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Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport

Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport. Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport. Presentation. Pete Dahl Construction Management. Senior Thesis, Spring 2004 Penn State University.

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Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport

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  1. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Presentation Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  2. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Pedestrian Walkback Tunnel, Finishes Package Introduction Project Background Breadth Study: Soil Retention System Breadth Study: Curtain Wall System Depth Study: Airport Project Delivery Conclusions Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  3. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions About the Project… Intended Use: “Allow passengers the choice of a short walk between the Main Terminal and Concourse B, or transport via Mobile Lounge” Key Issues: 1) Two levels below grade, Tunnel and Basement Level, 60,000 CY of bedrock to be removed from the site Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  4. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions About the Project… Key Issues: 2) Entire North Face of façade is glazed curtain wall 3) Pedestrian Walkback Tunnel Project is split up into 4 separate “packages” Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  5. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Project Design Tunnel Shell, Connector A under separate contracts Existing Conditions for the Finishes Package: Rendering of Tunnel: Finishes in the Tunnel to recall the swooping roof of the main terminal Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  6. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Project Team Owner: Metropolitan Washington Airports Authority (MWAA) Owner’s Representative: Parsons Management Consultant (PMC) Design Consultant: PMC Design Engineer: Earth Tech Architect: Giuliani Associates General Contractor: Hensel Phelps Construction Co. (HPCC) Major Subcontractors: Soil Retention System: Berkel & Co. Contractors Rock Grinding: J.H. Becker Co. Earth Removal: Strittmatter Contracting, LLC Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  7. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Project Organization Fee-Based Contract Fee-Based Contract Lump Sum Contract Lump Sum Contract Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  8. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Project Execution Projects are broken into phases, or “Packages”, in this case… Connector A Connector B, Tunnel Interior Finishes APM Tunnel Tunnel Shell Combined to form “Finishes Package” Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  9. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Project Site Existing Main Concourse Connector A (NIC) “Portal” (Tunnel Entrance) ACTIVETAXIWAY “Object Free Zone” Tunnel Shell (NIC) ACTIVE TAXIWAY Tunnel Finishes Connector B Existing Concourse B Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  10. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Project Cost For the Pedestrian Walkback Tunnel project… Cost: $50,000,000 Schedule: Spring 1998, Design began December 2004, expected completion For the Finishes Package alone… Cost:approx. $25,000,000 Size: Connector B: Four Stories – 20,000 SF Tunnel: 750 ft long x 30 ft wide – approx. 22,500 SF Schedule: October 2002 – December 2004 Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  11. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Project Timeline Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  12. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Construction Process • Rock Grinder grinds rock in 7’ lifts • Spoils excavated with Excavator in 7’ lifts • Drill and place tiebacks • Spray 1st layer of shotcrete • Tighten and test tiebacks • Spray 2nd layer of shotcrete 7 repetitions to reach an overall depth of 44’ Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  13. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Original Design 8” Shotcrete wall with tiebacks on a 7’ x 7’ grid 4” Shotcrete w/ WWF Install Tiebacks 4” Shotcrete w/ WWF Waterproofing with foundations Constraints/Issues No setback allowed Highly fractured, weathered rock Poor RQD Heavy surcharge loads Existing Concourse B adjacent to site Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  14. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions System Analysis Post-Construction Extremely weathered rock Frequent minor collapses Additional shotcrete Groundwater issue Sump pumps, temp. plumbing Holding tanks Carbon filtration process, fuel spill Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  15. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Alternate System Selection Suggested systems, from geotech report: Braced Walls using Wales and Struts Soldier Beams & Lagging Braced Sheeting Bored-Pile Walls Diaphragm/Slurry Wall Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  16. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Alternate System Selection Diaphragm/Slurry Wall Major Issue:Rocky subgrade conditions Solution:The Big Dig in Boston, MA: Similar soil conditions Hydromills/Rock Mills Clamshell bucket removes spoils Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  17. Excavate the Trench Fill Trench with Slurry Place Rebar Cage Pump Concrete… …While Removing Slurry Fill in all Adjacent Panels Image courtesy of www.bigdig.com

  18. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Alternate System Design • Using the same design conditions for the shotcrete & tiebacks • Terzaghi and Peck Trapezoidal Apparent Earth Pressure Diagram, as recommended by the Geotech • 44’ Height of Excavation GRADE 44’ Designed a beam with 1’ unit width to form a wall of multiple vertical beams BOTTOM OF EXCAVATION Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  19. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Alternate System Design • Input the 1’ width beam into STAAD • Design reinforcing for the wall based on, • STAAD results • ACI Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  20. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Impacts on Sequencing Old: CYCLE: Grind, Excavate, Shotcrete, Tiebacks, Shotcrete New: Construct entire slurry wall before excavation begins CYCLE: Grind, Excavate, Tiebacks Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  21. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Schedule Impacts Old: 8 month duration, due to Differing Site Conditions New: 3 weeks at front end for slurry wall 3-4 days per lift = 5-6 weeks total! 3 weeks + 5-6 weeks 8-9 weeks ~2 months! ~6 MONTH DIFFERENCE Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  22. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Cost Impacts • Including, • Rock Grinding: ~$400,000 • Excavation: ~$500,000 • OLD SYSTEM: • ~$2,000,000 • NEW SYSTEM: • ~$1,350,000 COST SAVINGS: $650,000 Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  23. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Conclusions Efficient use of slurry wall in most locations on the project However, Alternate system on South side at Concourse B, and at the Tunnel connection Shotcrete problems vs. Slurry wall problems The original shotcrete design is justified in its application on this project. Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  24. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Overview • Permanent building systems • Greater impact on the building’s overall performance • Long-term owner, long-term building • Improving quality will have lasting effects • Security vs Energy Efficiency • Life-cycle costs Minor components, major impacts Example: Curtain Wall System -Glazing Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  25. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Modeling the original design • Curtain Wall modeled into ENERGY10 software • Double glazed system • 1/4” glass with low-e coating • 1/2” airspace • 1/4” glass • 2 layers of 1/8” sandwich a polyvinyl membrane • improves soundproofing • improves security • U-value: 0.509 BTU/(hr-SF-F) Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  26. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Change impacts of various components • Value Engineering • Coatings: • Low-e • Shading: • Add shading system • Layers of Glazing: • Triple glazing Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  27. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Cost Impacts Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  28. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Conclusions • Evaluate the importance of Energy Efficiency with respect to… • the actual application • the initial cost • the operating cost The original glazing design holds the most value to the owner in this application. Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  29. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Project Evaluation • Major elements of the design • Retention System • Structural System • Building Enclosure • Project Delivery? • Design of the Project Delivery Process… • Affects: Pre-design through close-out • Impacts: • Level of coordination • Methods of communication • Overall project success Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  30. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Overview – A Project Delivery System • Project Delivery Selection • Owner Decision • Impacts seen throughout the Pedestrian Walkback Tunnel project • Define impacts on Pedestrian Walkback Tunnel project • Analyze the impacts on other airport projects • Identify common tensions • Applicability to other market sectors… Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  31. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Project Delivery Selection Elements affecting the Project Delivery Process Owner experience, capabilities -e.g. Multiple projects for MWAA; construction staffing Source of funding -e.g. Public bonds for MWAA Project complexity -e.g. Tunnel Construction is unique Project timeline -e.g. Not urgent; compare to data center, pharmaceuticals Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  32. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions The ‘Packaged’ Project Team Contracted directly with the owner Fee-Based Contract Fee-Based Contract Lump Sum Contract Lump Sum Contract Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  33. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Owner MWAA Owner’s Representatives PMC, PMC Design Owner’s Representatives General Contractor HPCC General Contractor Engineer Earth Tech Design Team Finishes Package Owner’s Representatives Tunnel Shell Package General Contractor Connector A Package Design Team All Entities are Contracted Directly with the Owner Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  34. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport MWAA Other Projects Other Projects Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Dulles Airport Pedestrian Walkback Tunnel Tunnel Shell Connector A Tunnel Finishes Connector B West APM Tunnel Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  35. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Commonalities to other Airport Projects • Data Collection • Survey • Sent to airports across the country • Gathering information from multiple airport projects • Results • Four International Airports: • Washington Dulles International Airport • Baltimore Washington International Airport • Miami International Airport • Seattle-Tacoma International Airport Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  36. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Commonalities to other Airport Projects Key questions: How was the project awarded? How was the project funded? What type of contract was used? What were the effects of phasing or packaging on the project? Additional questions alluded to the relationship developed between project team members -Corresponds to the number of change orders, schedule extensions and general communication Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  37. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Commonalities to other Airport Projects Respondents: Primarily contractors, an architect • Common Responses: • Use a contractor selection method based on Best Value • Low Bid is insufficient • Funding source not a barrier – eg. BWI • Use a lump sum contract • If quantities are unknown, use Unit Price – eg. Excavation Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  38. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Commonalities to other Airport Projects • Responses cont.: • Packaging common throughout the Airport market sector • Due to increased communication between packages • As a result…significant cost growth • Phasing less common • Less cost growth seen, as on BWI (NO cost growth) • Better relationship between Owner’s Rep and GC Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  39. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Analysis A change is needed… • The first steps: • Owner decisions related to Project Delivery have the ability to create, or relieve, tensions in the project team • How does an owner know if a decision will negatively impact their project? • More owners must be educated to understand impacts of their decisions Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  40. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Owner Education • Help more owners to realize the impacts of… • Contractor Selection Criteria Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  41. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Owner Education • Help more owners to realize the impacts of… • Type of Contracts Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  42. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Owner Education • Fast-Tracking the project Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  43. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Conclusions A fundamental change is needed. Until then, Owner education is key Allowing for, Decreased tensions Better relationships within team Less wasteful projects Better product delivered to the owner Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  44. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Presentation Summary • Analyzing the Pedestrian Walkback Tunnel, • Soil Retention System  Slurry Wall • Significant issues eliminated • Cost and schedule decreased • Curtain Wall System • Low-e, double glazed windows are optimal • Project Delivery Systems Analysis • Further education • Increase awareness of the impacts of owner decisions More importantly, Analysis focuses around the owner’s needs and requirements and their definition of value Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  45. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions QUESTIONS? Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  46. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Impacts Cost Costs can be justified through the savings of time from the duration of the excavation, and also the redesign of formwork for the concrete foundation walls. Old: SRS original cost: approx. $700,000 Change Orders: nearly $700,000 -DOUBLES the original cost of the system -Due to Flooding and Earth Movement New: 20,000 SF @ $10/SF = $200,000 for trench and slurry 2000 CY concrete, 1500 tons of rebar = $250,000 Rock Grinding: $400,000 (unchanged) Excavation: $500,000 (unchanged) Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

  47. Dulles Pedestrian Walkback Tunnel, Finishes Package Washington Dulles International Airport Introduction Project Background Soil Retention System Curtain Wall System Airport Project Delivery Conclusions Impacts Schedule Old: 8 month duration  7 lifts ~ 1 month per lift New: 3 weeks added at the front end of the project for slurry wall -Mobilization: 1 week -100 lf/day @ 400 lf = 4 days ~ 1 week -Demobilization: 1 week Better flow of work due to decreased activities on site -2 rock grinders: 2 days -Full use of loader and excavator -Tiebacks installed in 2 days 3-4 days per lift = 5-6 weeks total! Pete Dahl Construction Management Senior Thesis, Spring 2004 Penn State University

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