coleytown middle school exterior enclosure & mechanical … · 2018-11-06 · exterior...

November 5, 2018

COLEYTOWN MIDDLE SCHOOL Exterior Enclosure & Mechanical System Study

Westport Public Schools: Coleytown Middle School –Exterior Enclosure & Mechanical System Study

Presentation to the Board of Education

PROJECT TEAM

KG+D Architects - Specialize in Educational Planning, Design & Construction

• Erik A. Kaeyer, AIA LEED AP Principal/VP

• Joe Reilly, Associate, Construction Specialist

• 10 Licensed Architects, 2 Construction Administration focus, Staff = 27.

• KG+D designs and administers an average of approximately $35 million academic/educational facilities per year.

• We have analyzed 14 million sf of educational facilities within the past 5 years and provided detailed reports and budgets to School Districts.

• 50 Educational Clients over past 20 years. Currently working with Greenwich PS, Darien PS, Weston PS, as well as 15 public school districts in New York.

Watsky Associates - Roofing Consultant

• Thomas Olam, President

OLA Consulting Engineers - Mechanical & Electrical Engineers

• Jill Walsh, PE, Principal

The KG+D Team

We listen to understand.

We actively imagine potential.

We responsibly buildtoward the future.

KG+D Design Philosophy





HH Wells Middle School Middletown High School Roslyn High School

Post Road Elementary School





Rippowam Cisqua School Trinity Pawling School





Photovoltaic Panels

Geothermal Heating/Cooling

Green Roof & Sun Shading

Process: A team of licensed architectural and engineering professionals visited the building to evaluate the condition of the roof, exterior walls, mechanical systems, and adjacent site.

Approach: Develop a “Good, Better, Best” set of options.

Requirement: Be able to state that all options will provide a long-term, safe and healthy environment for the students and staff.

History: Most studies have resulted in additions and alterations to buildings. Five previous school condition studies resulted in ‘replacement’ projects over the past 20 years.

GATHER PROGRAM INFORMATION:FACILITIES ASSESSMENT @ COLEYTOWN MS

Coleytown Middle School - Facilities Review Process:

CMS Process: Facilities Assessment

Orientation & Strategy

• Listen to the Administrators & Facilities Staff

• Develop Study Timeline & Approach

• Coordinate Study w/ Building Scientist

Gather Building Information

• Review existing documentation

• Perform Visual Inspections & Destructive Test Probes

Explore Remediation Options

• Building Enclosure (Walls/Roof)

• Mechanical Systems

Prepare & Present Final Report

Coleytown Middle School Study Purpose & Objective

CMS Process: Facilities Assessment – Purpose & Objective

1. Determine where and how, water and moisture are entering the school.

2. Determine the scope of remedial work needed to prevent further water entry.

3. Determine what mechanical system work is needed for good air quality and comfort.

Coleytown Middle School Background

CMS Process: Facilities Assessment - Background

• The school building was erected circa 1963. The palette of exterior finishes was established at that time.

• Existing Documentation (plans & specifications) are incomplete; Building constructed in 3 phases including new additions in the late 1990’s.

• Additional ground face concrete block facade, new windows & sunshades were installed in the late 1990’s.

• Roofing installed on the additions in the 1990's remains in place; the balance of the roof was replaced circa 2000. Roof averages 20 years old.

Coleytown Middle School Roof Summary

CMS Process: Facilities Assessment – Roof Summary

ROOF

• The total roof area is approximately 105,840 square feet; it is divided into 25 different areas.

• 18 year old EPDM rubber is in fair condition and covers 65,670sf of flat roof. It is at the end of useful life.

• Hypalon roofing covers 40,170sf of sloped roof. These roofs have failed and are being kept watertight w/ applied coatings.

• All roof areas are under-insulated by current standards; there are wide-spread deficiencies and inadequate drainage provisions.

Coleytown Middle School Roof Summary

CMS Process: Facilities Assessment – Roof Summary

Coleytown Middle School Façade Summary

CMS Process: Facilities Assessment – Façade Summary

WINDOWS/GLAZING

• The total area of the facade is approximately 60,600 sf; 22,000 sf of facade is clad w/ aluminum curtain window wall; 38,600 sf is clad with ground face concrete blocks.

• Many of the insulated glass windows have failed; moisture is visible between numerous individual panes.

• Some of the curtain wall gaskets have failed and sealant has been applied on the surface of the aluminum extrusions and transom panels as ‘fix’.

• Window system has inadequate or missing sill flashings -water penetration.

Continued…



MASONRY

• The ground face block facade walls were installed in multiple configurations:

a. 10 in. thick no cavity w/insulation + gypsum board adhered to inside b. 8 in. thick no cavity w/insulation + gypsum board adhered to insidec. 8 in. thick no cavity with nothing behind them d. 6 in. thick no cavity with nothing behind the block at the columns e. 4 in. thick with a cavity, insulation and block back up wallf. 4 in. thick with a cavity, insulation and gypsum board back up wall g. 4 in. thick with a cavity and gypsum back up wall.

• The placement of flashing and weeps is not uniform and most appear to be non-functional.

• Wide-spread evidence of water leaking through failed mortar joints and water saturated block.

Continued…



WALL DESIGN ISSUES

• Most facade walls were installed on a concrete foundation that is at the same elevation as the finished interior floor. Water runs down the facade and seeps in at the level of the floor.

• Some of the facade walls have no air/water barriers and flashings to collect water and direct it harmlessly out of the wall. Others have some elements. None are properly constructed.

• Sun shade support arm/bracket attachments are problematic. There are visible gaps between the brackets and block facade, algae is visible on the facade and surface applied sealant at many brackets confirm the sun shade system has been a source of wall leaks.



GRADE PLANE ISSUES

• In many locations around the building, the exterior grade creates water/dampness issues. Conditions include:

• Concrete walkways that pitch towards the building

• Mechanical UV louver bases align with exterior grade

• Grass areas against building without positive pitch or water outlets – ‘ponding’ is created at building edge

• Some exterior grades are built up against porous block exterior.

• Canopies and roof downspouts dump water at building base.

Coleytown Middle School Mechanical Summary

CMS Process: Facilities Assessment – Mechanical Summary

MECHANICAL SYSTEMS

• 2 Duel Fuel Boilers (Hot Water) to entire building

• 300 ton McQuay Screw Chiller & Marley Cooling Tower

• HVAC – rooftop air handling units and in room unit ventilators

• The existing hot water piping was reused to supply chilled and hot water. Portions of piping are undersized for the requirements of chilled water.



FINDINGS

• Poor Exterior Envelope has major detrimental effect on HVAC performance. System is overloaded due to excessive H20 infiltration.

• Improper install or non-functioning air handling units.

• The existing cooling tower is in poor shape and should be replaced.

• Unit Ventilators – 4 major issues: 1. location of intake louver at grade-not industry standard minimum

of 12” above grade; excessive moisture/water in the UV.2. Portions of piping designed for heating are undersized for cooling

requirements.3. UV control Sequence - system was modified which potentially

turns off cooling/dehumidification when it is needed to be ‘on’.4. Condensate piping – drained to soil (not to sanitary piping)

Coleytown Middle School Roof & Facade Probes

CMS Process: Facilities Assessment – Roof & Façade Probes

PROBES

• 30 probes were made in the roof and 25 in the facade to determine the typical configuration and condition of roof insulation and wall components that are hidden from view

ROOF

• The underlying roof insulation and the top surface of the roof deck were dry at 29 of the 30 probes.

• Conventional metal, structural wood fiber plank, plywood, oriented strand board, tongue and groove wood, and concrete was used to construct the roof decks.

Continued…

Coleytown Middle School Facade Probes


PROBES - WALL

• 8 of 25 wall probes were wet; most showed signs of moisture infiltration, i.e. water stains, deteriorated gypsum board, and rusted metal studs.

• Rodent droppings were present in two wall probes

• Mold on wall components was present at two wall probes

• Corroded structural steel column was present at one wall probe.

• Multiple locations - strong dank odor emanated from the wall cavity including classrooms and corridor of the 2-story wing.

Continued…

Coleytown Middle School Facade Probes


PROBES - MECHANICAL

• Unit ventilator (UV) grills do not align with the UV cabinets; poorly insulated plenums have created the formation of condensation inside the plenums and walls.

• Unit ventilator grills - positioned flush with an exterior sidewalk; this encourages the entry of wind driven rain and snow - as well as rodents.

Coleytown Middle School Conclusions & Recommendations

CMS Process: Facilities Assessment – Conclusions & Recommendations

ROOF

Due to age, a new roof should be installed throughout.

• The 18 year old EPDM sections are approaching the end of their service life

• The Hypalon sections have failed.

• New (additional) roof insulation should be installed – to meet Building Code, to save energy, and to improve occupant comfort.



FAÇADE/WALL

Issues with the facade are wide-spread and pervasive, localized repairs will not prevent future water entry and resultant issues.

• All of the ground face masonry walls should be removed and replaced.

• All of the windows and curtainwalls should be replaced.

• The sun shades should be removed, an alternative assembly or method to control sunlight should be installed.



EXTERIOR GRADE

In general, the majority of the perimeter finished grading requires modification.

• Where concrete sidewalk/hard surface meets building, surfaces should be lowered to minimum 6” below finished floor/foundation wall w/positive pitch.

• Where grass meets building, finished grade should be lowered w/positive pitch and storm water collection.

• Where grade slope is higher than interior spaces, proper waterproofing and insulating of the wall is required.

• All stormwater drainage from roofs needs to be connected to piping system away from building.



MECHANICAL

IF CURRENT SYSTEM IS TO UPGRADED

• Unit Ventilators –shift the UV ‘inboard’ to create an inslated space/plenum so that the louver can be raised to 16” above grade.

• Condensate drain piping should be added.

• Retro-Commissioning of systems – complete air and water balancing; ensure all systems are operational.

• Supplemental cooling and dehumidification systems should be added to treat the large common spaces.



MECHANICAL

IF HVAC DISTRIBUTION SYSTEM IS REPLACED

• Recommend utilizing a ducted system with new rooftop air handling units w/ energy recovery and ductwork distribution.

• Classrooms would have variable air volume (VAV) with some individual control.

• Reuse of existing chiller and boiler plant.

• Commissioning of systems – complete air and water balancing; ensure all systems are operational.

Coleytown Middle School Remediation Options Budget Estimates

CMS Process: Facilities Assessment – Budget Estimate

To create a good, sound, energy efficient, and healthy environment is possible at Coleytown MS, but it will be at a significant expense (albeit at a lower price point than a complete replacement project). The building envelope deficiencies must be corrected in any option. This work includes:

• Replacement of the entire roof.

• Removal and reconstruction of all of the exterior wall systems.

• Regrading of the site around the building including replacement of hardscape elements.

• Renovation of interior finishes affected by the wall reconstruction and proposed HVAC work. This includes the replacement of flooring, ceilings, and casework. The extent of the interior renovation increases with the Option to entirely replace the HVAC distribution system.

Coleytown Middle School Remediation Option 1A Budget Estimate


This Option includes all of the envelope and site work. The HVAC work upgrades the cooling and dehumidification infrastructure and replaces the Unit Ventilators in-kind with modified louver configurations.

Roofing EPDM 65,670 $30 $1,970,100Sloped 40,170 $30 $1,205,100

Façade CMU wall system 38,600 $80 $3,088,000Glazed wall system 22,000 $180 $3,960,000

HVAC UV's & supplemental cooling 1 $989,300 $989,300Interior Interior Renovations 125,000 $40 $5,000,000Site Allowance 1 $1,000,000 $1,000,000

Sub-Total $17,212,500Contractor O&P 15% $2,581,875

Contingency 10% $1,979,438Sub-Total $21,773,813

Project Costs 15% $3,266,072Option 1A Project Total $25,039,884

Coleytown Middle School Remediation Option 1B Budget Estimate


This Option includes all of the envelope and site work. The HVAC work eliminates the Unit Ventilators and provides ducted distribution of conditioned fresh air and VAV distribution of heat and cooling.

Roofing EPDM 65,670 $30 $1,970,100Sloped 40,170 $30 $1,205,100

Façade CMU wall system 38,600 $80 $3,088,000Glazed wall system 22,000 $180 $3,960,000

HVAC VAVs, Rooftop ERUs 1 $4,000,000 $4,000,000Interior Interior Renovations 125,000 $75 $9,375,000Site Allowance 1 $1,000,000 $1,000,000

Sub-Total $24,598,200Contractor O&P 15% $3,689,730

Contingency 10% $2,828,793Sub-Total $31,116,723

Project Costs 15% $4,667,508Option 1B Project Total $35,784,231

Coleytown Middle School Replacement Option 2 Budget Estimate


Description Area (SF) Cost/SF Cost Cost/SF CostBuilding Demolition & Recycling 125,000 $20 $2,500,000 $25 $3,125,000Sitework for new building $2,000,000 $2,000,000New Building Construction 125,000 $425 $53,125,000 $475 $59,375,000

Sub-Total $57,625,000 $64,500,000Escalation - 2 years 8% $4,610,000 8% $5,160,000

Option 2 Total $62,235,000 $69,660,000

Coleytown Middle School – Next Steps / Options

CMS Process: Facilities Assessment – Next Steps

OPTIONS 1A & 1B: REMEDIATE/RENOVATE COLEYTOWN MIDDLE SCHOOL:

New roof, replace exterior wall system, replace windows and doors, replace/modify mechanical system. These two options also require some interior finish replacement including casework, carpet, acoustic ceilings and lighting, and other soft materials.

CONCEPTUAL SCHEDULE

• 11/5/18 – 12/15/18: Engage Design Team

• 12/15/18 – 8/15/19: Complete Design & Contract Documents for Permit & Bidding

• 8/15/19 – 11/1/19: Bid & Award Construction contracts

• 12/1/19 – 7/15/21: Complete Construction Project to Rehabilitate Coleytown MS

• 9/1/21: Re-Open Coleytown Middle School

Coleytown Middle School – Next Steps / Timelines

CMS Process: Facilities Assessment – Next Steps

OPTION 2: DEMOLISH COLEYTOWN AND BUILD A NEW SCHOOL ON CMS CAMPUS.

• Engage a Design Team to evaluate existing infrastructure condition and capacity.

• Establish a long term Educational Plan for the District.

• Complete a District-wide facilities use plan including programming for a new school building.

• Design and build a new school building on the CMS Campus

CONCEPTUAL SCHEDULE• 11/5/18 – 12/15/18: Engage Design Team for Facilities & Capacity Study

• 1/1/19 – 7/1/19: Complete Facilities & Capacity Study

• 7/15/19 – 10/15/19: Establish Program for New Building

• 10/15/19 – 11/15/19: Engage Design Team for New Building

• 12/1/20 – 9/1/21: Complete Design & Contract Documents for Permit & Bidding

• 9/1/21 – 11/15/21: Bid & Award Construction contracts

• 12/1/21 – 8/1/23: Complete Construction Project – Open School

Listen, imagine, build