridor to the STEM area.

A few sustainable highlights of the project include the reuse of existing walls, floors, and roof, the incorporation of recycled and regional construction materials, water efficient landscaping, water use reduction, and optimized energy performance. In addition, the facility earned credit for developing density and community connectivity, having options for alternative transportation, such as access to public transportation, bicycle storage racks, and changing rooms, as well as designated parking for low-emitting and fuel-efficient vehicles. The renovation was awarded LEED Silver certification.

SSOE provided LEED consulting, architectural design, interior design, mechanical, electrical, plumbing, and fire protection engineering services.

/in , , , /by

SSOE’s design team was selected to assist with Northwest State Community College’s (NSCC) plans to expand their Engineering and Workforce Development departments.

SSOE’s extensive experience with higher education, as well as manufacturing and industrial design, was key in designing NSCC’s Engineering and Advanced Manufacturing Training Center, which must meet tomorrow’s industry standards and promote recruitment and retention.

To achieve NSCC’s goals and obtain a successful program, the design incorporated high-tech learning environments that are flexible and user-friendly, as well as welcoming, with low-maintenance finishes.

The project consists of the interior renovation and reconfiguration of two existing floors for the new workforce development program. A new 16,000 SF academic and engineering laboratory addition for the School of Engineering will also be designed. Upgrades include new classrooms, department offices, conference rooms, student collaboration and lounge areas, computer laboratories, plastics laboratory, engineering and distance learning laboratories, as well as a large 10,000 SF workforce training and robotics laboratory.

/in , , , /by

When Owens Community College embarked on a project to complete major interior renovations within Heritage Hall, it selected SSOE as the A/E firm of choice.

SSOE provided full design and construction administration for the project, which transformed 35,500 SF of abandoned high-bay automotive space into a state-of-the-art academic instructional area. Prior to the renovation, the abandoned area sat empty for nearly 10 years. Upon completion of construction, the renovated space now supports the College’s School of Business.

SSOE’s design for the new academic area takes advantage of the building’s high-bay windows, higher ceilings, and large spaces to create bright and sustainable learning and technology environments. All of the building’s exterior windows were replaced with new, more energy efficient models. The design features technologically-advanced and flexible classrooms, conference rooms, and collaboration areas. Student lounge and seating areas are provided throughout, along with interactive corridors, a medical laboratory, and offices.

SSOE’s welcoming and user-friendly design incorporates the College’s standards and program of requirements. The design also addresses all low voltage requirements, HVAC, and electrical upgrades for the building.

/in , , , , /by

SSOE provided architectural, interior design, and engineering services to support construction of a new 15,000 SF Welcome and Training Center for Transportation Research Center (TRC), the largest independent vehicle test facility and proving grounds in the U.S.

As the gateway to the TRC campus, the facility is the main welcome and access control point to the campus. The center includes informal and formal collaboration areas, conference rooms, project lab space, and office space for three user groups: TRC security, the Regional Plan Commission, and the Ohio State University (OSU) distance learning program, which supports academic liaison efforts via teaching and research.

Designed to accommodate meetings of all sizes, the welcome center includes small gathering spaces, distance learning facilities, and, for seminars and presentations, a large meeting room featuring state-of-the-art AV technology and space for presentation vehicles. Within the OSU distance learning area, the space is flexible and reconfigurable for project and team needs. The design of the space allows for both team based work and lecture based presentations. Height adjustable tables with plug and play power allows for the space to be one level, verses a tiered layout. Interior design highlights include some areas with exposed ceilings with acoustical clouds, the lobby ceiling is designed with metal longboard, patterned with wood, to add warmth to the area, custom casework design, and sealed concrete flooring.

Budget, visual appeal, and functionality were top design concerns for this client. SSOE incorporated a strong graphical approach, both inside and out, for an attractive, modern, cost-conscious design. Exterior design resulted in a brick and metal façade with a welcoming entry and a strong daylight component.

/in , , , /by

Therma-Tru Doors, a Fortune Brands Company, is the nation’s leading manufacturer of fiberglass and steel exterior door systems. Fypon, who became a part of the Therma-Tru family in 2009, makes polyurethane millwork. Both companies are now headquartered in Maumee, Ohio. The Fypon and the Therma-Tru IT departments occupy the renovated first floor space.

SSOE led the original master plan design effort to create a collaborative work environment which started in 2005 with the renovation of the second floor of the facility. We continued with the master plan, bringing it to completion in March 2016, with the renovation of the first floor of the facility.

The design scheme incorporates a diagonal “avenue” of drywall soffits and luminous ceiling, which leads to an amenity area. This area provides a flexible space for social and informal meetings, with a small kitchenette located in this area that also supports the flexible function of the space. The workspaces are predominantly open office workstations with only three enclosed office spaces.

The open office concept is augmented with several informal meeting / work areas, and two larger enclosed conference rooms. The renovation design incorporates Therma-Tru doors and Fypon moldings throughout, as well as other Fortune Brands products (Master Brand Cabinets and Moen plumbing fixtures) which lends to a very comfortable, home-like working atmosphere that is enjoyed by the companies’ employees.

/in , , , , , /by

SSOE is providing architectural and engineering services to the Veterans Administration (VA) Ann Arbor Health Care System for design of a new Clinical and Administrative Building replacing the existing 1949 Building 4. The new 3-story building was designed to blend with the existing campus architecture and meet all federal VA standards. The structure will house the employee health, human resources, business office, prosthetics, and finance departments.

Services provided by SSOE include: civil, structural, architectural, interior design, mechanical, plumbing, electrical, information technology, and fire protection. Programming was completed with VA engineering and end users to determine how the new facility will meet all department requirements. Shared spaces include conference rooms, a large employee break room, and lobby spaces. The new structure provides for natural light penetrating the open floor plan, a visual interior with large expanses of exterior glazing, and a banded brick exterior to accentuate the horizontal lines of the structure. SSOE’s project scope included an asbestos survey, lead assessment, and examination of the existing site prior to demolition.

SSOE provided all site work, utility connections, communication wiring and connections, as well as handled any disruptions to the existing systems for the new structure. Existing utilities and connections on campus were field investigated for re-use and connection with the new building. Other items considered in the building design were personnel approaches, sidewalks, green areas, visual impacts, parking impacts, and landscaping.

/in , , , /by

SSOE was enlisted to provide architectural and engineering services to ProMedica Health System to fit-out the 6,000 SF second floor shell space with a new Innovations Incubator Suite at the Wildwood Medical Center campus.

The concept for the Innovation Incubator was to provide a completely flexible space that can be reconfigured by users and entrepreneurs to support innovation as it relates to healthcare. The space was designed around modular magnetic and glass walls, exposed ceiling, and modular mobile furnishings. The interior design for the space incorporated a white linear stone, stained concrete, and a mixture of carpets and brighter colors to inspire creativity. The suite included four business offices, three conference rooms, administrative offices, prototype area, and associated support spaces.

SSOE teamed with subconsultant, JDRM, who provided mechanical, electrical, plumbing, and fire protection design services.

/in , , , , /by

Native plantings and selection of low-flow plumbing create $5,000 in water savings annually. Use of highly efficient, sustainable systems and materials saves $5,000 in energy savings annually.

Owens Corning, a leader in the glass fiber industry, selected SSOE to design and engineer a new 27,000 SF Business and Technology Center in Gastonia, North Carolina. Connected to the company’s adjacent state-of-the-art non-woven glass fiber fabric plant, the technology center houses operations offices as well as research and development facilities for advances in Owens Corning bio-based products.

A Focus on Sustainability

Achieving LEED certification for this project was a key client objective. Early in the design process, SSOE led an “eco-charrette” that brought together all stakeholders, designers, and contractors to engage in an integrative process to analyze opportunities for sustainable design. Ideas generated in the charrette led to notable environmental and energy savings accomplishments:

  • The facility consumes 25% less energy than similar structures equipped with conventional systems and materials
  • Achieved 36% water use reduction by installing low-flow metered plumbing fixtures and faucets
  • Used energy efficient glazing along three façades of the building to optimize natural daylight and views of the natural environment

Distinctive Design, Welcoming Entry

Extensive site design resulted in an appealing façade with a welcoming entry and a strong daylight component. Careful evaluation of exterior materials led SSOE to design a unique longboard curtain wall that enhances and unifies the appearance of the building and adjacent manufacturing facility.

Landscape Design Creates Win‐Win Scenario

Restoring natural habitat and removing irrigation from the site was an additional design challenge that resulted in a win‐win scenario for stakeholders and environment alike. Because the industrial park had very strict requirements for site irrigation, SSOE – with the client and the local civil team – created a landscape design featuring native plants
and vegetation.

 

/in , , , /by

SSOE joined the Matheny Goldmon Architects’ team to provide mechanical, electrical, plumbing, and fire protection engineering for the design of the Huntsville Botanical Garden’s new Guest Welcome Center. Already a world-class botanical garden, they sought a way to increase attendance and revenue opportunities in order to continue to provide the Huntsville area with beautiful gardens to visit and utilize for event rental.

The resulting new Guest Welcome Center adds a distinctive sense of grandeur and southern charm to the gardens. The stately four-column southern colonial style facility is now the focal point for the Garden’s guests upon arrival, and houses a modern facility for their executive offices, retail space, and areas for the public to enjoy. The Grand Hall was designed as a wedding venue, with a large adjoining bride / groom suite containing elegant spaces that blend into the gardens. The new facility also boasts fine dining at Table in the Garden, three new event areas of various sizes for seating from 56 -350 guests for weddings or conferences, a gift shop, café, and meeting rooms.

The new 360-degree facility presented a challenge for SSOE’s MEP engineers as they were tasked to find placement for various equipment that would be out of the guests’ sight and hearing. SSOE’s site friendly design included walls used to screen the outdoor components both visually and acoustically. Exhaust and HVAC equipment were placed on the roof without hindering the building’s beautiful architectural lines and details. The MEP design also maintained advantageous site lines from balconies and windows into the gardens without having equipment heard or in view.

Site lighting was also a focus by the SSOE design team, as the overall aesthetic of the lighting needed to reflect the location and style of the Center during both day and night time. In The Grand Hall, primarily LED lighting was used along with a user friendly, “keep it simple” touchscreen lighting control system. A lighting control relay panel was also installed for programming event on / off time of day operations for energy savings and ease of use. For the water feature and backside of the facility, reduced glare lighting methods were used to most favorably render the exterior botanical environment. The grand lobby cupola and the glass-roofed conservatory utilize direct / indirect lighting techniques to help accentuate the architectural volume of the spaces.

The new Guest Welcome Center allows Huntsville patrons to have their special events in a gorgeous facility, surrounded by the beautifully designed and proudly tended botanical gardens that lay beyond its doors.

/in , , , , /by

SSOE completed a complex programming and schematic design effort for an approximately 1,100,000 SF, seven-story multipurpose building that serves as a model for workplaces of the future.

The building contains a 2.6 MW data center, two floors of class 10,000 high-tech cleanroom manufacturing and chip testing space, with five floors of office, cafe, and fitness center spaces to accommodate approximately 3,800 employees. Linked connections to neighboring buildings were created to provide passage for employees, utilities, and automated material handling systems. A pedestrian sky bridge to the parking garage was designed to accommodate a direct, convenient connection without impacting the existing wetlands. The project, utilizing a high-performance envelope, daylighting strategies, and high-efficiency mechanical systems, met the criteria for LEED Silver certification.

The office levels were organized into neighborhoods consisting of workstation groups, collaboration rooms, and community zones. These were combined with support spaces based on a formula for connectivity and an interactive office environment. Small and large community zones are located throughout the floor at strategic points where employees can work, meet informally, or relax as a community.

The objective was to create a design aesthetic to complement the existing campus architecture. Throughout the design process, this goal was elevated to create a distinctive architectural look that reflects the values of our client and today’s workers.

/in , , /by

Austin Powder Company realized the need in their industry for increased Energetic Material (EM) supply due to the dwindling supply of demilitarized materials available. As a result, the company decided build a new chemical facility for making virgin EM. After researching and selecting key technology partners, SSOE was chosen to provide engineering, architecture, and construction management services to integrate and implement the project.

This project involved a greenfield plant for the semi-continuous manufacture of Pentaerythritol Tetranitrate (PETN) within an existing production facility. This facility performs blending and packaging of explosives, but had no chemical synthesis capability. We worked with Austin Powder and industry experts to design a safe, efficient production facility with custom processing equipment and process modules for the processing and re-use of spent chemicals and wastes.

Our team was responsible for integrating specialty process equipment from three separate process technology vendors in three different countries. Key to this integration was coordination of process controls and utilities requirements across the major vendor packages, ensuring a smooth startup and allowing for safe shutdown and maintenance during weekends, holidays, and major process upsets.

SSOE’s design scope included an EM manufacturing and packaging building; site preparation, foundation, and interconnect for all vendor modules; chemical loading, offloading, and storage; fresh and spent process water treatment; utilities to support 24/7 operation without city water or sewer access and with minimal environmental impact; rail and tank truck access for multiple chemicals; safety reviews and environmental permitting.

/in , , , , /by

SSOE has a long and successful project history with BMW, including initial architectural / engineering services for previous expansions at BMW’s Spartanburg assembly plant. Because we also have extensive experience designing training and technical centers for automotive clients, BMW selected SSOE to provide design services for their new Southern Regional Technical Training Center. Our expertise in this area has proven invaluable throughout the design and construction phases of this project.

The new technical training center includes five training units, each consisting of a practical workshop and a theory classroom. SSOE worked closely with BMW to design the new facility to their unique specifications, which includes automotive equipment, furniture, ICS equipment, data network, and IT cabling routing and requirements. Additionally, design for all necessary special structural supports required for mounting of automotive equipment was included.

SSOE’s electrical engineers completed the lighting, power, emergency generation systems, fire alarm, security systems, network racks, patch panels, and cable for telephone / data networks. Parking layout, civil engineering, and landscape design also included the design of carports to utilize BMW-provided solar panels. SSOE’s structural engineers completed the design of the foundations (including soils and sub-slab specifications) and our Data / Fire / Security design team performed audio visual system design for the classrooms and public address systems.

SSOE also provided architectural, interior design, mechanical, and cost estimating services. Our partner, Alliance Consulting Engineers, provided civil engineering and landscape architecture services.

/in , /by

SSOE was selected to provide design services to CHI St. Vincent Hot Springs Rehabilitation Hospital. The project included converting an existing 64,000 square foot, 20 bed, surgical hospital into a 40 bed rehabilitation hospital, with the ability to add eight additional beds in the future.

The project included developing documents to repair and renovate the existing hospital and administrative office area. Also included was the addition of a commercial kitchen, dining room, 28 private patient rooms (8 rooms designed for future growth), physical therapy gym, conference room, support space (equipment storage, linen storage, soiled hold, supply storage), dialysis, and patient transfer canopy.

/in , , /by

The technology installed by SSOE is the world’s first and only FDA-approved commercially available LINAC-based, MRI-guided radiation therapy system that can image and treat patients simultaneously. It allows the client to be treated more accurately and in less time— offering an optimal patient experience.

Henry Ford Health System chose SSOE Group to provide architectural and engineering services for the removal of a linear accelerator (LINAC) and installation of a new ViewRay MRIdian LINAC / MRI system in an existing vault on the main floor of Henry Ford Medical Center – Cottage. This LINAC required additional shielding installed in the existing vault to provide radiation protection to the surrounding environment. As a result, SSOE worked with Henry Ford’s team of physicists to develop a comprehensive solution to the existing shielding, which consisted of designing supplemental floor-to-ceiling concrete walls to augment the existing vault structure.

Additionally, SSOE designed a copper fabric enclosure for radio frequency shielding throughout the room. The ViewRay MRIdian LINAC / MRI system is the world’s first and only FDA-approved commercially available LINAC-based, MRI-guided radiation therapy system that can image and treat patients simultaneously. Additionally, Henry Ford is the first in the world to offer patients this advanced radiation therapy with real-time magnetic resonance imaging and linear accelerator delivery for more precise and accurate radiation treatment. While similar ViewRay installations use cobalt as a radiation source, this new system provides the capability to simultaneously use diagnostic imaging with the MRI component and LINAC radiation treatment. The advanced MRI imaging will help Henry Ford physicians provide further accuracy in delivering radiation to a cancerous tumor.

SSOE is a trusted team member to Henry Ford, their shielding and equipment vendors, and construction manager. They entrust us to work quickly and effectively, providing creative solutions to complex project challenges. Delivering the most complex projects on time and on budget is the hallmark of our healthcare services.

/in , /by

Covenant Healthcare System selected the SSOE interior design team to develop a new Master Interior Standards for their Saginaw and other Michigan locations. The team started their process by evaluating current facilities, conducting interviews of staff and administrators to see what was currently working and not working. We worked with a patient and family peer group, guiding them from their perspective to give feedback on colors, concepts and schemes. Our interior designers used the gathered information combined with their expertise to develop and present three complete interior design concepts for selection.

The design inspiration that was selected by Covenant was “Life – Richness and Beauty”, which included elements of nature and nature images. This concept consists of five color schemes with an updated neutral core color palette, including multiple material options for Covenant to use throughout their healthcare system. The design also included incorporation of branding. SSOE’s interior design team worked with the client to carefully evaluate materials and finishes based on functionality, cost, patient safety, and maintenance. We also incorporated feature walls and lighting elements that align with client’s vision and branding.

SSOE developed a Furnishing Standards package that will be implemented along side renovation projects to ensure a cohesive image consistent with Covenant vision and patient expectation.

/in , , /by

SSOE was selected to provide architectural and engineering services for the phased renovation of Beaumont Health System’s 20-bed Cardiovascular Surgical ICU (SICU). The project included renovations of patient rooms, staff spaces and public areas. Some of the most notable pieces that SSOE worked on were new centralized nurse stations and sliding doors on patient rooms. Our team worked with Beaumont to do a complete overhall of the waiting area as well as the staff offices and lounge.

The SICU has remained completely operational during the construction process.  Additionally, SSOE worked with the CM on-board to build a mock-up of the patient rooms and the decentralized nurse station so the staff would have an opportunity to give their input on the design of the spaces.

/in , , , /by

SSOE provided complete architectural and engineering design services for the second phase build-out of the Herbert Perna Center for Physical Health Center. The project included relocation and redesign of the existing mental health and sleep lab space to the lower level of the Herbert Perna Center for Physical Health on the ProMedica Fremont Hospital Campus.

Services included: review, inspection and evaluation of the existing facilities, development and recommendation of alternatives, design development, preparation of construction and bid documents (detailed plans and specifications), conducting pre-bid meetings and walk-through, assistance during the bidding phase including recommendation for contract award. SSOE also assisted ProMedica in establishing overall project schedule and milestone dates for completion of the construction, and is providing complete construction administration services.

In addition to traditional design services, SSOE also provided data / technology, fire protection, security, communication, and access control.

/in , , , /by

ProMedica Fremont Memorial Hospital teamed with SSOE Group to design and establish a full-service cancer center to meet the needs of the communities it serves. This new facility offers more convenient access, enhanced privacy, and improved comfort for patients. The center offers the latest protocols for medical oncology, as well as the newest technology in radiation oncology, including a Varian TrueBeam linear accelerator. The design included eight chemotherapy infusion bays, dosimetry, CT simulator, new pharmacy to comply with USP 797 and USP 800 general chapters, laboratory and blood draw, four exam rooms, three nurse stations, and additional staff support spaces. Additional cancer-care services, such as genetic, dietary and family counseling, and rehabilitation services are included in the overall design of this facility.

SSOE was instrumental in aligning the hospital’s programmatic goals with the limited project construction budget, and worked through multiple design options with hospital leadership to minimize the amount of construction within the new facility. Project goals were accomplished by prioritizing necessary patient care spaces, such as linear accelerator vault, infusion bays, exam / treatment spaces, pharmacy and laboratory. Plans also included repurposing some staff areas to minimize demolition, while allowing staff to work contiguously and efficiently within these support spaces. SSOE led the design process from the onset of the project and confirmed and validated strategic and operational plans; determined budgetary and scheduling constraints; and coordinated the overall project quality with consultant engineers, and coordinated equipment layouts, requirements, and manufacturer specifications for specialized equipment. Existing conditions and capacities to projected needs to satisfy functionality, adequacy of spaces, and operational adjacencies were also compared.

/in , , , /by

Selected as the national healthcare design lead, SSOE teamed with local architectural firm, Shremshock Design Group, to revitalize the existing Memorial Hospital of Union County campus. The project goal was to create a new, state-of-the-art, high tech and multi-use campus, offering private patient rooms, upgraded clinical services, new on-campus ambulatory services, and medical office space.

The selection was based on several factors, including the strategic master planning process and design approach. Recognizing the organic quality of the process, not a predetermined approach; listening to and identifying what is important to the client; and the team’s experience in designing similar facilities were all attributes contributing to the selection of the SSOE team.

Solutions were offered based on “patient first” design and Evidence-Based Design (EBD) practices. The design process considered staff satisfaction as a way to recruit and retain top talent. In addition, lean design was employed to increase staff efficiency.

Our planners, architects, and engineers thoroughly understood the client’s objectives, aspirations, and needs. The SSOE team supported the client’s goals by understanding the latest trends and national best practices, providing market trend analysis and forecasting to assist Memorial Hospital with “right-sizing” their facility now and into the future.

/in , , /by

Dialysis Clinic, Inc (DCI) teamed with SSOE for the development of a prototype for their End Stage Renal Dialysis Clinic. The DCI-Union project was one of the first prototype facilities to be built in Union, South Carolina. The new, free-standing facility is about 10,000 SF and has twenty-four treatment stations and one isolation treatment room. SSOE worked with DCI’s equipment vendors to coordinate the dialysis equipment and furniture.

We provided each patient station with an abundance of natural light, a heated recliner, television and pillow speaker to help with patient satisfaction surveys. A wide open treatment room aids the visibility of the patients to ensure patient safety. The clinic also houses a home training unit that helps patients be able to perform dialysis in the comfort of their own homes.

This facility had a fast-track schedule for completion due to the increase in patient volumes in the area. SSOE worked closely with the contractor to assure the inspection and approval processes were expedited.

/in , , /by

With overall objectives to create better healing environments and efficiencies in operations, St. Luke’s Hospital selected SSOE to renovate and expand their existing Level 1 Trauma emergency department while remaining fully operational.

The emergency department renovation was the first project of an overall hospital master plan, setting the tone and direction for the remaining projects and phases. The new plan included twenty-four exam / treatment rooms, seven express care exam rooms, new nurse stations, dedicated X-ray, laboratory, and additional staff support areas. In addition, separate waiting areas (main department, waiting, lobby, and express care), a dedicated children’s activity area, a new registration area and triage area were provided.

With the design focused on process flow, comfort, and patient experience, all patient rooms were renovated and converted to private spaces to improve patient satisfaction, efficiency and infection control. A centrally located nursing core and physicians’ station allows nurse and physician teams to have better vision and ability to stay connected to patients. Glass walls provide an acoustical buffer between staff conversations and patients and the nursing core. Plans also utilized adaptive use of latest technologies (incorporating new and old), including full implementation of electronic health records.

A combination of cherry warm maple, earth tone color palette, and natural sticks encased in resin reinforce nature influences within the space, transforming the spaces into healing and comforting environments for patients and their families. Upgrades and new finishes were provided throughout the entire unit, including staff / office areas, treatment areas, and waiting / reception. Additionally, upon completion of the renovation, SSOE coordinated loose furnishings and artwork selections to continue the interior vision of the space and to make a welcoming atmosphere for patients and their families.

/in , , , /by

SSOE provided services for renovation of the Covenant Cancer Care Center at the Saginaw campus, including space for medical and surgery oncologist practices, expansion of the infusion suite, relocation of the oncology research suite, relocation of the cardiology and diabetes suites, and the addition of a new front entry.

The intent of the renovation project was to utilize existing clinic spaces where feasible, with modifications and upgrades to meet the needs of the new functions.

The existing building documentation was in 2D AutoCAD format. SSOE converted the existing building area into a BIM model utilizing Revit software. This six-story building was modeled through BIM to allow the team to take full advantage of the 3D capabilities. Having a fully integrated BIM model created a clear vision for hospital administrators and staff. By including hospital administrators and staff in the 3D modeling process, conflicts between construction and operations were easily pinpointed.

/in , /by

Transformation of the facility from institutional to residential resulted in positive patient and family satisfaction surveys and increased occupancy rates.

Originally designed by SSOE in 1997, Lutheran Village at Wolf Creek is a Continuing Care Retirement Community (CCRC) offering independent living apartments, private assisted living suites, and skilled extended nursing care. To reflect the culture change in senior living, SSOE also renovated the nursing home located on campus at a later date.

Focused on empowering seniors to make choices and express their preferences, resident-centered care is the new philosophy behind providing skilled nursing in a home-like environment. Even the previous clinical-style nurse station was replaced with a resident and family lounge area. SSOE’s updated design for Wolf Creek incorporates a great room, a buffet-style dining room, smaller dining rooms accommodating groups of six to eight for more private entertaining, and a family kitchenette. The “lodge” concept features a fireplace and stone materials creating a warm environment, ideal for resident and family socializing.

Accompanying these facility transformations are changes in the staff care practices. Caregivers now provide more than just personalized care; they serve as extended family members, helping residents plan meals, organize events, and make choices about their activities and diet. These upgrades have increased both resident and employee satisfaction, as well as the facility census. This renovation creates an environment which promotes comfort, autonomy, and relaxed socialization for residents.

/in , , , , , /by

Permit requests done in parallel to reduce project execution schedule and meet permitting needs. 30% savings in energy use.

When the Anniston Army Depot (ANAD) and the United States Army Corps of Engineers (USACE) embarked on a project to consolidate the transmission remanufacturing process for all tracked military vehicles it serviced into a new, world class manufacturing facility, they enlisted SSOE to provide full facility architectural and engineering design services, as well as equipment migration design for the new facility.

As one of the top ranked firms in automotive facility design, SSOE brought state-of-the-art technology into an open floor plan, while modernizing and consolidating ANAD’s transmission remanufacturing program. This enabled a more efficient process flow from transmission disassembly through the cleaning process, to reassembly and testing.

The scope included design to support the relocation, installation, and point-of-use connections for more than 170 existing pieces of equipment from 13 buildings on the site. Additionally, more than 70 cranes, up to 10 dynamometers, and more than 30 pieces of new process machinery, both government and contractor furnished, were integrated into the facility. This project also incorporated the expansion of an existing 15kv switch yard to support the facility.

SSOE considered potential site constraints including Anti-Terrorism Force Act (ATFA) requirements, existing boundaries and easements, environmental permitting, and a concurrent USACE Cold Water Creek Relocation project, as well as project specific permits required to move an additional tributary creek flowing through the site. SSOE recommended that permit requests be done in parallel to reduce overall project execution schedule.

The facility, which is LEED Silver certified, also supports all applicable energy sustainability standards, including a 30% decrease in existing energy use, sustainable solutions for grass and landscaping, and the incorporation of natural light and high reflectant materials to minimize heat gain.

/in , /by

Reduction of engineering costs as a percentage of construction from 13% to 6%. Project savings of $53 million.

A chemical manufacturing client with whom SSOE had a 20+ year relationship, enlisted the firm for a series of projects to expand their facilities. Initial expansions involved capital investments of $50 million; subsequent expansions grew to over $2 billion in capital investment. SSOE provided front-end loading, detailed design, procurement, project controls, and start-up support for these projects that involved complex and highly proprietary chemical process expansions as well as facility additions.

Over four years and four projects, SSOE tracked the project’s engineering costs against the total installed cost. The firm’s goal was to drive cost out of the overall project, as well as to reduce the engineering costs on each subsequent project. Working together with the client, SSOE saved more than $53 million in overall costs and was able to drive down the engineering costs as a percentage of construction from 13% to 6%. One key factor in this dramatic reduction was SSOE’s ability to develop an intimacy with the client and commitment to learn the client’s process and use that knowledge to work more efficiently.

/in , , , /by

Significant savings in total project cost. Fast track execution to minimize manufacturing downtime.

When this chemical client embarked on an EPA mandated upgrade at four of its manufacturing facilities, SSOE was enlisted to execute the industry-wide directive. The project required integration of a new agent into its insulation board processing systems, a formulation change intended to reduce emissions. SSOE’s extensive background in implementing process upgrade and modifications in the chemical industry proved integral to implementing the change. Putting multi-disciplined teams in place at each of the facilities, the firm ultimately helped the client save time and project costs had they conducted the upgrade internally, while simultaneously enhancing the existing process.

As part of the scope, a new extruder needed to be upgraded and a blowing agent reformulated to manufacture insulation board. Ozone depleting hydrocarbon was replaced with more environmentally compatible agents. As a result, the existing layout was revised and different raw material handling equipment was installed and integrated into areas where existing operations took place. SSOE managed material handling, chemical additions, instrument upgrades, electrical upgrades, and ensured the environmental process transition. To create efficient space for the process, SSOE designed building additions at two of the sites, retrofitting them into the existing buildings, and one transformer addition to support power requirements. The firm also handled procurement for three of the sites.

SSOE needed to consider several factors in its design plan, including integration of explosion proof electrical classified components (Class 1, Div. 1 components), as well as the correct classification for process instruments. Sensitive to the confidentiality of the transition to alternative agents, SSOE created a task force with key clients to ensure ongoing communication efforts regarding the scope of the process enhancement.

/in , , /by

Decrease natural gas use by 30 billion BTUs a year; saved 19 million gallons of water during first year; project savings of more than $280,000.

When a long-time food manufacturing client wanted to assess opportunities for energy savings at one of its facilities, SSOE had the expertise to both evaluate existing plants and systems and also recommend and implement process and mechanical improvements to achieve cost and energy savings. By conducting an energy savings audit, including heat recovery potentials, SSOE helped identify areas for energy savings.

SSOE first reviewed heat recovery and other energy saving opportunities at the plant. Over a two-month period they conducted an FEL 1 study on three different projects where the client had initiated plans for energy conservation. SSOE determined whether or not the client’s projects were viable enough in terms of expected results and return on investment (ROI) to proceed in implementing. The results and SSOE’s recommendations were then provided to the client for further internal action.

SSOE’s energy audit proved to be successful, as it identified potential energy savings of over 70 billion BTUs per year (70 million cubic feet of natural gas per year). SSOE also reported more than $280,000 savings on the project.

/in , , , /by

3D object models of the facilities and their utility infrastructure were developed and shared with the contracting partners proving invaluable in the design of the intricate routing of utilities between components in the facilities.

SSOE provided facility engineering and architectural services for two new paint shop facilities. 3D object models of the facilities and their utility infrastructure were developed using Bentley Structural, and sharing them with the contracting partners in DWG format. The object models proved invaluable in designing the intricate routing of utilities between components in the facilities.

SSOE and equipment vendors were able to study facility and process components in relation to their true magnitude. Clip volumes, perspective drawing, and isometric detail extractions aided in studying these complex relationships. From the piping models developed, SSOE used Bentley Structural’s drawing extraction feature to create several evolutionary construction details to delineate the complex routing and transitions of utility systems. These details passed the advantages of BIM to fabrication and construction members of the team.

/in , , , , /by

Created a detailed RFP and negotiated with multiple vendors to reduce material and installation costs, saving the client nearly $150,000.

SSOE’s in-house Data/ Fire/ Security (DFS) team designed data, fire, CCTV, security systems, and voice systems for a  500,000 SF Research and Development (R&D) facility. Several state-of-the-art video conference and projection rooms were designed, as well as a 3,250 SF, Tier 4 data center and back-up power system to support all of the data and server needs.

The data distribution system was designed with in-floor data communication ports and wireless connectivity. The building communication infrastructure was designed to standards far exceeding TIA/EIA standards. More than 150 networked interior and exterior CCTV camera were installed to monitor and protect the owner’s intellectual property. Placement of the cameras and video storage needs were evaluated and determined by SSOE with 3D modeling views provided for reference.

The team designed a fire alarm system that was integrated into the campus style fiber optic fire alarm network, CCTV system, and access control system. The office building’s paging, sound masking, and other notification systems were integrated into the consolidated head-end, so each system took the appropriate action during an alarm condition. SSOE teams designed a complete premier detection system for the facility with several detection devices, including motion detection and glass break sensors.

SSOE integrated sustainable design features which led the main facility to achieve Gold Level LEED certification.

/in , , , /by

Negotiated with vendors and integrators as well as created a design and installation guide. This reduced costly overruns and saved the client approximately $200,000.

Volkswagen selected SSOE to oversee architecture, engineering, and construction management for its new greenfield production facility in Chattanooga, Tennessee. SSOE was responsible for the campus’ data centers, fire alarm system, access control, and CCTV systems.

The data center was designed with multiple cooling systems, power systems, and data routes for redundancy. In addition, a primary and secondary command and response building was designed, each with video walls and several communication pathways.

The campus includes ten, multi-level buildings that were connected in a Style 7 fiber optic network to eliminate communications gaps. The fire alarm system also serves as a mass notification system to alert occupants of all emergency classifications, interfacing with production-based equipment and other internal automation systems. In addition to the fire alarm system, a complete access control system was designed for several of the buildings in the complex. The entire system was designed to be monitored from primary and back-up on-site control rooms.

Cameras and monitoring systems were installed around the site and consisted of both analog and Internet Practical (IP) cameras. The CCTV system was connected to the fire alarm annunciator to allow the camera to locate and view a specific area in the event of a fire. The alarm within the facility will automatically be displayed on the video wall.

The fire alarm, access control, and CCTV systems were integrated together to provide for a converged system. If a fire alarm occurred it would unlock the respective access control doors for emergency egress and point cameras to cover the area in question. All systems were designed such that a common reporting method could be used.

/in , /by

SSOE’s extensive 3D model coordinated the efforts of multiple engineering sources and prevented potential interferences prior to construction, creating savings of $100,000. In addition, a design recommendation increasing the cumulative live load deflection criteria saved $300,000 for a total of $400,000 in savings on design and steel.

SSOE’s extensive structural engineering capabilities were a crucial factor for the success of the upgrade and expansion of the largest sorting and distribution facility and parcel conveyor process in the world. Several of SSOE’s engineers and designers who were part of the original facility’s design were also part of the expansion, bringing extensive knowledge and experience to this project. Included in the scope was the design of primary and secondary steel support, and tertiary steel (grating, handrails, ladders, stairs, catwalks, platforms, etc.) associated with the installation of parcel conveyors. Creating a 3D model for the project, SSOE coordinated information from other engineering sources involved in the various design aspects of the distribution center. The model allowed for automated detection and graphic depictions of potential interferences prior to construction, and proved to be key in resolving critical design decisions for the conveyor installation.

SSOE was faced with many design challenges, including extremely stringent deflection criteria to ensure the proper functioning of highly sensitive sorting equipment. The conveyor layout was very complex with multiple conveying systems, including provisions for future systems, multiple levels of access, and adjacent conveyors that sloped in opposite directions. With this in mind, SSOE recommended a design solution to increase the cumulative live load deflection criteria, which provided more than $300,000 savings for the overall steel costs, all while maintaining the project schedule.

/in , , /by

In addition to safety improvements, SSOE’s upgrades also improved product distribution and reduced downtime.

SSOE completed multiple projects for the Marathon Load Rack Program. This program was charged with improving safety and optimizing truck loading across their facilities by eliminating potential fall hazards. The Detroit Load Rack was one of the larger projects completed due to the extent of piping and electrical changes implemented.

The scope included the design of new platforms, gangways, stairs, safety cages, load arms, and piping. The safety-enhanced version of Marathon’s load rack included improved controls and safety interlocks, as well as improved lighting. The operator interface was redesigned to assure that safety interlocks and protocol for loading are satisfied prior to the start of loading. To ensure safety and ergonomics, many of the hand-operated valves were replaced with actuated valves. SSOE also integrated the control of the hydraulic gangway as part of the load rack controls. Hydraulically actuated gangways were installed to prevent injuries related to strain and poor ergonomics. In some areas, SSOE added stairs or extended platforms to create an optimal distance between the operator and the fill point.

SSOE’s experience with asphalt piping and electrical systems extends far beyond addressing safety issues, providing the added benefit of increased efficiency at this facility. Redesigned piping at loading stations improved product distribution. Reconfigured controls ensured that only affected lane(s) would shut down in the event of a problem, resulting in less downtime. The features integrated were part of a standard used throughout Marathon’s facilities so that workers can now safely operate equipment at any location.

/in , , , , /by

By using BIM, the contractor’s GMP pricing was $500,000 under project budget with no change orders for time or cost.

SSOE provided complete planning and design services to develop a new, full service cancer center. Developed by real estate investor Welltower (formerly Health Care REIT), the freestanding facility spans two floors and is situated on a 4.9 acre site.

To offset the feel of a high technology environment, SSOE’s design features exterior and interior colors and details, which create a warm, inviting setting for patients. The first floor contains a radiation oncology suite and common area. The suite will supports future construction of three new linear accelerator vaults, a CT simulator, CT / PET simulator rooms, and related support spaces. The second floor houses a large medical oncology suite, gynecology suite, additional oncology office, and common area.

The design integrates sustainable design principles, and the facility is LEED® Silver certified. Additional green features of the property include a healing garden with a walking path.

/in , , , /by

Negotiated with multiple vendors to reduce material and installation costs, saving the client over $700,000. Created design and installation standards which assured contractors and integrators installed all systems the same way. This greatly reduced cost overruns and maintained schedules.

Since 2004, SSOE has been providing this chemical manufacturer with design and start-up support for a series of complex facility expansions. SSOE’s Data / Fire / Security team provided complete design of telecommunications, LAN, WAN, MAN security, access control, CCTV, fire alarm, sound, paging, and mass notification systems as well as an extensive fiber optic network. This network, which consists of thousands of strands of single and multi-mode fiber and required installation of more than 30 miles of fiber, serves the client’s telecommunications, data, and process communications needs. The design also included an automated CCTV premier detection and alarm system.

SSOE provided the complete design for Tier 3 and Tier 4 data centers. Each tier has attached state-of-the-art control, which monitors all of the key operation processes. The primary control building space is comprised of several server rooms, offices, and a large operator room that houses a 16-foot by 80-foot video wall and 20 high-end operator stations, each equipped with six, 30-inch LCD screens. The facility is equipped with several methods of redundant cooling, communications, and power feeds.

SSOE also designed a 9ll quality, two-way radio system with multiple redundant repeaters that exceed 911 and interoperability requirements.

SSOE engineers provided on-site construction support and supervised the entire installation of the system and commissioned its operations. The entire project came in under budget and ahead of schedule.

SSOE ordered all equipment on behalf of the client and negotiated bulk discounts. The team’s deep understanding of the client’s facility and processes earned the firm “preferred engineering partner” status. It also resulted in SSOE being hired to provide similar services for the client’s new facility in southeast USA.

/in , , , /by

14% less energy use for long term savings. Environmental pilot for future facilities.

As part of the Army and Air Force’s initiative to construct all new buildings to green standards, the Army and Air Force Exchange Service (AAFES) made plans for a new, sustainable retail facility on the Randolph Air Force Base in Texas. The one stop, state-of-the-art facility, serving more than 50,000 active, reserve, and retired military personnel and their dependents, was one of the first AAFES facilities to pursue LEED Silver certification. It was also part of the USGBC’s pilot program to develop LEED guidelines for the retail industry. SSOE spearheaded the design of the facility with a with a food court, sales area, specialty vendors, onsite fuel stations, outdoor lifestyle areas, and a loading dock, while also leading LEED certification efforts.

SSOE designed a data / voice, fire alarm, and mass notification combination system for this 167,000 SF facility. As part of the data communication system, a wireless study was performed to determine the best placement of wireless internet antennas. The wireless system was designed to comply with the IEEE 802.11 wireless standard.

Using more than 20% recycled materials, the facility also features an energy management system to coordinate efficient lighting, heating, and air conditioning systems that reduce energy consumption and costs. A roofing membrane reflects 78% of sunlight minimizing energy use within the facility and water-efficient equipment reduces water consumption by 20%. A central cooling tower and chilled water system provide a high efficiency means to cool the complex. Using 14% less energy than a traditional similar facility, AAFES has used this environmental model as a pilot example of how to conduct future design and construction projects. Other distinctive aspects of the project include implementation of Anti-Terrorism Force Protection (ATFP) standards relative to siting considerations, building controls, and security systems.

/in , , , /by

SSOE’s efforts, along with other design consultants, will save $100 million a year through sustainable features.

When the National Nuclear Security Administration (NNSA) decided to develop a new site with multiple facilities, SSOE was enlisted to lead design efforts for all Mechanical, Electrical, Pluming (MEP) and structural systems. With a large multidiscipline team in place and innovative use of 3D BIM design, SSOE played an integral role to the success of the project.

Mandated by Kansas City’s Responsive Infrastructure, Manufacturing and Sourcing (KCRIMS) transformation plan, the project was implemented to protect some of the nation’s most premier security assets. The new complex incorporates five buildings, featuring manufacturing spaces, laboratories, office spaces, and warehouses. SSOE led all MEP and structural design efforts for the campus buildings and provided structural and MEP design for a central utility plant, which included a chilled water system, cooling tower system, hot water boiler system, and a compressed air system. SSOE’s scope also included the electrical design of medium and low voltage power, lighting, auxiliary, grounding, and outbuilding systems.

The new campus, which manufactures non-nuclear mechanical, electronic and engineered materials for national defense systems, was developed to replace outdated facilities. SSOE’s efforts enabled the client to upgrade from an outdated complex into a 21st century Nuclear Security Enterprise.

SSOE followed sustainable design principles in an effort to reduce environmental waste, maintenance and energy costs. The efforts from the design team and their consultants will result in saving the client more than $100 million each year and qualified the project for LEED® Gold certification.

/in , , , , /by

BIM’s interrelationship of project data allowed for rapid decision making and quality control review, virtually eliminating problems with dimension strings. A flexible design strategy with phasing plans allowed the hospital to be re-built while maintaining all services.

A small, rural community with a strong sense of history, community pride, and support retained SSOE to program and design an on-site replacement for its only hospital. The new Bryan Hospital replaces the existing facility, which was composed of several buildings of varying ages and conditions, none of which met contemporary standards. SSOE’s design supports 60 beds with capacity for expansion to 100. The hospital has been developed according to LEED® principles.

The main project challenge was to replace the outdated, existing facility, which SSOE addressed by proposing a phased demolition and construction plan. The first phase includes construction of a new energy plant, allowing the remaining hospital wing to be reconnected followed by the integration of new components in stages. The hospital includes leased clinic and shell space for future expansion.

Use of BIM was key in our team’s ability to meet the aggressive project schedule and satisfy budgetary constraints. Since 3D imaging allowed quick representation of the proposed design elements for the owner’s review and approval, BIM became the consummate coordination tool. Used to identify potential conflicts such as slab edge coordination, cross bracing, and major duct runs, BIM virtually eliminated problems with dimension strings. The interrelationship of project data allowed for rapid decision making and quality control review. BIM also easily accommodated any last minute owner modifications.

Featured improvements included new surgery, emergency, intensive care unit, laboratory, obstetrics, recladding of existing facility, new lobby / entry, and complete site work.

/in , , , /by

With careful planning and design, SSOE was able to reduce the building footprint by 20%, saving the Owner approximately $3 million.

Plans to replace this aging hospital have begun with SSOE’s design of a new healthcare campus on a nearby 38-acre greenfield site.

The campus master plan will accommodate the new hospital, skilled nursing facility, and a full range of support services—including Life Flight. SSOE incorporated a full-service, 24-hour emergency department, a medical / surgical ICU, inpatient and outpatient surgery, rehabilitation services, pastoral social services, along with all of the necessary laboratory, diagnostic, and dietary rooms, and an enhanced patient experience — all of which were major criteria in the design of this facility.

The design of both the facility’s exterior and interior satisfies all of the strategic goals outlined by the client, which include a new hospital identity, a vision of strengthening the community, design accommodations for the future, and the creation of a comprehensive healthcare campus.

/in , , , /by

Within 36 hours, SSOE arranged and obtained aerial photography of an alternate project site.

In addition to designing this greenfield truck assembly plant, SSOE also provided site evaluation services for the 2,000 acre site. The project required a high level of confidentiality throughout the entire site evaluation process and SSOE worked with state and local economic development authorities to locate the potential properties for analysis.

Site services included evaluating topography, climatic conditions, severe weather potential, transportation, soils, hydrological, electric service, gas service, water service, wastewater treatment service, and rail service at various locations in multiple states in the central and South Central United States. SSOE evaluated project sites ranging from 1,800 acres to 2,300 acres. Site observation visits were performed on the preferred geographic locations. A site report was prepared along with supporting documentation for each site. To provide a ranking of each location, a summary matrix of critical attributes was presented to Toyota electronically for use by top management.

Utilizing 3D MicroStation design platform, SSOE electronically produced the architectural rendering for ground breaking announcements, press releases, and public relations purposes. Toyota also requested an additional site evaluation in a neighboring state and within 36 hours, a helicopter was dispatched and obtained digital video of the site fully annotated showing key site features.

/in , , /by

Dover Light & Power, with whom SSOE has a 20+ year relationship, called upon our firm to design a fiber optic backbone loop around the City of Dover, Ohio. The fiber optic cable used was a multimode type, with the loop consisting of 48 and 96 stranded fiber cable. The fiber optic loop is approximately 10 miles in length.

Initially, the fiber optic system was utilized by the electric department for relaying and Supervisory Control and Data Acquisition (SCADA) communications. SSOE then designed a governmental and educational wireless Wide Area Network (WAN). The governmental WAN connects the department networks and provides data and voice communications between various city buildings and offices. The educational WAN provides data, voice, and video communications for the city’s public and private school systems.

The backbone system can be used in the future for cable TV, telephone, and internet services.

/in , , /by

SSOE assembled a team specializing in cleanroom design and construction to engineer, design, and support construction of multiple basebuild systems including a cleanroom installation at a facility in Boise, Idaho. The client, a semiconductor and memory manufacturer, relied on our expertise to provide support for the projects under a fast-track schedule, while managing multiple onsite subcontractors as SSOE converted the building into a cleanroom facility.

After meeting with the client and performing an exhaustive investigation of the site, SSOE provided preliminary engineering and scope development services for the facility. The existing structure required a thorough structural analysis to ensure that it could support future equipment installations, which we provided under a tight deadline.

The structural scope included an exhaust stack support, utility racks, a bulk gas tank, and the cleanroom ceiling. Our process team created numerous systems including ultrapure and hot ultrapure water, solvent waste, chemical delivery systems, and bulk and specialty gasses. SSOE designed the cleanroom HVAC system for clean production space, and modified the existing HVAC system for the support areas.

In collaboration with the client, SSOE constructed the house VAC and OFA systems to meet the requirements of the upgraded facility as well as modifying the air handlers to change capacity as needed. The coordination of the bulk tank and chilled water systems required constant cross-discipline communication and careful schedule management. The utilities for tools and building services, and controls were also included in our scope. Understanding the client’s needs, we laid out the facility for future tool installations, and took care to include as much of the existing system as possible, while offering cost-effective recommendations for modifications and upgrades based on future need.

SSOE integrated the client’s existing project documentation procedures with our own, which allowed for swift responses to critical questions and submittals.

/in , , /by

A leader in cancer treatment technology, Slidell Memorial Hospital needed a comprehensive cancer center that consolidated all of their existing treatment options resulting in a new, three-floor building on the hospital campus. The development of this facility also allowed for expanded services increasing the number of patients Slidell could care for.

SSOE provided mechanical, electrical, plumbing, and fire protection, as well as data, fire, and security to this facility in support of AE Design’s architectural services, with whom they have worked on multiple cancer centers. The familiarity of this teaming produced a beautiful, esteemed facility with design features that were showcased in Healthcare Design’s annual project showcase edition, all while meeting schedule and budgetary demands.

This new cancer center houses radiation treatment areas, including multiple linear accelerator vaults requiring a process fluid cooler and chilled water systems that must be fault tolerant, highly reliable, and incorporate the appropriate radiation shielding. These vaults include one new Varian high-energy clinical linear accelerator, relocation of a unit from the existing facility, a brachytherapy vault, a CT simulator suite, on-site mobile PET scanner accommodations, and site and foundation components for a future linear accelerator vault. Other features of this facility include a USP-797 compliant pharmaceutical compounding site with specialty filtration and air controls. SSOE also completed the data backbone for communications, including the nurse call system, fire alarms, and overhead paging.

/in , /by

The Women and Infants Center is contained in 430,000 SF on seven floors of the 639,000 SF building, housing a two floor, 70,000 SF radiation oncology center. The remainder of the building is earmarked for future growth and will include medical offices and clinics.

SSOE provided fully integrated mechanical, electrical, plumbing, and fire protection (M/E/P/FP) engineering as part of the owner’s design team using a bridging project delivery method.

M/E/P System Features Included:

  • Electrical and HVAC systems designed to comply with ASHRAE 90.1-2004 energy efficiency standard, in accordance with the Green Guide for Healthcare v 2.1.
  • On-site hot water boiler plant with redundant 800 hp bi-fuel boilers.
  • Standby emergency power plant with two 1500kW diesel gensets, with provisions for a third with 5000 AMP paralleling switchgear.
  • A 30,000 gallon underground fuel oil storage and delivery system.
  • Electrical service provided with reliable spot-network served with four 2500kVA transformers and two 4000 AMP main switchgear.
  • Power quality for Radiation-Oncology systems with four 45kVA rotary power conditioners.
  • A 160kVA central uninterruptible power system to support IT and medical systems infrastructure.
  • On-site medical air and vacuum systems.
  • Connection to campus district chilled water and medical gas (oxygen) plants.
/in , /by

More than $1.5 million in total energy incentive rebates, in addition to energy savings of 650,000 therms of gas and 96,000 kWh of electricity per year.

SSOE was instrumental in completing a highly successful manufacturing complex renovation for worldwide energy leader General Electric in Schenectady, New York. Work on the 40,000 SF autoclave piping area involved the renovation and redesign of steam/asphalt co-axial piping, vacuum, nitrogen, steam and condensate systems. SSOE provided comprehensive design and construction management services for the project.

The project included redesign of a largely undocumented complex industrial system and development of a construction schedule to minimize manufacturing operation downtime. SSOE addressed suboptimal routing in the complex using intensive as-builts to compensate for lack of documentation. Prefabricating many of the piping spools off-site helped minimize manufacturing downtime and streamline the construction process.

Hailed as a tremendous success, this project netted approximately $1.5 million in total energy incentive rebates from National Grid, an electricity and gas company that delivers electricity to approximately 3.3 million customers in Massachusetts, New York and Rhode Island. SSOE’s work helped GE achieve efficiency upgrades that will save more than 650,000 therms of gas and more than 96,000 kWh of electricity per year.

“The project savings are substantial. SSOE did an excellent job managing construction. They picked up the design very quickly and drove the project to completion. Our autoclave operators are very happy with the upgrades, especially in the areas of safety and functionality.”

Michael J. McGowan, P.E.
Facilities Mechanical Engineer
GE Power & Water

/in , , , /by

SSOE has deep experience across many manufacturing sectors. The following are examples of GE Power & Water industrial / manufacturing project experience:

  • Punchline Process Improvement
  • Asphalt Distribution System Analysis
  • Powerhouse Backup Fuel Study
  • Storage Tank Building Demolition
  • 160 PSIG Steam Stress Analysis
  • 400 PSIG Steam Stress Analysis
  • De-Superheater Stress Analysis
  • Stress Analysis HPS Steam Main

Punchline Process Improvement (2013)
Schenectady, New York

SSOE performed process analysis for the purpose of increasing product quality and throughput in the following punchline functional areas: stamping, deburring, final coating, and curing operation. Recommendations and costs were provided for replacement and improvement of the existing manufacturing equipment. The project included manufacturing flow diagrams and equipment selections.

Asphalt Distribution System Analysis (2012)
Schenectady, New York

SSOE performed various engineering services for an existing asphalt distribution system in the plant’s bar shop. The project included fluid flow analysis, pipe stress analysis, pipe support system redesign and reconfiguration, project scheduling, and estimates.

Powerhouse Backup Fuel Study (2012)
Schenectady, New York

SSOE developed a study investigating various fuel options for various fuel alternates for an existing 400 PSIG steam plant. The investigation included comparison of propane air mix, natural gas, and #2 and #6 fuel oils. SSOE performed preliminary design services to help develop proof of concept. The firm also performed energy and cost analysis calculations for proof for funding.

Storage Tank Building Demolition (2012)
Schenectady, New York

SSOE provided a demolition design package for an existing abandoned asphalt storage tank and mixer. The project design included demolition and rework required for segregation from the building’s steam and electrical systems. The design required development of system understanding to minimize interruption to existing manufacturing operations. The project included design, project scheduling, and estimation services.

160 PSIG Steam Stress Analysis (2011)
Schenectady, New York

SSOE performed stress analysis per ASME B31.3 for an existing 160 PSIG system to accommodate operational temperature increase. The firm investigated field conditions to verify existing valve classes and piping infrastructure. SSOE mitigated resulting stresses through system modifications and upgrades of existing components.

400 PSIG Steam Stress Analysis (2011)
Schenectady, New York

SSOE performed stress analysis per ASME B31.3 for an existing 400 PSIG system to redesign the damaged support system. The firm provided analysis with a new recommended support scheme.

De-Superheater Stress Analysis (2012)
Schenectady, New York

SSOE performed stress analysis for a new steam loop for de-superheating per ASME B31.3. The firm worked with GE to simplify system design to expansion joints and minimize impact to the 80-year-old boiler house.

Stress Analysis HPS Steam Main (2011)
Schenectady, New York

SSOE completed an analysis of an existing 600 PSIG / 750 F superheated steam piping, 14″ line size, to confirm adequate flexibility prior to modifications performed during shutdown. Autopipe software package was used to perform the analysis and recommendations were provided back to pipe fitters prior to work.

/in , , /by

Creative design planning saved floor space and enabled uninterrupted operations during early phases of construction.

In 2013, SSOE provided comprehensive design services for a wheelbox upgrade for General Electric’s Steam Turbine Test Laboratory in Schenectady, New York. A leading manufacturer of critical high-speed rotating equipment for the power generation industry, GE Power & Water uses the test laboratory to perform vibration testing of turbine wheels.

One of GE’s major test systems, the wheelbox is a large evacuated chamber in which turbines are run through a range of operating speeds to determine bucket vibration response.

Wheelbox 2 SmallFor this project, SSOE performed the design for removing an existing 4,000 HP induction motor located in the Building 262 (B-262) wheelbox drive pit. Our design included removal of associated control and power control equipment and the eddy current clutch. SSOE also provided detailed design to support installation of the new 5,000 HP induction motor with associated new VFD and new isolation transformer. Modifications to existing switchgear, new motor power feed cabling to the switchgear, oil system connections, control system and vibration monitoring system, including associated wiring, were also part of the scope.

Working within an aggressive project schedule, SSOE addressed a number of project challenges, such as floor space limitations and the client’s need for uninterrupted use of existing systems and equipment during the early phases of construction. Creative repurposing of existing space, namely installing the new VFD on the mezzanine above the lab, helped us work within space limitations. Relocating system connection points and modifying system designs to allow for later installation enabled the client to use the existing equipment to complete current ongoing testing.

/in , /by

SSOE was able to reorient the replacement so the conduit could be reused, resulting in a savings of $50,000. By reusing storage and surge tanks and suggesting an alternate insulation for piping, our team was able to save another $60,000. To date, total cost savings equal $110,000. The refrigeration system replacements are expected to produce an annual cost savings of $780,000.

The U.S. Army Corps of Engineers enlisted SSOE to replace outdated equipment that would decrease the environmental impact and reduce energy costs at the Aeropropulsion Systems Test Facility, part of the Arnold Engineering Development Center (AEDC). The AEDC is the world’s largest ground flight simulation complex, testing nearly all the Department of Defense and NASA systems since the 1950s. Work on this project showcases SSOE’s extensive capabilities to support state-of-the-art technology projects and leverages our experience in large-scale facilities and high-tech laboratory environments.

Known as the Turbine Engine Dry Air Capability (TEDAC) program, the goals of the project are to replace the existing 30-year-old refrigeration system, reduce the facility’s dependency on Trichloroethylene (TCE) and R-12 refrigerant, improving reliability and maintainability. These hazardous substances will be replaced by more environmentally friendly fluids.

Utilizing design-build project delivery, SSOE provided full engineering analysis and design for the demolition and replacement of two existing refrigerant systems. These systems supply 3,000 to 6,000 tons of brine to a cooler, measuring 150 feet in length and 42 feet in diameter, that dries and cools process air used for turbine altitude testing. Because simulating altitude conditions for testing these engines requires a climate controlled environment, the HVAC/R systems are a critical component of this facility.

/in , /by

This fast-track project was completed on time and on budget with documented SSOE generated savings of $12.8 million.

TPCO America, a manufacturer of high quality API Grade steel tube, sought to establish production facilities in South Texas in order to capitalize on the growing demand for steel tube generated by the oil and gas industry. As a subsidiary of Tianjin Pipe Corporation, China’s largest producer of seamless steel pipe, TPCO understood the importance of having American engineering and construction companies on board who are experts in designing and delivering integrated production facilities worldwide. SSOE and its construction partner, Yates Construction, were selected for their vast experience successfully delivering similar projects worldwide.

The design / build team of SSOE and Yates is responsible for the complete design of the pipe rolling / pipe finishing mill, with SSOE providing architectural, engineering, and design services for the plant, including facility and infrastructure design, facility and process utilities design, process integration, equipment installation, and construction support.

Working closely with Yates, SSOE is applying a concurrent design / build approach, which makes it possible for the team to deliver the 1.6 million SF facility on a compressed schedule. The pace of the project increases the importance of SSOE’s job to coordinate all aspects of the work with Yates.
The project site provided significant challenges, as a substantial amount of stabilization was required due to its sandy composition and the need for very stable foundation for processes. SSOE designed a piling network to stabilize the substructure and distribute the load to maintain alignment and functionality of manufacturing systems in the future. To maintain the project budget, SSOE worked with Yates to research and provide the most economical design and construction solutions for this site.

/in , , , /by

Due to an increase in patient demand and more stringent care requirements, ProMedica Bay Park Hospital’s existing Intensive Care Unit (ICU) department could not adequately serve its patients. Patient care spaces, equipment, and required technology required upgrades if the facility were to retain its reputation for providing exceptional care.

In an effort to continue serving the community with quality healthcare services, ProMedica decided to construct a new ICU on the second floor of the existing hospital. This allowed the facility to continue providing patient care while the new ICU was constructed. The new, 11,000 SF ICU was constructed above the existing first floor of the hospital, with some portions extending over the loading dock and emergency ambulance drop-off area. The project also involved selective demolition and the renovation of adjacent spaces. The addition of a new dedicated patient elevator provides patients with direct and private access to the new ICU from the ground floor.

Sustainable design initiatives were incorporated into the enhanced building envelope and involved natural and artificial lighting, acoustics, and energy reduction / usage. The inclusion of room and headwall mock-ups were integral to the project success by identifying operations, connections, safety, and access prior to mass production. As a result, the completed ICU rooms clearly articulated patient, family, and caregiver zones.

/in , , /by

SSOE worked with facilities and operational staff to reduce the square footage by 15%, saving the hospital nearly $4 million.

Aiming to increase patient access to state-of-the-art medical technology and professional healthcare services, Mercy Tiffin Hospital sought SSOE’s expertise to construct a new, fully integrated hospital and medical office building.

In approaching the project, SSOE partnered with construction manager Lathrop Turner and several key trade contractors. Integrated project delivery collaboration allowed for unrestrained discussion about cost saving strategies and methods of accelerating the project schedule. The result of these incorporated efforts is a new, full-service healthcare facility featuring superior technology and expanded accommodations for guests, visitors, and staff members.

SSOE created a welcoming and modern hospital environment to maximize the patient’s privacy, safety, and comfort during recovery. In addition to increasing patient access to innovative medical equipment, physician offices, and professional health services, the new hospital features a spacious layout which has vastly improved patient flow.

/in , , , /by

The expandability of the Uninterruptable Power Supply (UPS) systems will save the client money and the trouble of replacing the entire system.

As a result of a major utility power failure, due to a lightning strike, the main data center for a large regional healthcare system lost all normal and emergency back-up power. This failure affected all operations in every related facility within the organization. The failure also caused damage to the UPS system. SSOE was on-site late that evening and through the weekend, assisting in returning power to the critical systems. During the course of the evening, the emergency generator also failed, requiring the rental of a large trailer-mounted diesel generator.

It was determined that the existing data center lacked the emergency back-up systems required to continue seamless operations in the event of a prolonged outage. The result was approximately a $5 million expansion and renovation project which included a new addition to house the equipment and the installation of redundant services, two emergency generators with paralleling switchgear, and two additional UPS systems.

SSOE’s Data / Fire / Security (DFS) group ensured proper grounding of the existing IT equipment, along with the new UPS, and generator systems. The new UPS systems were sized to fit the client’s current needs and can easily be expanded as the IT load increases. The UPS system and generators are monitored through the client’s network and communicates when there is any trouble conditions within the entire emergency backup power system.

/in , , , /by

Taking advantage of the local climate allowed SSOE to design an energy efficient facility, reducing energy costs.

In late 2012, SSOE Group merged with Evergreen EDC bringing significant synergies to both firms’ data center capabilities.

Digital Realty, a worldwide leader in data center solutions, selected SSOE to provide architectural and engineering services for its customer’s new 52,000 SF facility in Hillsboro, Oregon. The 4.5 MW data center was designed using modular and scalable design principles and includes four identical and independent server equipment room PODs, each approximately 4,600 SF and containing 120 cabinets. Two additional PODs have been included on the site master plan and can be added in the future. The modules are organized along a central service corridor, which provides access to the server, electrical, and battery rooms. The rooftop air handlers utilize air side economizers to provide “free cooling” to the data center for up to 10 months a year. Cool air is supplied to an overhead plenum that distributes the air to the server cabinet cold aisles. The cold aisles are architecturally isolated from the rest of the room (hot aisles) using modular wall components, which assures efficient air flow and eliminates the mixing of hot and cold, thus reducing overall energy costs.

The most significant challenge on this project proved to be fitting the building program requirements within a small, sloping site. By implementing a rapid prototyping design process, SSOE was able to quickly produce a wide range of building configurations and site master plans, allowing the owner the opportunity to provide timely input. The use of this design process was instrumental in keeping the project on schedule and ensuring the owner’s needs and expectations were met. In the final design, SSOE maximized the building footprint by wrapping the support spaces around the server room modules.

The result is a dual-corridor system, one for service and the other for client access, which meets the varying levels of security protocol required by the owner. The building was also orientated and formed to take full advantage of the overall depth of the site, while still maintaining a separate and secure entry for both on-site parking and service yard access. SSOE raised the finished floor elevation of the building in order to balance the cut and fill requirement on the site, and to eliminate off-site soil disposal.

SSOE’s design process, relationship, and familiarity with the local code jurisdiction were instrumental in meeting the aggressive project schedule. We worked cooperatively with Digital Realty to design a cost effective, energy efficient data center that met their current demands, while also maintaining flexibility to adapt to future growth.

/in , , /by

Reduced furnace emissions by converting to oxy-fuel.

When a glass bottle manufacturer wanted to upgrade its furnace and get ahead of potential EPA emissions mandates, it turned to SSOE to define the detailed engineering and construction requirements for the project.

The client had conducted an initial assessment on its own, but wanted to confirm it had considered all aspects of the expansion of its processing facility. They needed to present their stakeholders with accurate estimates for funding approval of the furnace modification. Noting that the EPA was intending to mandate new emissions regulations, the client also wanted to upgrade to a system with lower emissions. As a result, SSOE provided the detailed engineering and construction requirements to convert the furnace to oxy-fuel. After conducting an assessment and outlining the scope of work involved to improve the furnace system, SSOE provided preliminary costs for engineering and construction, as well as procurement of all necessary equipment.

During the planning process, SSOE needed to consider several issues including the relocation of fire lines and a water shed that could not be infringed upon. We also recommended a new electrical power substation for the upgraded oxygen furnace.

/in , /by

Specifying more economical equipment options saved the client nearly $950,000.

SSOE worked with this long-term client to add a third production line to deliver needed additional capacity of unbonded loose fill fiberglass used for blow-in insulation. Having installed the existing two lines, our team was thoroughly familiar with the process and facility, enabling the firm to utilize an efficient design / build approach and work within tight budget limitations. The addition of the third line significantly increased the facility’s throughput.

SSOE provided controls, electrical, process, and structural engineering services. The design included modification of the existing batch system, installation of a new glass furnace, forming system, and bagger; and addition of a storage area. Variable speed drives and efficient cooling towers resulted in significant energy savings for the facility.

/in , , , , /by

SSOE suggested the use of steel eccentrically braced frames in lieu of ordinary steel moment frames on a new building in a seismic zone saving the client $80,000.

A long-term client enlisted SSOE to design a laminator addition that would enable them to manufacture a new shingle product. This involved reconfiguring the shingle manufacturing process and designing a building to house the new equipment.

The strategy included two major phases: Phase 1 included relocation of the existing packaging system equipment to make room for the new laminator. Phase 2 included the installation of the new laminator and auxiliary systems. SSOE engineered and designed extensive controls to handle process changes to the granule, asphalt, and new laminator system.

The expansion also involved joining a manufacturing facility on one property to an adjacent warehouse facility that was owned separately. Electrical service had to be fed separately to the two adjacent sites and underground piping for a fire main rerouted. SSOE provided architectural, structural, electrical and process controls design, and upgraded the alarm system and fire protection for the expanded facility. The team assisted the client with attaining permits and installation and commissioning of equipment.

SSOE fast-tracked the project in order to meet the client’s schedule for plant start-up and manufacture of the new product.

/in , /by

Designed the cullet handling system, which recycles 90% of the manufactured glass.

Emhart Glass, a major equipment supplier for the glass container manufacturing industry, wanted to build their own Reasearch and Development (R&D) center for their container forming and testing equipment. The company previously relied on their clients’ facilities to test equipment, which often meant delays in schedule. Emhart called upon SSOE’s glass manufacturing expertise to design the process systems for the plant.

The unique center includes an actual glass manufacturing plant and quality control laboratories. SSOE developed the building layout and coordinated with a local architect. SSOE designed the complete layout of the center’s batch house, melting furnace, and process equipment. In addition, we worked with Nikolaus SORG GmbH & Co KG on the furnace integration. Our engineers also designed the hot and cold cullet handling system, recycling 90% of the manufactured glass to the batch house.

Other responsibilities included designing the installation of a new IS machine, designing the furnace exhaust system, and coordinating with the utility company to determine proper electrical loads.

“SSOE conducted their work with the high level of expertise and professionalism necessary to enable the plant to become operational 12 months from project approval by our parent company Bucher Industries,” said Steven Pinkerton, Project Manager for Emhart Glass.

/in , , , /by

Phased construction to compress schedule by three months.

When American Snuff wanted to convert a recently purchased facility into new processing facilities, SSOE had the EPCM expertise needed to lead the project. With the goal to increase capacity and achieve FDA compliance, a new requirement for its product, SSOE proved key to renovating and expanding the site, largely due to its expertise serving FDA regulated industries and renovating brownfields.

Originally designed in the 1970s by SSOE, the site, previously operated by Union Carbide, produced large carbon electrodes for the steel industry. The brownfield site had been abandoned for eight years, making the conversion challenging. However, SSOE’s extensive cGMP and renovation experience allowed it to accommodate immediate and future manufacturing needs while transforming an idle general manufacturing environment to one that satisfies new FDA regulations for the industry.

SSOE’s scope of services included conceptual planning and budgeting, design, procurement, cost control, scheduling, monitoring and reporting, commissioning, and construction management services.

In an effort to achieve American Snuff’s ambitious schedule, SSOE recommended construction sequencing (phased construction with multiple primes) to compress the project construction schedule by three months. Aggressive cost management and early identification of cost trends put the project on track to be delivered within budget.

/in , , /by

SSOE provided comprehensive electrical engineering consulting and design services to GE Intelligent Platforms, a business unit of GE Energy Management. Over the course of a year, SSOE addressed electrical needs for an existing 45,000 SF building and a new 20,000 SF addition to GE’s Huntsville, Alabama, campus.

A key location for GE Intelligent Platforms, the Huntsville campus manufactures an array of high-technology products serving defense and aerospace, medical, semiconductor, industrial, and communications customers.

In the first phase of this project, SSOE performed a detailed site survey to determine costs for construction of the addition and evaluated the existing building for compliance with current codes. SSOE then conducted feasibility and code studies and provided electrical system design criteria and alternatives.

Once the design was finalized, SSOE provided construction administration services for the electrical portion of the project, including shop drawings and submittal review. SSOE also helped the client update electrical plans for the 613 SF Shaker and Control Room and relocate the thermal chambers in the manufacturing area.

Additional work included power and circuiting for the 940 SF single-story storage area addition, modifications to exterior site lighting (metal halide fixtures changed to LED fixtures), and electrical design for revisions to a 10,000 SF second floor in the building.

During the course of the project, the Owner presented a number of revised requirements that demanded quick design modifications. SSOE rapidly incorporated all changes and successfully met an expedited timeline associated with the relocation of GE’s Albuquerque, New Mexico plant operations to Huntsville.

After successful project completion, GE sought SSOE’s assistance in sourcing support during an emergency equipment failure.

/in , , /by

Having successfully performed design work for thousands of greenfield production plants, SSOE was well qualified to serve as the Engineer of Record (EOR) and oversee architectural and engineering services for the configuration and installation of a new steel tube production facility. Strong project management was needed to coordinate the efforts of the design / build contractor, multiple OEM suppliers, and an international client to meet an aggressive time line for production start-up.

Located on a 300-acre, greenfield site, the production facility consists of a pre-engineered metal building with a concrete mezzanine, operations, and production floors. Primary manufacturing operations include billet preparation, piercing, sizing, finishing, testing, and all related furnace and heat treating equipment. Other facilities on the site include in and outbound logistics, administration / training center, utilities, water treatment, chemical treatment, and cooling towers. SSOE also provided site preparation services.

Utilizing the 3D MicroStation design platform and Navisworks, SSOE electronically produced the architectural rendering and video of the plant for ground breaking announcements, contractor outreach program, press releases, and public relations purposes.

/in , /by

Innovative design solutions and advanced project controls resulted in $115,000 of documented savings for the client.

When a large chain superstore mandated that its suppliers become SQF (Safe Quality Food) certified, MOM Brands needed an expert firm to get their largest facility compliant, and in record time. With a solid reputation in start-up management and implementation, SSOE proved to be the best firm for implementing this food safety project. Working against a 10 day downtime timeframe, SSOE put the right team of experts in place to ensure MOM Brands’ compliance. With an ever-changing project scope, SSOE responded and improved the indoor quality.

MOM Brands secured SSOE to determine and implement what needed to be done in order to achieve SQF certification. SSOE leveraged project controls software to coordinate and phase numerous contractors to address the issues. While cleaning and painting occurred, SSOE needed to comply with client mandated guidelines for construction projects, which included reconfiguring the HVAC to make the affected areas negative to the rest of the plant, and wrapping all line components and duct work within the facility. To meet the aggressive timeline, SSOE and contractors worked non-stop to isolate the area within 20 hours, a unique feat for a plant of such size. SSOE also utilized a quick curing paint to save four days within the aggressive schedule. Dry ice blasting was used to clean the equipment.

SSOE successfully completed the project within the tight schedule and MOM Brands passed the SQF audit.

/in , /by

$90,000 in savings through re-use of existing process machinery.

When a sausage snack manufacturer experienced catastrophe at one of their production plants, SSOE proved integral to getting them back in production, and with quick results. Noted for its expertise in start-up management, SSOE’s involvement with this project showcased its ability to provide quick response to client crisis situations, whether it be floods, explosions, or product tainting.

With combined expertise in process, packaging, and plant operations, SSOE was retained to coordinate and manage the equipment installation at a co-packer’s facility to enable production start-up. This included obtaining equipment and installation quotations, submitting purchase requisitions as well as installation coordination. The firm also assessed potential manufacturers to determine if they met necessary qualifications to execute the production scope.

SSOE determined the best location within the existing facility to conduct the pickling process, established production timelines, and managed the start-up process. The firm also modified conveyor processes, ink jet coding, and designed a three-step packaging process. In addition, SSOE worked with the co-packer to install a scrubber fan system which pumped caustic feed to neutralize the vinegar and suggested use of sanitary curtains to prevent product tainting. To minimize the disruption of the site’s natural ecosystem, SSOE integrated outdoor tank containment for used brine into its design. Acting on the client’s behalf, SSOE designed a bulk vinegar tank system and coordinated installation to eliminate the need to purchase small totes reducing the plant’s ingredient costs. To minimize costs, SSOE recommended reuse of existing machinery as needed.

/in , , /by

SSOE saved the client 1,000 man hours and helped to streamline activity in the plant.

When this food manufacturer built a pilot plant to develop a new method of making tomato products using a new evaporator system, they realized they were limited in the manpower they needed to master the process. With a need for additional on-site support, the food manufacturer wanted a partner that not only had expertise in design process, but had a fundamental understanding of the hands-on approach needed to learn the functionality of the system and to help ensure its success. With an alliance agreement in place, the client commissioned SSOE to manage the start-up process at the facility under a Master Service Agreement (MSA). Noted for its vast expertise in tomato-based products, SSOE’s experience runs the gamut from bulk ingredient receiving through USDA/FDA inspection, sorting, processing, filling, packaging, palletizing, and warehousing.

The pilot plant, built on an existing tomato processing site, used outdoor energy efficient evaporators that used less steam to process, at minimum, 5,000 pounds of tomato for concentrate and paste. In its role, SSOE was first charged with the oversight of day-to-day pilot plant operations, including running the process system, leading repairs, troubleshooting processing issues, as well as cleaning the system.

In its second year of on-site support, SSOE transitioned plant operations to the client’s team, training them and sharing the expertise acquired during the initial pilot plant phase. SSOE also offered input on implementing control measures and means for improving site processing. Ultimately, SSOE saved the client 1,000 man hours and helped to streamline activity in the plant.

/in , /by

SSOE’s expertise in process design and an in-depth knowledge of the client’s needs led to an annual operational savings $700,000 by modifying ingredient flow and production lines for a more efficient design.

During an unexpected shutdown of its production, a food manufacturing client called on SSOE, its long trusted engineering resource, to quickly improve processes and return the facility to full operation. Because every week of lost production meant lost revenue, the team was directed to fast-track the project, but not at the expense of the client’s stringent quality standards.

To complete the project, SSOE’s team repaired various system inefficiencies and redesigned the production system to enhance food safety. Several pieces of older equipment were replaced, and a process to sanitize raw ingredients separate from processed ones was incorporated. SSOE consulted on the facility design modifications.

Additionally, SSOE designed a process to sanitize the complex product piping system using hot soybean oil that would not affect the quality of the client’s product. The client took advantage of the plant shutdown and also upgraded controls to increase yields, reduce energy consumption, and incorporated a new air quality system.

At the height of the project, SSOE’s team consisted of ten onsite engineers and designers to sustain the crucial schedule.

/in , , , , /by

SSOE identified more than $3 million in cost savings for this project, which represents more than half of its total fee.

American Snuff, LLC called upon SSOE to provide a project solution for their new tobacco product manufacturing, warehousing, and packaging facility in Memphis, Tennessee. As part of the conceptual design effort, SSOE accompanied American Snuff on walkthroughs of several vacant buildings being considered for the new plant. Based on our observations, SSOE recommended building what would best meet American Snuff’s needs and budget.

SSOE developed and implemented a plan to renovate and reconfigure an existing distribution center to a food grade production and packaging facility and satisfy new FDA regulations for the tobacco industry. The renovation also created spaces for various staff offices, maintenance areas, a developmental lab, a pilot plant, and a new entrance / lobby. SSOE provided structural, civil, fire protection, construction management, project planning, procurement, cost control, HVAC, electrical, commissioning, monitoring and reporting, and scheduling services. A building management system, communications, security, and information technology systems were also part of the project scope.

Environmentally friendly practices were implemented including recycling 60,000 cubic feet of concrete and 50 tons of steel, reuse of excavated soil for backfill, and implementation of LEED® certification prerequisites. Modifications to the building added daylighting and use of energy efficient materials.

Contact Us

Have a question regarding our services? Need assistance with an upcoming project? Send us an email. We look forward to hearing from you and will follow up soon.

Contact Us

Our Services

© SSOE GROUP 1948-2025
Legal | Privacy Policy | CA Privacy Policy

Employee Portal
Vendors / Subcontractor

Website designed and developed by
Raincastle Communications, Inc.