1. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005

2. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005 AE Senior Thesis:  Research: Modular Construction Applied to Sullivan Trail Junior High  Breadth 1: Structural Implications of Modular Construction  Breadth 2: Modularizing Mechanical Systems

3. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005 Goals of Presentation:  Inform on state of modular construction in today's industry  State advantages and disadvantages of modular construction  Apply a modular construction design to Sullivan Trail Junior High  Show minimal changes to floor plan  Show a schedule reduction of four months

4. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005 Background information: Pocono Mountain School District  Over 11,200 students and 1,400 faculty members  305 square mile coverage area  Increase in enrollment of about 4% or 400 students a year  Pocono Mountain West High school: Completed in 2002 is already 200 students over capacity.

5. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005 Background information: Sullivan Trail Junior High  Features  285,575 Sq. Ft.  44.6 million dollars  16 Prime Contractors  Built into the side of a hill and is two stories on each level  Auditorium  Multi Purpose Room  Cafeteria  Three Classroom Pods  Construction started in March 2004  Completion date December 2005

6. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005 Background information: Sullivan Trail Junior High  Structure  Structural steel frame  Concrete spread footings and piers  18 Foot high retaining wall  Combination of CMU and steel stud and drywall walls  Split-face CMU facade  Mechanical Systems  3 boilers  2 Chillers  41 Single and Multi-Zone Air handling units  Fully Sprinkled

7. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005 Modular Construction  Advantages  Requires little or no shake out area  Generally saves money  Reduces construction time by 1/3 because modules can be started while foundations are being dug  Reduced schedule leads to a faster payback period for the building  Minimizes schedule risks by having portions of the construction take place in a controlled environment and shortens critical path  Safety concerns are reduced because of controlled work environment  Portions of the building can easily be added or removed as needed

8. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005 Modular Construction  Disadvantages  Requires substantial planning so front end of projects can be prolonged  Sometimes there will be an up cost  Works best on repetitive buildings such as jails and hotels  Increase in columns  Maximum clear span of 28 feet  Modular designers prefer to have very little or no CMU

9. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005 Types of Modular Construction  Static Modular Construction  Modules are built similar to a conventional building  The modules are fully assembled them portions removed on match line  Typically are shipped on flat bed trucks  Adaptable to existing floor plans  NRB Incorporated  Assembly Line Modular Construction  Module moves to different stations  Modules are never fully assembled until on site  Typically have wheels attached to frame  Focuses on efficiency  Mark Line Industries

10. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005 Static Build Modular Construction

11. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005 Static Build Modular Construction - Connections

12. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005 Static Build Modular Construction - Connections

13. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005

14. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005 Assembly Line Modular Construction

15. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005 Assembly Line Modular Construction

16. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005 Sullivan Trail Junior High Modularization  Reduce schedule to have school completed by August 31, 2005  Use static built modularization  Modular design follows classroom pods  Auditorium, Gyms and Cafeteria would be conventionally built

17. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005 Area A Floor Plan

20. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005 Area C Floor Plan

23. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005 Area D Floor Plan

26. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005 Area E&F Floor Plan

29. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005 Modular Construction  Erection Sequence  Area A, C and D2, D1 and F and E

32. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005 Modularization Recommendations  Floor to floor heights would have to be lowered  Redesign of locker rooms to accommodate new columns  Flat roofs with roof top mechanical units  Modularize mechanical systems rather than mechanical room  Labor costs could be reduced by 1/3 because prevailing wage would not need to be used on off site construction  Save temporary modular classrooms and estimated cost of over $650,000

33. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005 Special Thanks to..  Turner Construction: Bill Booth and Steve Miller  NRB Incorporated: John Crisp and Don Engle  AE Faculty  Gilbert Architects  Pocono Mountain School District

34. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005 LowerMainUpperMezzanine Area A 16'-8"14'-0NANA Area C 16'-8"14'-8"15'-6"18'-10" Area D 16'-8"14'-8"15'-6"18'-10" Area E 16'-8"14'-8"NANA Area F 16'-8"14'-8"NANA

35. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005

36. Sullivan Trail Junior High Pocono Summit, Pennsylvania Andrew Mellow Goals Background Drawings Site Plan Schedule April 13, 2005