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CONSTRUCTION KNOWLEDGE BLOG

December 7, 2011

Opportunities in Bench-Marking
Filed under: Quality Control — Tags: — nedpelger

When I was a young foreman on a construction site, an old guy (younger than my age now) taught me how to do construction layout with an optic level. The first thing he explained was about bench-marks. To measure the relative elevation of different objects (I was laying out curbs…badly), I needed to be able to measure the height of my instrument off a known elevation, a bench-mark.

As I just completed the judging for the Engineering News Record Best Projects of 2011, I’ve been thinking about bench-marks. The most challenging aspect of judging the projects came from the inconsistency of the data presented. In our tele-conference yesterday, the other judges agreed.

Safety should be one of the easiest categories to bench-mark. Many years ago, OSHA tried to resolve that problem by requiring construction firms to measure their Experience Modifier (1.o being the average), their Lost Time Accident Rate and their Recordable Incident Rate. These measures should provide objective data to rate a firm’s safety effectiveness. Yet we’d see huge projects with Recordable Incident Rates of zero, that simply seemed impossible. To work millions of man-hours and not have any splinters in the fingers or strained muscles seems quite unlikely. It appears the numbers are being gamed or mis-reported somehow.

In another area, I’ve often noticed the lack of standards in measuring the costs of building projects. Some projects include everything from land to process equipment, while others only list the vertical building construction costs. I’m amazed how many times smart people don’t ask what is included in the stated costs. (Note to self: if you want to look smarter, make it a habit of asking what’s included and not included in prices when they are offered…learn to think critically about what any stated construction cost includes).

I’m a proponent of listing building project costs with the following simple break-outs:

  1. Land costs, including settlements and right-of-wayss
  2. Design fees, including estimating costs
  3. Sitework costs, everything outside the footprint of the building
  4. Building costs, footing excavation and all other vertical construction
  5. Equipment costs, including process equipment, appliances, furniture, fixtures, etc.
  6. Soft costs, including permits, tap-in fees, other utility fees, etc

I also like to always look at those costs as both a sf cost and a percentage of total project cost. These measures start helping you see trends, that help you understand the business better.

If you learn to present your projects in a clearer way, you’ll lose fewer projects to yahoos that confuse owners with scammy pricing. Remember, part of your job in selling a project is to educate the owner on the value you provide.

CONSTRUCTION KNOWLEDGE BLOG

December 1, 2011

Learning from the Best Projects of 2011
Filed under: Cool Projects — Tags: — nedpelger

I’m spending many hours judging the ENR Best Projects 2011. The 80 nominated projects spread between categories: civil works – infrastructure, cultural – worship, green projects, industrial – manufacturing, residential – hospitality, retail – mixed-use, projects under $10M, sports – entertainment and transportation. As I thoroughly review the proposal from each project, I’m enjoying learning from some of the best construction operators.

For example, when the Facebook Data Center had a transformer failure in the start-up, the team agreed they needed to understand what actually happened in order to avoid a future operational failure. So they studied the transformer failure with a millisecond by millisecond analysis. The team gained an understanding of what actually happened and was able to use that knowledge to improve the process.

How often do we encounter failure and go with the quick fix response rather than putting in the work to truly understand the situation? We can’t study everything ad nauseum, but we can probably slow down a bit and improve our understanding and our process.

A Merck Vaccine Facility took planning and bench-marking to an amazing level.  The team decided to design and build this facility much faster than a similar facility had ever been built. They succeeded by fanatically considering every reasonable contingency. They also used lots of modular construction, especially in the mechanical, electrical and plumbing areas. That’s a technique all of us could use when faced with compressed schedules.

Turner Construction probably impressed me the most with their Lean Construction approach. Evolved from the lean manufacturing model, Lean Construction manages and improves the design and construction process with an emphasis on customer needs, striving for minimum costs and maximum values. Simply put, it’s a thoughtful approach to determine the best thing to build and the best way to build it.

The constraint log illustrates the concept well. The team maintains a constraint log that identifies potential problems six weeks away, then devises a plan to help avoid those constraints from affecting project momentum. On the one hand, it’s a simple concept that good project managers and job supers do in their head. On the other hand, formalizing that process probably leads to a better outcome, particularly on complicated or intense projects.

So I’m having fun learning, even as I watch the hours melt away and know I should be evaluating bids and writing contracts. Oh well, a well spent life always fights to balance the necessary with the extraordinary.

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