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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.

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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.

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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.

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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.

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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.

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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
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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

 

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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.

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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.

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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.

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In Mexico, Walmart is ramping up its distribution capabilities with a number of new distribution centers to expedite and improve product delivery to its stores. The new distribution centers will allow Walmart to strengthen and expand its logistics operations, with the goal of reducing time and costs in the supply process.

With an ambitious multi-year schedule for program completion, Walmart’s plan involves the construction of new distribution centers and the upgrading of existing centers. The retailer has engaged SSOE as one of their strategic partners to help design and build new centers in Chihuahua, Tabasco, and Chalco, with potential for additional projects. The facilities in Chihuahua (35,000 m2) and Chalco (60,000 m2) are dry warehouses, while the facility in Tabasco (38,000 m2) is a refrigerated distribution center—a project requiring unique refrigeration experience that other A/E firms in Mexico were unable to provide.

SSOE’s phased design approach prioritizes close communication and coordination between multiple Walmart divisions (including logistics, human resources, safety, and operations) and the SSOE project team. This includes continuously updating coordination and communication tools used for project delivery, and leading workshops and design review meetings that incorporate 3D Virtual Reality walk-throughs. This approach ensures that the integrated design team is able to focus on project goals and provide an operationally efficient and flexible design.

The benefits of SSOE’s ongoing partnership with Walmart include in-depth understanding shared by all team members of Walmart’s goals, needs, and business objectives, as well as the ability to ensure consistent implementation of Walmart’s global design and construction standards from project to project.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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Kemin sought a research and development facility design that represents their entrepreneurial spirit and embraces the company’s energy and excitement for discovery. The laboratory and office spaces provide the basis for an orderly and innovative professional working environment.

The new R&D facility’s two-story lobby contains a large glass curtain wall and floor to ceiling external windows to allow natural lighting to flow into the facility. The entry and lobby are situated to establish a dominant façade, giving the building a formal presence on the project site. The front lobby contains a coffee bar with seating area, adding an extra collaboration environment for employees and customers. Reflecting the facility’s modern and concise style, a spiral, steel structured, glass stairway is the main vertical transport between the lab’s first and second floors.

The building’s floor plan was organized to facilitate efficient scientific analysis and interaction between labs and staff. This facility houses multiple lab types, including a general lab, specialized lab, pilot lab, laboratory support rooms, offices, and administrative areas. The pilot labs, mechanical rooms, and consumable items testing storage areas are located near the lab area, promoting internal experimental interaction and allowing for the central location of lab supplies. The general labs are open and modular, containing abundant natural light. Customers touring the facility will appreciate the flexibility of the general lab’s layout, allowing them to easily be reconfigured per the client’s needs.

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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.

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Input from programming phase was used to eliminate duplicate space requirements and reduce the building footprint by 15%. Additionally, developed method to capture and reuse energy generated during dynamometer testing process throughout the facility.

To meet the market demand for new products in China, GM built its first Chinese R&D facility in Shanghai. This facility, which is the most comprehensive and advanced automotive development center in China, included areas for advanced vehicle development, powertrain design, electrical and fuel cell design, chassis, HVAC, body, exterior and interior development, and telematics. SSOE applied its vast experience in designing automotive R&D facilities, and familiarity with the Chinese design and construction process to deliver this high caliber, sustainable project.

SSOE designed an interior hydrogen fuel cell garage space, along with an exterior hydrogen fueling station and garage space. Special considerations, including distance from nearby high rises, were made during design due to safety considerations. Fuel farms were also integrated to provide for blending and testing operations for hydrogen-based vehicles and hybrids.

A significant design feature was a central garage space that separated the building into two halves. The central garage space functions as a central spine and serves as a common use area for multiple groups. It potentially allows groups to share tooling.

Another feature was a visually secure, exterior patio for GM to view vehicles in natural sunlight. This requirement created an interesting challenge since the site was located within city limits and near a multiple story building. SSOE designed a visual screen to obstruct the view from the building while still allowing the natural sunlight to enter the space.

SSOE provided an innovative design which minimized environmental impact, while maximizing occupant safety, health, and comfort. Design criteria also emphasized the use of sustainable materials and other energy reduction features.

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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.

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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.

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By having a strong understanding of the client’s needs for their new plant, SSOE was able to eliminate over $12 million through value engineering and improved production throughout by 25% due to process innovations.

SSOE, the client’s engineering firm of choice, performed comprehensive services on this new specialty chemical plant that produces components of high-performance electronics. Based on SSOE’s impeccable past performance from both a technical and client service standpoint, the client engaged SSOE for civil, structural, architecture, project management, mechanical, chemical process, estimating, cost control, and procurement. The facility is comprised the following functions: administration, waste recycling, bulk storage, complex chemical production, and basic utilities.

SSOE’s modification of the client’s chemical process resulted in improved conversion efficiency. The percentage of recycled chemicals increased from 14% to 20% to reduce production costs. Through process innovations and refinements driven by SSOE, the client has been able to improve production throughput by 25%.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.
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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

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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.

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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.

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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.

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Saved the client $26,000 through cost effective practices such as using aluminum conductors instead of copper conductors and reducing the quantity of clean agent tanks.

Boeing was contracted to deliver an end-to-end satellite communications system that included two new ground monitoring stations. Each station consisted of a highly technical control room and server rooms. Boeing called upon SSOE to provide mechanical, electrical, and fire protection engineering services for the rooms.

SSOE’s responsibilities included design of the facilities’ Uninterruptible Power Supply (UPS) systems, back-up generators, HVAC systems, and fire protection systems. SSOE used a clean agent suppression system as part of the fire protection that would not harm the sensitive equipment. Additionally, because both facilities are located in extremely hot and dry environments, special considerations were made for the HVAC systems. Seismic considerations were also incorporated into the design for the Mexico City facility.

SSOE designed the stations in accordance with International Building Code and worked closely with the end- user’s construction manager and architect in Mexico.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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$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.

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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.

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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.

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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.

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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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Fast-track conversion of abandoned brownfield factory into full-fledged food manufacturing facility. Modified original site layout saving $500,000.

When Hershey embarked on the conversion of an abandoned brownfield factory into a new candy manufacturing facility in Mexico, SSOE was asked to join the design / build team that turned it into a viable production facility for its chocolate products. With a history of success on fast-track food projects, the team was able to immediately respond to the challenging project demands, which allowed for parallel design and construction.

SSOE’s scope entailed design for the addition of 300,000 SF of process and packaging space, which included nine production lines, an 85,000 SF warehouse, a new 15,000 SF cafeteria, and a new substation. SSOE also designed in-plant laboratory space and consulted with Hershey on the purchasing of utility equipment.

The original facility was not in compliance with U.S. food processing standards. SSOE provided expertise in this area throughout the facility design.

SSOE was able to provide an optimal design solution by enlisting the best labor force and working with local government and community agencies. Early bid packages for site, sewer, and foundation were issued within two-three months of project award. In the end, SSOE helped Hershey meet its ultimate goal, under budget and on schedule. What resulted was a state-of-the-art facility four times larger than its initial size meeting strict FDA standards.

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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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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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SSOE made more than 30 recommendations to reduce energy use, equaling a combined total annual savings of more than $2 million.

For more than 20 years, SSOE has been providing a leading chemical manufacturer with quality process and facility engineering. When the client wanted to examine ways to decrease the energy consumption at its U.S. manufacturing facilities, they called upon SSOE’s energy management expertise.

SSOE conducted a full-scale energy assessment of one of the client’s largest production facilities. The goal of the assessment was to generate energy saving opportunities based on industry best practices, with paybacks of fewer than five years. The client also wanted to use the results from the assessment as a benchmark for its other U.S. plants.

As part of the assessment, SSOE interviewed plant personnel, collected utility and equipment information, and conducted field observations. The team examined all major sources of energy generation and use. SSOE assessed system performance, condition, and operational maintenance practices.

A unique challenge of the project was that all field observations had to be complete before a scheduled plant shutdown, leaving SSOE with a short amount of time to examine the 150 acre facility. SSOE moved quickly and worked closely with the client to meet this aggressive schedule. The field work, assessment, and report generation were completed in less than six weeks.

SSOE’s final deliverable was a detailed report consisting of more than 30 energy saving opportunities, along with their estimated cost and payback. This report was reviewed with Corporate Energy Management for concurrence.

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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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Coordinating standards set by General Motors’ Global Facilities Group with the local design and construction standards of the actual plant in Silao, Mexico was a challenge that could have proved costly for General Motors. Without careful communication and teamwork, extensive redesign efforts could have been required to comply to all codes. SSOE’s understanding of General Motors’ Global Facilities Standards, as well as the local design and construction methods, provided a smooth incorporation of design into construction.

As a result of this close collaboration and understanding, this plant expansion project for a new, eight-speed transmission production line progressed on time and within budget through all three phases, while also meeting all client objectives. Serving as a liaison, communicating with both the Global Facilities Group and local plant officials, SSOE closely monitored the budget and schedule and quickly addressed concerns or nonconforming design elements. A 3D model was utilized throughout the program for integrated project delivery and interactive communication between teams. Representatives from SSOE’s León office attended construction meetings, facilitating the resolution of issues between design and construction.

In addition to project coordination and management, SSOE also provided the program’s Phase I bridging documents and bidding support. For Phase II of the project, SSOE partnered with a construction firm for a design / build delivery, further expediting the schedule. Phase II drawings were provided by SSOE for the transmission plant addition, office and cafeteria expansion, GSC warehouse building, and central utility complex building.

Due to the success of the first facility expansion, SSOE was requested by General Motors to design the project’s Phase III – a design / bid / build, five-bay addition incorporating as-built conditions into the 3D model. SSOE also provided construction administration services.

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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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Energy saving features with less than five year ROI.

To meet the market demand for new products in China, this automotive OEM built its first Chinese R&D facility in Guangzhou. SSOE’s relationship with this client extends more than 30 years and includes experience at no less than 10 of their facilities throughout the world. With robust expertise in R&D facilities and knowledge of China’s governmental standards for design and construction, SSOE was a clear choice for this project.

SSOE was selected to design an R&D facility that consolidated multiple facilities throughout Guangzhou, bringing the team together in a new location to foster more efficient internal collaboration. R&D areas included trial manufacturing, materials testing, body testing, aesthetic design, crash testing, and EMC chambers. Individual buildings were connected with access roadways separate from normal vehicle flow. The main site access was limited to one entry point in order to control entrance to the campus. The most notable design feature was an onsite high-speed test track for new product development. For the client, it was important to also build an onsite recreational facility reflective of its corporate culture. As part of the design process, SSOE interviewed individual client user groups to find out specific functions, demands, and cultural aspects.

The facility was constructed with an emphasis on use of recycled, renewable, and non-polluting materials. Though the campus had large power requirements, SSOE integrated features that provided the highest possible energy efficiency such as water conserving plumbing fixtures and strategies to reuse the power generated from processes, such as the engine dynamometers. A grey water system was incorporated to minimize overall water consumption and was used to provide the most cost effective method of supplying water for the testing processes on the test track. Such systems were designed to provide less than a five year return on the client’s investment.

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SSOE suggested incorporating high efficiency lighting saving the client approximately $300,000 annually in operation costs. SSOE also suggested using PVC roofing membrane and sandwich panel siding to minimize the installation time.

In order to provide R&D capabilities in India and to better supplement their existing fabrication plant, an automotive client set about to build a new technical center and office complex. Having completed several successful projects for the client’s U.S. facilities, as well as projects for other U.S.-based companies in Asia, SSOE was selected to provide full architecture and engineering for the project.

The center includes performance, structural, environmental, oil flow and lubrication, and metallurgical testing, as well as noise, vibration, and harshness (NVH) testing capabilities. SSOE worked closely with an Indian design firm to ensure the center met Indian regulations, while still providing the client with the international appeal that they were trying to achieve.

Comprised of two filled-in quarries with irregular soil makeup, the site posed a unique challenge. Special considerations had to be made in the facility’s structural design, specifically in the areas that house dynamometers and other large equipment. The site also lacked connections to public utilities, so city water storage tanks had to be designed.

The facility is state-of-the-art and places a high priority on features that maximize occupant safety, health, and comfort. As a result, air conditioning and fire protection systems were included in the center’s design, going above and beyond government requirements for R&D facilities.

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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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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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