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Expedited the recovery of process systems, helping the plant return to full operating capacity well within the client’s schedule.

In June 2008, widespread flooding submerged much of Iowa. This food client’s plant, one of the world’s largest food manufacturing facilities, was among the many businesses affected by the rising water. Located near a main river, the plant suffered considerable internal damage to operating equipment and was forced to stop production. Water filled the basement and rose nearly two feet into the first floor, destroying much of the on-hand product and damaging the facility’s operating process equipment.

The client called upon SSOE’s assistance to restore process operating systems as quickly as possible. Already familiar with the operation from previous projects, SSOE’s professional team initiated a comprehensive inventory of the process equipment in the flooded area and determined how to replace the damaged pieces. The team developed a master inventory list that prioritized tasks, documented vendor information, and tracked progress of rebuilding and purchasing of new equipment. The list was updated daily, keeping the entire team of contractors informed on required next steps.

Working with client’s staff and local contractors, SSOE also helped redesign and relocate the plant’s central compressed air system.

SSOE’s production process knowledge and dedication to our client’s success made our team a trusted advisor on this fast-track project. Just eight weeks following the flood, and well within the client’s established schedule, the facility returned to full operating capacity. In comparison, neighboring manufacturing plants were shutdown for several months while executing their recovery plans.

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In addition to moving production forward by 3 months, SSOE utilized an innovative approach to the design of the process waste discharge system. This established a realistic peak flow number which the existing infrastructure could support. The realistic flow saved $700,000 in system cost, labor, and installation time.

When a major food manufacturer sought to add production capacity through the addition of a second Ready-to-Spread (RTS) frosting line, it looked to SSOE to provide the same high quality engineering services it had provided on the original RTS line installation more than 20 years prior. SSOE provided complete EPCM project delivery for the line, from raw ingredients to the finished product warehouse, and repurposed existing warehouse areas. The project was slated for completion in just 13 months.

As an industry leader in design technology, SSOE employed Virtual Design and Construction (VDC) to deliver a construction strategy that pulled critical path activities forward, allowing maximum time for process design.

To allow activities to occur concurrently SSOE utilized a phased construction approach. The prequalification process mandated contractors that have the ability to accept a 3D model, add detail, and trade the model back and forth. This allowed the use of the 3D model as a project delivery tool to drive a higher degree of coordination and project delivery integration.

Liquid process elements were modularized and built in fabrication shops on skids, allowing construction to take place in tandem with facility construction. Construction in this type of controlled environment leads to higher quality and is 30% faster, 30% more cost effective, and 80% safer than traditional construction methods. As the 3D model served as the basis for all reviews, no 2D skid drawings were required. Fabrication-level documents were produced for piping, skids, and structural steel in lieu of design intent documents. As a result, contractor rework and SSOE review of submittals were essentially eliminated, accelerating the schedule.

The ultimate result of this approach was a successfully executed project delivered in just 10 months within the budget allocated for a 13 month schedule. This resulted in an additional 3 months of production—-which translates to millions of dollars in revenue and profit.

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SSOE recommended the installation of a relocated fire riser in the Aseptic Room and supply air be distributed from the ceiling, thus eliminating the need for bump-out / chase of the addition’s north side. This, coupled with the reuse of various existing equipment and several design modifications, ultimately saved the client $73,000.

A production increase at a client’s existing facility required a new aseptic line addition to the existing production process. This capacity increase required process, packaging, and palletizing equipment installation, as well as a 1,000 SF process area expansion and 1,600 SF truck dock expansion. Given SSOE’s strong relationship with the client, as well as our experience providing mechanical utilities and HVAC controls for a previous aseptic expansion at this facility, the firm was the obvious choice to provide engineering services necessary to successfully deliver this project.

SSOE provided preliminary and detailed design to prepare the site, building, infrastructure, process piping, fire protection, electrical power, and controls systems for the project. The design of all mechanical, electrical, HVAC, and utilities required for all third-party “turnkey” systems, such as sterilization, refrigeration, filling, packaging, and palletizing, to be integrated into the overall production system, was also provided. Plumbing and HVAC systems were expanded to facilitate the larger facility’s needs. A new electrical transformer was integrated to serve the new production equipment, high bay fluorescent fixtures, and electrical distribution systems.

Process systems included three tanks, three pumps, a drum dumper, two filters, two platforms, and associated solenoid and electrical panels. SSOE provided the relocation design for the existing CIP skid to blending areas, including a new layout, extension of utility headers, electrical services, chemical supply piping, and CIP fluid delivery piping.

This complex project involved numerous entities. SSOE’s project management bridged the gaps between vendors and other engineering suppliers. The project was executed as a whole and incorporated multiple turnkey systems into an integrated solution. Work was coordinated with scheduled plant shutdowns to minimize operational disruptions.

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Executed 16,000 offshore engineering hours over the course of six months, exceeding the client’s goal.

When a household care manufacturer wanted to integrate an offshore engineering partner from India at its highest revenue generating site in North America, SSOE proved to be key to the successful integration. With more than 20 years of experience on the site, SSOE had personnel capable of managing, controlling, and delivering the entire site’s engineering capital as well as managing integration of an offshore partner over the course of a year.

Because the offshore supplier did not have familiarity with the site, SSOE first worked to integrate them into the existing processes, identify potential challenges and outline plans for troubleshooting them. This included a recommendation to provide a cultural training course for the offshore principles as well as the SSOE team. SSOE was also charged with a goal to manage 15,000 offshore hours over the course of a year and a $3 million site engineering budget for related yearly projects. Projects included capacity and efficiency increases, product additions, as well as site clearance to make the facility more usable. What resulted was the planning and support needed to improve the onboarding of future engineering suppliers, timing of projects, and breakdown of projects depending on complexity.

Additionally, SSOE’s experience and expertise allowed projects to be conducted as planned and exceeded the 15,000 man hour goal in just six months.

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Cost savings of $200,000 resulting from integration of re-purposed equipment. Increased throughput by 30 bags per minute.

With a need to increase its bagged pet food output, paralleled with a corporate-wide initiative to diversify its packaging capabilities, this confidential client sought SSOE’s expertise to execute a packaging line addition. A long time alliance partner, SSOE applied its knowledge to design a process to increase packaging efficiency, volume and capacity.

The design plan for the new line included installation of a bagger, quality inspection equipment, a palletizer, a full pallet conveying system, stretch wrappers, and related structural components. Noted as packaging specialists, SSOE also assessed the custom design components for ergonomics to ensure quality results and safety for line workers. Subsequently, the client also utilized SSOE’s expertise in evaluating additional vendors and bids.

SSOE successfully implemented the relocation and reuse of a conveyor and stretch wrapper from another facility, resulting in more than $200,000 in cost savings for the client. The line addition aided in increasing product throughput by 30 bags per minute.

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SSOE took immediate measures to restore the partial function of a warehouse, saving the client the cost of leasing an off-site space.

After a tornado struck a pet food warehouse facility, the client sought SSOE’s construction management expertise to restore and improve the building so on-site storage could be resumed. The immediate first step, installing a temporary roof, and subsequent staging of repairs created sufficient warehouse space to meet the demands of full production months before repairs were completed. This was crucial as there were no nearby temporary storage facilities that could meet the client’s criteria.

Due to suppliers’ inventory reductions, some materials were difficult to obtain. SSOE minimized the resulting schedule delays by relocating the project manager to the site for four weeks, managing the project efficiently, and doubling up efforts to secure equipment and materials.

Returning the warehouse to working order included replacement of 50% of the roof, the entire front of the facility, and the east wall. Damaged roof fans were replaced with wall fans as a precaution against future wind damage. The team replaced windows, gutters, vents, and overhead doors that had been blown out, and realigned 12 supporting concrete columns. SSOE also devised a method for reinforcing concrete columns with steel plates so they could withstand forklift collisions and not be damaged. These new column wraps became the standard for future repairs.

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The Nutrien facility in Lima, Ohio was under staffed and looking for a project manager to step in and take over several projects to meet their department goals. PCS enlisted the help of SSOE to develop and execute a number of projects during their busy construction season. The work was intended to be temporary but the contract was repeatedly extended because of the client’s satisfaction with SSOE’s delivered results.

SSOE was initially responsible for two projects. The first was to install two chemical truck loading scales and the relocation of eight chemical lines. The replacement of the scales was safety driven, due to significant corrosion of the scale pits, lack of adequate fall protection, and inadequate process controls. SSOE oversaw the consulting firm that developed a FEL 1 grade estimate. In order to find the best solution, the SSOE team created an electronic 3D model of the scale site to be able to foresee any maneuverability issues the trucks might have. SSOE was able to adjust plans early in the process to produce optimal results. SSOE specified piping material, determined tie points, specified scale size and location, reconfigured truck routing, and developed the AFE grade estimate for this portion of the project.

The second project consisted of installing an ammonia suppression system. This entailed designing a system to knock down ammonia vapors with water in the event of a leak. SSOE determined spray location, specified piping spray nozzle material, sized lines and spray nozzles, developed bid packages, and managed electrical power design, process control design, and construction activities.

After proving performance on the first two jobs, SSOE was hired to complete multiple maintenance projects. Vibration issues and discontinued replacement parts led to the need for replacement of an induced draft fan turbine. SSOE oversaw the civil design firm, developed the scope of work and bid packages, and developed a schedule for minimum down time. Another project consisted of the installation of a heat exchanger. The previous unit was overheating and was producing calcium, so a new unit was installed upstream of an existing intercooler which lowered the air temperature and prevent fouling. The most recent assignment was to replace the scale house building since the previous building was small and in toxic and blast zones. SSOE designed the building size, layout, and location, specified blast and toxic requirements oversaw the electrical and controls upgrade, and developed estimate and AFE.

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When a long-established chemical client needed master planning assistance for a new solar product manufacturing facility, they called on SSOE as their trusted engineering partner. SSOE established interface points between the plant and site services and developed an overall master site plan.

Coordinating with city officials, intersection, and traffic patterns were updated to improve access to the site. These updates were then incorporated into the master plan. To improve site safety and security, a loop road design separating employee access from truck access was implemented. A design was also developed for site drainage, collection, and waste treatment. Service water and fire water loop tie-ins and completion were also included. Site based utilities (steam, water, process water, and compressed air) were integrated into project needs, by the SSOE team.

SSOE provided the design for a guard house, integrating products manufactured by the client into the aesthetics. The energy-efficient design included high sound isolation from the adjacent plant. Architectural security fences, turnstiles, and truck security gates were also included. Client-specific standards for security layers and boundaries for truck and employee plant access were supported in SSOE’s design. Electrical power distribution for the guard house incorporated the client’s manufactured solar power system. A sidewalk snow melt design was developed, including all power and control equipment. The guard house lighting design incorporated client-specific light levels. Client-specific requirements for perimeter security, loop road, parking, and truck inspection gates were integrated into the overall site lighting design.

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SSOE worked with TOK America to duplicate the design and installation of a mixing and blending tank at their Hillsboro, Oregon, location. With our history of efficient design and precise field verification, SSOE staff analyzed and mirrored the corresponding system, installing a new batch tank and transfer system in the existing building. After managing the construction effort, the facility drawings were updated with the new tank and its associated systems.

Later TOK America decided to add an additional tank. SSOE compiled six options for the new tank – from reusing a tank on-site to installing a brand new system, keeping in mind budget, time, and operational expenses. Through 3D modeling SSOE was able to illustrate how the tank would fit into the existing facility, and make swift changes in response to TOK’s needs. A structural frame was also engineered and fabricated to support the mixer sitting above the existing tank. SSOE then provided programming for the new mixed tank. Throughout the process, SSOE collaborated with TOK to analyze their needs and provide cost-effective solutions.

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SSOE’s innovative design for the abatement system and operational energy efficiency improvements saved the client $11 million.

SSOE was selected by the site owner to provide engineering services for detailed design and construction to produce ceramic materials at a site in the Southeastern U.S. Although the client already had a specialized engineering team working on the facility, it was recognized that the effort was resource limited, and SSOE had the resources and experience to keep the project on schedule and on track. As part of this effort, SSOE also led the air permitting process and was responsible for other environmental permits required to build and operate the facility.

First priority for SSOE was to assist the local environmental consultant in obtaining information necessary for air permit application and approval. SSOE’s environmental specialists worked with the process specialists and engineers to determine critical process emission information required, and also assisted with communications with the appropriate people in the state environmental office.

In addition to the air permit, SSOE also completed other required federal, state, and local environmental permits. These were separated into preconstruction, construction, and pre-operation / operating permits. Until the client assembled an on-site environmental staff for operations, SSOE acted as the client’s environmental engineer, assigning operating permits and plans to appropriate parties to complete. These plans included permits to install / operate, tank permits, spill plans, wetlands, water withdrawal permitting, NPDES wastewater discharge and stormwater permits and plans, and communication plans.

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Saved $20 million prior to design phase by avoiding approximately 5 million cubic yards of earthwork.

SSOE was commissioned to perform the master planning and design of the Toyota plant near Tupelo, Mississippi. The new plant was originally intended to produce the Highlander vehicle. With the turn in the economy, the plant will now produce the fuel efficient Prius, one of Toyota’s most sought after models.

The design of the facility and infrastructure is configured to allow for future expansion and the utility needs for the increased production capacity. The overall project has been issued in multiple packages for site work, foundations, structural steel, and general contract work. 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.

The first phase of master planning efforts for this 1,700 acre site required more than 16 million cubic yards of earthwork. Site infrastructure was developed in conjunction with the State of Mississippi and the PUL Alliance which originally developed the area. Site utilities were not only required by the main plant, but also by the other onsite suppliers. SSOE coordinated  the overall utility requirements for Toyota Motor Manufacturing, Toyota Logistics Services, and Toyota Tsusho of America.

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Through design modifications, experience, and innovation, SSOE has saved the client nearly $5 million.

To meet their growing product demand in North America, renowned automotive parts supplier, ZF Friedrichshafen (ZF) chose to build a new transmission plant in Greenville, South Carolina. ZF selected an experienced team comprised of SSOE and other contractors to design and construct the 970,000 SF facility.

SSOE is currently providing architectural, mechanical, and electrical design and engineering for the entire facility, which will consist of manufacturing spaces, offices, laboratories, a data center and a cafeteria. The facility, which is ZF’s first passenger car transmission plant in North America, will produce fuel efficient, eight and nine-speed automatic transmissions.

As part of the original project scope, the facility was classified as an F-1 and S-1 use group (International Building Code). However, with SSOE’s vast experience with similar facilities it was realized the facility should actually be classified as an F-2 and S-2 use group. As a result, several unnecessary fire protection systems were eliminated, saving the client $575,000. This cost savings, combined with several other design innovations, has resulted in a project savings of more than $4 million.

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EPAct 2005 building related energy standards with 50% annual energy reduction.

When BMW needed additional production capacity at its most utilized campus in Spartanburg, South Carolina, they needed a firm known for their expertise in automotive facility design. Having completed a previous energy study for the automotive manufacturer and with recognized capabilities, SSOE was secured for the project. The expansion allowed BMW to increase their output from 160,000 to 240,000 automobiles annually.

SSOE provided the detailed architectural design as well as civil, structural, mechanical, electrical, and fire protection engineering services for the assembly plant built on an existing BMW site. With a multi-discipline team in place, SSOE’s scope for the new facility included design for parking areas, a central energy plant, conveyor enclosures, and all utilities required for the plant. Working against a compressed construction schedule, a comprehensive planning process allowed SSOE to meet an aggressive four-month design schedule. The results were plans for an energy efficient building, designed for future expandability.

SSOE also had to consider site challenges, including the property size, proximity to private residences, and mitigation of streams flowing across the corner of the property. The building’s design meets the Energy Policy Act of 2005 (EPAct 2005) standards for “Energy Efficient Commercial Buildings” and includes increases in insulation in the walls and roof, efficient lighting systems, high efficiency heating and cooling systems, and high efficiency hot water systems. The result is projected to produce a 50% total energy savings over the American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) recommended standards.

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SSOE led the value engineering effort for this facility, developing more than $17 million in savings opportunities, resulting in more than $11 million in total incorporated changes.

In an effort to expand their market into the United States, a European tire manufacturer looked to SSOE to provide site evaluation, risk assessment, architectural and engineering services, and construction management for their 875,000 SF greenfield tire manufacturing plant. The scope included pursuing a viable site as well as providing assistance with environmental permitting requirements, including air permitting data. The facility will have the capacity to manufacture up to 4.65 million passenger / light truck tires per year within the first construction phase. The master plan for the greenfield site will accommodate up to 2 million commercial vehicle truck tires manufactured per year.

The plant features just over 100,000 SF of office, 600,000 SF of production, and 130,000 SF of warehouse space to support their projected 800 employees. Each area is unique to the intended user group and includes precast concrete, cast in place concrete, and structural steel framing systems. The process utilities are complex and range from multiple cold and hot water systems, natural gas use, compressed air demands, and high-pressure steam. SSOE provided electrical, power and lighting, data, fire and security, as well as an appropriate architectural statement for the Owner’s first major expansion in the United States.

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SSOE was selected for this project based on excellent service on a prior KSM project, where SSOE’s intensive value engineering helped KSM reduce estimated completion costs by 33%.

Following a highly successful partnership with SSOE on their first U.S. facility — a greenfield high-pressure aluminum castings plant — KSM Castings again called on SSOE to provide design and engineering expertise for a second U.S. facility, a 53,000 SF state-of-the-art counter pressure casting (CPC) facility. The new facility expands KSM’s U.S. operations and provides a novel cutting-edge casting technology for automotive components manufacturing.

SSOE provided civil, architectural, structural, mechanical, and electrical design services for the CPC facility, incorporating efficiencies developed during the design and carrying those through construction of the aluminum castings plant.

Acting as Owner’s Representative, SSOE planned and coordinated construction activities for the new CPC facility to meet KSM’s facility milestones. To streamline progress, SSOE leveraged proven communication strategies based on Virtual Design and Construction (VDC) tenets and used clash coordination within the model to avoid delays during construction.

Early and ongoing communication with all involved parties, including construction contractors, created a fluid workflow with fewer interruptions, early buy-in, proactive solutions to potential schedule or construction conflicts, and a more successful project overall. KSM is positioned to easily expand in the future.

“SSOE knows us as a company, so they meet our technical needs. It’s very uncomplicated to work with SSOE. They offer us a whole scope, from site selection to architecture and engineering, into construction management. Dealing with only one consultant is very lean and straight forward.”

Jan-Christoph Schwarck
President / Plant Manager
KSM Castings USA

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SSOE was awarded a nationwide, five-year IDIQ contract for A/E services related to master planning for over 12 million SF of the EPA’s environmental and analytical laboratory and support facilities. This included coordination with EPA program and regional offices to incorporate their missions and strategic goals into specific master plans.

SSOE has completed the following tasks for the EPA:

Research Triangle Park (RTP), North Carolina
The RTP EPA Research and Administration Facility consists of approximately 1.4 million SF of laboratory, vivarium, office, and special use space.

SSOE has performed the following tasks at this site:

  • Facility master plan
  • Programming and planning to relocate the EPA Division now located off-site into the RTP facility
  • Energy reduction strategies
  • Evaluation of sustainability opportunities

Chapel Hill, North Carolina
SSOE completed an engineering study to provide recommendations for energy reduction strategies and HVAC improvements.

Narragansett, Rhode Island; Athens, Georgia; and Corvallis, Oregon
SSOE provided master planning services to address the renovation of the existing 40 year-old laboratory buildings, strategies to meet/exceed EPAct and EISA criteria, and a “green” strategy for restructuring the site.

Las Vegas, Nevada
SSOE developed a POR and Design Intent documents for a new two-story, 40,000 SF leased laboratory / office building. This building will house the offices and laboratories of the EPA’s Radiation and Indoor Environments National Laboratory currently located at the University of Las Vegas.

Houston, Texas
SSOE developed the POR for a new EPA Region 6 build-to-suit 10 acre campus, including a 90,000 SF laboratory building and support facilities.

Edison, New Jersey
SSOE developed a POR for a new 400,000 SF, state-of-the-art Environmental Science Center. The new facility consolidates the Edison EPA’s program into one building, replacing the aging, inadequate existing facilities.

Fort Meade, Maryland
SSOE completed a conceptual design for modifications of the EPA Environmental Science Center to allow for chemical warfare agents testing as requested by the Department of Homeland Security.

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SSOE was selected to create a master plan and design for Kemin to not only reflect the entrepreneurial spirit and corporate brand that is Kemin, but also to position the company appropriately for future projected growth. SSOE provided an overall assessment of the Kemin site to situate the new Research and Development (R&D) laboratory and future corporate headquarters in such a manner to promote oversight and engagement with the existing campus and manufacturing facilities, while also offering a formal gateway and introduction of Kemin innovation to the public.

The new R&D laboratory is designed for collaboration to promote intensive idea generation and product development. The two-story laboratory facility is organized with an emphasis on access to daylight, spatial efficiencies, and flexibility to expedite idea exchange and staff interaction. The main, general laboratory area is open and modular with specialty laboratories and related open office area located directly adjacent. Administrative offices, conference rooms, and informal meeting / break areas surround the primary laboratory function. Attached to the main laboratory are Class 1, Division 1 pilot laboratories which accommodate large-scale experiments and processes, a designated shipping and receiving area, chemical and sample storage areas, and mechanical / electrical services, including a generator.

The main entrance to the facility features an open, light-flled, two-story atrium. This common area presents visitors with a formal introduction to Kemin and will act as the central circulation hub to connect the future planned additions of a corporate administrative headquarters, 350-seat cafeteria and food service area, and an additional laboratory block.

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Designed hospital to meet program goals and saved approximately $2 million by reducing square footage by 10%, reducing to one floor, and minimizing infrastructure system lengths and material costs.

This single-story, freestanding, orthopedic, and spine specialty hospital is located on a satellite outpatient campus of the ProMedica Health System. Support spaces include those required for state licensing and program operation. This facility is ProMedica’s first all digital hospital, complete with electronic health records technology, comprehensive inpatient and outpatient diagnostic services, including CT, MRI, and general X-ray.

This project constitutes Phase II of the campus development for orthopedic services (Phase I, construction of a Medical Office Building [MOB], was completed separately). Phase II involved linking the hospital to the MOB, which houses the primary orthopedic physicians’ practice, via an enclosed, overhead pedestrian connector. Our team of BIM experts utilized 3D modeling to develop and illustrate details of the project.

Since the new hospital is a significant addition to the existing campus, coordinating site access, circulation, parking, and utilities was critical to the project’s success. To address these issues, the orthopedic facility was designed to be consistent with the existing campus master plan. Future expansion needs were considered during the site / facility planning stage, as was the hospital’s environmental impact, to which SSOE responded by incorporating LEED principles into the design.

The construction duration was approximately 15 months. Early civil and structural engineering packages were issued to expedite the construction process. To eliminate the need to fireproof the structural steel, the facility was classified as three buildings (each Type IIB construction). Each building was separated by a two-hour fire wall, with each containing two smoke compartments.

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SSOE performed a complete renovation of the former surgical suite at Oakwood Hospital & Medical Center. The suite was vacated when the North addition (Fitzgerald Pavilion) was opened and inpatient surgery functions were relocated. SSOE designed a new 53-bed, 23-hour Interim Stay Unit (ISU) to infill the vacant suite.

As the largest nursing unit on campus, the ISU houses short-stay patient rooms and observes patients from several hospital areas consolidating the 23-hour function from various outpatient testing and procedure departments. Emergency, special procedures, catheterization laboratory, general radiology, endoscopy, and ambulatory surgery patients requiring short-term observation or recovery remain in this one central unit until they are prepared to leave the hospital under their own care.

SSOE’s design of the ISU recognizes both patient amenities and staff efficiencies. The facility provides for flexible assignment of beds, varying from Emergency Department Observation Unit (EDOU) cubicles to 23-hour rooms with private toilet areas. Conceptually, the space is divided to accommodate 18, three-walled EDOU cubicles, three private, four-walled EDOU enclosed rooms, 24 short-stay / recovery rooms, and eight short-stay recovery rooms.

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SSOE provided architectural design services for a new freestanding 25-bed critical access hospital in Choctaw County, Alabama.

This 70,000 SF project included renovating a 36,000 SF existing manufacturing building and adding 34,000 SF to replace the existing Choctaw County General Hospital. The new hospital with medical office building was designed for 25 private patient rooms with toilets, showers, and a kitchen with a public dining room to seat 60+ people. The hospital was designed with an emergency room, diagnostic facilities, inpatient / outpatient physician’s therapy, pharmacy, lab, outpatient clinical services, and support space for equipment, storage, laundry, and more.

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The project was a multi-specialty ambulatory surgery center build-out, approximately 11,000 SF, in a medical office building. It opened with two operating rooms and one future operating room. The following areas were developed in the available space: waiting room, reception, business office, bulk storage, soiled and clean work, mechanical room, medical gas room, sterile storage, staff lounge / lockers, semi-restricted staff lounge and control station, anesthesia work, prep and recovery stations with medical gases, private recovery room, consultation room, and exam / private prep room.

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The Benjamin Russell Hospital for Children is a new, 12-story, replacement hospital with a central energy plant. This project is the largest medical facility expansion in the history of the state of Alabama. It is located directly north of the current facility and is bridged to the existing facilities.

The new facility accommodates projected growth in patient volume, anticipated medical technology needs, planned consolidation of pediatric services, and features a family centered design that enhances comfort for patients and families. The hospital houses 332 beds, plus 48 Neonatal Intensive Care Unit (NICU) bassinets. The new hospital includes larger rooms, a larger emergency department, and two additional general operating rooms. Additionally, two cardiac operating rooms dedicated to pediatric cardiovascular surgery have been relocated to this facility. The new hospital is expected to become LEED® certified, and will become Alabama’s first LEED certified hospital building.

The design features stunning views, including two roofs with native plants. Facing due north, it makes the most of natural lighting, while ensuring the sun never hits the windows on the broad side of the building. Other green features include a coated roof that reduces heat gain from the sun and a central plant that collects 30,000 gallons of water daily from air conditioning vents for other uses, such as irrigation for green spaces.

SSOE served as the associate electrical and data / fire / security (DFS) engineering firm for this project, provided peer design review, provided construction-period services, and designed the fire alarm systems for the entire facility. Some of the systems incorporated are the systems on the connector bridges to the four existing buildings adjacent to the new structure, as well as systems for the new stair tower at the existing hospital.

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75% of the existing building envelope and 50% of interior, non-structural elements were maintained saving the client construction costs.

Savage Arena, located in the heart of the University of Toledo’s main campus, was renovated and expanded to transform the arena into a state-of-the-art facility for student athletes and fans.

The 163,000 SF facility features numerous amenities for student athletes and fans, including a new entry pavilion; the Wall of Champions and Hall of Fame; improved locker, weight, and training room facilities; specialty seating, including 12 suites, 17 loges, and 194 club seats; 13 concession areas with 34 points of sale; and a pro shop selling Rocket apparel.

Keeping with the university’s mission to be a leader in sustainability, the facility is LEED® Gold certified. Other efforts to minimize environmental impact included reducing water consumption by 20% through the use of landscaping materials that require little to no irrigation, installing low-flush toilets, and using certified wood and recycled content materials throughout the facility. Meticulous construction management allowed for more than 50% of construction waste to be diverted or recycled.

This renovation also included the transformation of the existing Savage Arena lower level from racquetball courts to a steam generating facility for the entire campus, requiring installation of a 90-foot tall stack in a 25-foot deep areaway.

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The new Maplewood Elementary School replaces a 1920s, three story K-5 facility that was in deteriorating condition, lacked accessibility, was undersized in total, and was expensive to maintain and operate. It’s presence in the community and the neighborhood closely knit around it, was going to be truly missed in terms of its scale and articulated historical design. The new facility had to fill this void and replace it with a new presence, twice the size, that still respected scale, community, and function along with being highly efficient in terms of energy costs and operation.

This criteria influenced a very efficient heating and cooling system, incorporating a field of geothermal wells under the sport fields in conjunction with a high level of individual control at the heat pumps serving the individual classrooms and spaces throughout the building. All classrooms and occupied spaces were provided with daylight views. Advantage was taken of south- faced glazing for maximizing daylighting in these classrooms with automated control of artificial light. The extensive list of valued added sustainable features is noted below.

The building aesthetically drew upon the cues from the community and the existing building. Elements included rebuilding stone pineapple reliefs replicated from the old building and incorporation of colors and materials from the original.

Sustainable Value Based Design

  • High efficiency lighting system and integrated daylight control
  • Daylight/views from all occupiable spacers
  • Operable windows
  • Anti-microbial finishes and low VOC materials and sustainable floor finishes
  • Sustainable site concepts with storm water control/detention systems
  • Geothermal well field with locally controlled heat pump zones
  • White membrane/reflective roof surface
  • Durable low maintenance finishes
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Rightsizing the overall square footage of the building, plus a lean delivery method, resulted in savings of approximately $900,000 in contingencies.

SSOE was selected to assist Bowling Green State University and the Ohio Attorney General’s Office / Bureau of Criminal Investigation (BCI) for the design of a new 28,330 SF structure to house BCI’s regional offices, operations, and criminal labs in Northwest Ohio.

Included in the scope of the project was the design of administration and investigation offices, firing range, forensic labs, evidence storage space, public access seminar and conference rooms, security and surveillance, A/V design, redundant electrical and HVAC systems, site amenities, and parking. MWL Design Group teamed with SSOE for this project, providing the forensic design expertise essential for BCI operations and activities.

SSOE was able to provide all design services in-house, with a single point of contact for the client. Services provided include: architectural, interior design, structural, landscape architecture, mechanical, electrical, and plumbing design. Additionally, SSOE provided specialty design services that included: access control, IT / technology, A/V, and security. Lean project delivery principles were also utilized throughout the process, including collaboration with the construction manager from the onset of the project. The project was completed on schedule, below budget, and earned LEED® Silver Certification.

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Owens Community College selected SSOE to perform design and construction administration new Culinary Arts Center, located at the Toledo-area campus. SSOE scope of services included engineering, interior design, security / access control, and IT / technology design services. SSOE worked closely with Owens’ administration to meet an expedited design and construction schedule. Design was completed using a 100% BIM platform, with 3D sections and details used throughout the design process to aid shareholders in envisioning and understanding the design intent and layout of the space.

The project included the renovation of an existing, 14,000 SF vacant space. The new Culinary Center offers three unique laboratories – Culinary Skills, Restaurant Skills, and Food Science and Baking. The Culinary Skills Laboratory incorporates the latest cooking equipment and devices, allowing students to practice technical skills. The Restaurant Skills Laboratory simulates what students would find in the industry, including a beverage wait station and expediting cooking stations. The Food Science and Baking Laboratory is equipped with heat and humidity controls to allow students to learn advanced pastry skills. In addition the space also hosts a large dining area for holding lunches and special events, providing students with real-world experience in creating menus, preparing and plating food, and serving. A demonstration station, complete with cameras and television screens and a new outdoor gathering area were also added to provide additional functionality for special events.

Renovations to the center included state-of-the-art equipment and technology upgrades, such as new access-control door hardware and additional security and monitoring equipment.

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In addition to architecture, engineering, and construction management services for this new production facility, SSOE also performed a full-spectrum renewable energy survey to determine the most suitable and cost effective technology to utilize to meet Volkswagen’s energy production and system integration requirements.

The survey included all available renewable energy technologies such as solar electric, solar thermal / cooling, wind, biomass, and landfill gas to meet a 4 million kWh renewable energy production target. The study aimed at developing the most effective renewable energy systems to meet Volkswagen’s sustainability and economic objectives for the campus on a 1,500 acre site. A preliminary design of a 3 MW photovoltaic system and a 2 MW landfill gas generating system resulted from the study.

The photovoltaic segment of the project included a full technology comparison of ground based and building-integrated systems, multiple module technologies, and tracking system evaluations. This project resulted in preliminary design of an 800 kW and 3 MW building integrated photovoltaic system which included a CSI master specification-based bid package.

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On April 16, 2013, a Silicon Valley power substation was attacked by a sniper. Shots were fired into the radiators and conservators of 17 transformers, causing the equipment to leak 52,000 gallons of oil, disabling the yard and interrupting service to customers. Prior to this attack, communication lines were deliberately severed near the site to delay local law enforcement’s response time. As a result, $15.4 million in damages were reported by the utility company, with 27 days spent repairing the substation to bring it back online.

In light of this attack, critical utility service providers are now compelled by the Utility Commission, the North American Electric Reliability Corporation (NERC), and the Federal Energy Regulatory Commission (FERC) to reduce the vulnerability of critical sites through the enactment of the Critical Infrastructure Protection Reliability Standard 014 (CIP-014). To comply with these guidelines, a large electrical utility provider partnered with SSOE and a well known security equipment supplier to design and implement site hardening strategies at its Tier 1 critical sites.

An overall programmatic approach was established, including the definition of hardening objectives, identification of site threats and vulnerabilities, development of recommendations for hardening protocols, and identification of technology sources. SSOE provided project management and engineer of record services for plan implementation by creating detailed design packages with coordinated designs from civil, structural, electrical, and data / fire / security disciplines.

In compliance with safety protocols, SSOE worked with the client’s transmission group in providing all engineering and construction support for the implementation of the following security measures:

  • Electronic access control systems
  • Complete video surveillance
  • Multiple layers of perimeter intrusion detection
  • Anti-climb and anti-cut perimeter fencing
  • Vehicle rated barriers, ditches, bollards, and gates
  • Landscape modifications for visual block
  • Intrusion detection system triggered alarm based lighting
  • Ballistic protection and detection around major assets
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Through the utilization of laser scanning, SSOE was able to gather site information while spending a limited amount of time in the field. This reduction in required field time created approximately $100,000 in project savings for DTE.

DTE Energy sought an engineering alliance partner to efficiently and effectively deliver its Belle River Mills (BRM) Compressor Station Mechanical Drawing As-Built Legacy Program, meeting their delivery deadlines for confirming and updating existing mechanical drawings to reflect current conditions. SSOE was engaged as the partner of choice for this program, having successfully demonstrated its proposed project team’s ability to provide top quality deliverables, while thinking outside the box to maximize value for the client.

In order to provide the best possible value solution, SSOE partnered with an image servicing subcontractor to utilize 3D laser scanning to scan the BRM site at project kickoff. The scans were then used to remotely verify dimensions and locate missing items. An additional, short site visit was required to field investigate a handful of areas that were too congested and detailed to capture on the 3D laser scan. However, utilizing laser scanning reduced the required time for on-site walk downs from months to less than a day. This reduction in on-site staff equated to approximately $100,000 in savings for DTE.

Cost savings are not the only benefit realized through the use of laser scanning. By reducing staff time spent in the field, the risk of injury also decreased. Additionally, laser scans also increase the accuracy of combined drawing sets. Over the years, minor alterations have the potential to create match line errors. SSOE’s process in updating drawings allows measurements to be referenced to a single datum at the site, eliminating errors occurring between drawings.

Ultimately, SSOE met the client’s required deliverables. These requirements include redlines conforming to DTE’s complex drafting field data collection procedure, finalized CAD drawings, and high resolution photography for areas of changes, all while meeting DTE’s standards and procedures.

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Tight coordination of the procurement process prevented potential schedule delays and cost increases due to a scarcity of available parts.

Increasing demand for gas in areas served by an obsolete pipeline prompted Consumers Energy to engage SSOE’s engineering and procurement services to upgrade and replace the line. The project included developing multiple iterations of the routing plan to avoid  recreational areas. SSOE assisted in obtaining permits from the township and various other agencies. The approved route added two miles to the line, making the 24-inch pipe 11 miles in length. SSOE also designed a temporary bypass to maintain gas service while the 2.5-year project was completed.

The project also involved significant changes to the existing metering stations. One station was demolished and replaced, while the other was upgraded and remodeled. A separation wall was installed to provide safety in the event of a gas leak. SSOE developed renderings of the stations and designed landscaping to create a residential character to these buildings, allowing them to blend into their surroundings.

Procurement proved to be challenging due to the extent of supplies and materials that had to be pre-purchased and the difficulty of obtaining the needed parts. SSOE responded to the challenge with careful tracking and tight coordination of the procurement process.

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SSOE applied significant value engineering to the preliminary schematic project design. Through design innovations, utilization of specialists in blast resistant design, and other ideas, Husky realized more than $7 million in savings.

In an effort to improve safety and communication at their Lima Refinery, Husky embarked on a plan to relocate all non-essential personnel away from blast risk zones to a centralized location outside the battery limits of the production facility. They called upon SSOE’s extensive refinery expertise and familiarity with blast resistant structures to design their new control building. SSOE provided full architecture and engineering for the 250,000 SF, two-story structure, which consists of a central control room, laboratory, warehouse, maintenance shops, vehicle repair center, and unit personnel housing.

Due to it’s proximity to plant production operations, the facility was designed to resist a substantial blast over-pressure while maintaining an open and architecturally appealing structure. SSOE collaborated with the owner, specialized design consultants, constructors, and material systems providers to provide a functioning structure that is fully code compliant, protects its occupants from hazards, and allows for the operation and controlled shutdown of systems should an event occur. This collaboration and the application of specific design techniques resulted in a $3 million reduction in the cost of the structural frame alone.

As part of the project, SSOE customized the fire alarm, access control, data cabling, and raceway systems including the specialized protection needs of potentially hazardous operations. SSOE’s Data, Fire, and Security (DFS) team also designed an electronically secure enclosed area featuring anti-passback technology within the access control system.

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Process developed had six month payback and increased the overall product yield by 10%, generating $2 million per year in extra production without an increase in feed stock quantities.

When the client acquired a rural site to take in municipal waste, railroad ties, and used tires, it sought SSOE’s process engineering expertise in transforming the brownfield site into an alternative energy facility. The client needed to ascertain if these elements could generate sellable chemicals and result in a commercially viable business. As one of the top ranked chemical plant and green industrial and manufacturing design firms, SSOE was uniquely qualified to tackle the complexities of front-end process design while planning a fully functioning, energy-efficient facility.

SSOE performed preliminary and detailed chemical process engineering involving putting the waste products through a plasma gasification system, producing syngas, and generating methanol and DiMethyl Ether with future capacity to produce mixed alcohols (butanol, ethanol). In developing the process, SSOE discovered a means of recovering hydrogen from the purge gas stream that increased the client’s overall product yield by 10% with a six-month payback. Overall, the plan generated $2 million per year in additional production without an increase in feed stock quantities.

SSOE performed process studies for capacity improvement and evaluations of alternative technologies, including alternative refrigerants. Its process engineering services included developing the process alternatives, process modeling once the Process Flow Diagram (PFD) was finalized, and identifying manufacturing solutions for all of the unit operations. It also provided input for environmental filings and responses to due diligence queries from the financing engineer.

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Met the client’s aggressive schedule, enabling them to submit their grant proposal on time.

With the next step in their growth (and a major expansion) on the line, Xunlight looked to SSOE to provide the Department of Energy (DOE) with an extensive review of their planned expansion from an initial 25 MW plant to a full scale 100 MW production facility.

This review included:

  • PV cell manufacturing and module assembly processes
  • Facilities and site requirements
  • Chemical handling and safety requirements
  • Production cost estimating
  • Permitting review
  • NEPA assessment assistance

The challenge was to provide a very rapid assessment of Xunlight’s scale-up plan that would also be thorough enough to ensure the DOE’s review process would be smooth and quick. With extensive resources in both industrial process and facilities, SSOE was able to instantly assign a team of multi-disciplined experts to fast-track the process.

The successful technical review that resulted was a product of a proactive and responsive client as well as deep technical resources that allowed a fast-track review by “A-team” experts for each discipline. SSOE’s extensive experience in integrating facility and process design and large project execution produced findings that satisfied Xunlight’s specialized needs.

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On the merits of SSOE’s broad experience with chemical / energy projects and front-end process design, Secure Energy enlisted SSOE to help it develop a coal gasification system at its Decatur, Illinois plant.

SSOE served as the lead process engineering firm and integrated the various technologies required for the process into the plant. The firm was responsible for modeling and design of the process areas as well as scheduling and cost estimating for the overall engineering effort. With a minimal number of coal gasification units working in the U.S., SSOE developed a mathematical model of the chemical processes involved in transforming coal into synthetic natural gas and utilized the first gasifiers brought into the country by the client’s technology provider.

Running at full operational capacity, the gasification units convert 1.4 million tons of coal annually to 21 billion cubic feet of pipeline quality synthetic natural gas. The gas is supplied to the interstate natural gas pipeline network.

The client’s coal gasification transition was sparked by loan guarantees from the U.S. Department of Energy’s Energy Policy Act of 2005 designed to spur the deployment of alternative energy technology projects.

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This prominently sited, five-story structure ties the University of South Carolina (USC) traditional campus to its new urban “innovista” research campus. The facility supports programs in engineering, technology, scientific research, and industrial development of alternative energy sources.

Research includes two floors dedicated to hydrogen fuel cell studies with laboratory areas for Proton Enhanced Membrane (PEM) and Solid Oxide Fuel Cells (SOFC). The first floor is dedicated to characterization chemistry and the second floor has a program in nanopolymers. The ground and fourth floors are set aside for future development.

Each laboratory utilizes high performance variable air volume fume hoods with air flow control based on sash position. Fuel cell research laboratories have centrally piped hydrogen and nitrogen gases and also house cylinders for hydrogen rich specialty reformate gases. All laboratory process equipment utilizes a recirculating cooling system to reduce portable water usage.

SSOE was involved in the planning and programming efforts and provided mechanical, electrical and fire protection construction documents for this building. Review of the contractor’s shop drawings, was performed to detect errors and omissions which were found and corrected prior to the fire marshal’s review. The fire alarm design was upgraded to meet code. This allowed passing of the drawings by the jurisdiction on the first review. Life cycle analysis and careful evaluation of alternative energy usage systems were important to the sustainable aspects of this building. The construction was fast-track accomplished by utilizing Construction Manager at Risk (CMAR) method.

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SSOE provided on-site assistance at the fist beta site unit which has prepared this company for additional installations and further enhancements to the turbine and balance of system design.

Wind Energy Corporation executed a multiphase project at two separate locations. SSOE provided design and application engineering services for a new vertical axis wind turbine. In the first phase of the retrofit project, SSOE optimized the design of the turbine unit, its structural supports, and power electronics integration. In addition, the project scope included the complete integration of the prototype vertical axis wind sail system. SSOE also provided inverter specification, electrical permit drawings, and controls system development.

As part of SSOE’s Value Promise, SSOE provided on-site assistance at the first beta site unit, which prepared this company for additional installations and further enhancements to the turbine and balance of system design.

For the second phase of the project, SSOE delivered product development support which required multidiscipline team coordination. This effort included control and transmission development, inverter specifications, and system integration for planned installations – executed by our electrical controls team. SSOE’s structural team provided specifications for tower mounting and building integration. By utilizing a planned installation project delivery method, SSOE delivered the project on schedule, which was based on timelines and critical milestones.

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Through innovative design concepts, benchmarking common practices, and scheduling, SSOE offered Volkswagen a savings of more than $44 million.

Having successfully performed design work for more than 50% of all greenfield automotive assembly plants built in the United States over the last 10 years, SSOE was well qualified to oversee architecture, engineering, and construction management services for Volkswagen’s new automotive production facility.

Volkswagen was also looking for a firm with a strong sustainability focus who would help the company execute its green initiatives.

Located on an 830-acre brownfield site, the production facility includes conventional steel framed buildings with concrete columns, roof structures with skylights, metal wall panels with windows, and a single-ply membrane roof. The plant has the capacity to produce 150,000 mid-sized vehicles annually. The primary manufacturing operations include weld, paint, and assembly. Other facilities on this site include outbound logistics, an extensive training center, media (utility) center, social hall with cafeteria, technical center, tank farm, recycling center, and fire station. SSOE provided environmental permitting, civil, architectural, structural, mechanical, fire protection, plumbing, electrical, fire alarm, access control, and security system design as well as construction management. SSOE’s expertise led to the first and only LEED® Platinum automotive assembly plant in the world. SSOE assisted with the preparation, submittal, and multiple agency approvals of the air permit in record time—2 weeks ahead of an aggressive 3-month schedule.

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