Component Remanufacturing Facility
GMHILL performed master planning and requirements analysis, developed design criteria, completed a model planning charrette, and postured full DD1391/project programming packages for the construction of a modern CRF campus that directly improved process flow, efficiency, repair cycle time, and inventory control through the use of efficient layout and modern technologies. This key campus modernization initiative addressed requirements for new construction, facility repairs, and facility conversion across a range of facility types, including vertical facilities and horizontal infrastructure, postured accurate cost estimates, incorporated ancillary design work, and integrated sustainable design principles.
Specifications
Our team delivered a full range of A-E services for the CRF facility construction, additions and alterations to two facilities, and sustainment, restoration, and modernization (SRM) for eight campus facilities to accommodate consolidation and selective demolition. Our team developed the concept site layout plans, architectural floor plans, and elevations in conjunction with the concept plans and final Planning Charrette Report (PCR) that included detailed 15% design level requirements and associated parametric cost estimates.
The new CRF consolidated operations into a single location in the Nichols Industrial Complex at ANAD, including industrial process and support areas. It is designed to house a large amount of equipment, including cranes, state-of-the-art manufacturing equipment, and new and relocated equipment from other facilities. The mission scope was divided into six complete and usable facilities.
Our team first reviewed the statement of work, prior charrette reports, initial parametric estimate, and draft DD1391s provided in the request for proposal. A kickoff meeting was conducted at ANAD to meet project stakeholders, set project expectations, and perform an on-site tour and evaluation of the facilities and manufacturing operations. Additional project information was obtained from multiple charrette questionnaires, site visits, and client interviews prior to three on-site charrettes. With an understanding of the magnitude of the industrial process scope, stakeholders agreed project development efforts would benefit from conducting three separate planning charrettes: one for the industrial processes, one for the facilities, followed by one for the relocation and SRM planning to accommodate relocations.
Before the first charrette for the industrial processes, our industrial engineering team conducted site visits to conduct interviews to gather key data for existing equipment and workflow processes. Then, we analyzed the data gathered and developed the initial program square footage and three proof of concept diagrams using existing building massing. The design team architect and civil engineer developed site concept diagrams on the proposed CRF site to confirm that the site size would accommodate the CRF. Additionally, the design team developed preliminary rough order of magnitude cost estimate ranges and began gathering DD1391 justifications. At the end of the first planning charrette, the stakeholders validated the industrial processes to be included in the CRF, the requirements to support these operations, developed initial industrial process functional relationships and workflow, and identified the total scope of the project, including mission, occupancy, and equipment. The industrial engineering team gathered and analyzed the extensive amount of data to determine the requirements for the most efficient remanufacturing routes.
Prior to the second charrette for the site, facility, and associated utilities, the design team developed initial concepts for:
- Program areas
- Workflow diagrams
- Area comparison analysis
- Updated concept floor plans for industrial areas
- Space adjacency considerations
- Special building details to support production, cranes, lighting, architectural character of the building
- Mechanical considerations.
The design team also provided an explanation of the DD1391 and Economic Analysis (EA) processes, enabling client stakeholders to determine the Facility Category Code and type of EA that was conducted to provide justification for the DD1391. A partial EA was subsequently approved for the EA type. During the charrette, the design team and client developed the initial program of requirements for the CRF, concept floor plan, concept architectural elevations and models, a site diagram for circulation patterns, requirements for mechanical, electrical, plumbing, and fire protection, and a concept building section validating the height to accommodate cranes.
The phased PCR activities shaped the following key aspects of the concept design:
- Programmatic requirements for direct industrial and non-direct support personnel spaces
- Basis of design for specialized equipment like large cranes
- Flexibility of industrial processes
- Centralized, automated, and streamlined industrial processes
- Regulated environment for optimized machinery and personnel performance
- HVAC system location and performance criteria
- Life cycle cost analysis to determine effectiveness of solar, photovoltaic, hot water, and rainwater collection
- Sustainable design principles to include LEED Silver certification under LEED v4.0.
Additionally, the CRF campus layout effectively used GIS-based planning deliverables and CAD deliverables for the facility concept design.
Services included master planning, architecture, structural mechanical, electrical, plumbing, civil, fire protection, and industrial engineering, comprehensive interior design, communications distribution design, cost engineering, and project programming. Our team also completed ancillary design work to inform the design, including special report preparation for topographical survey, geotechnical data assessment, and utility capacity analysis.
