The Construction Industry Institute reported that 55% of construction rework is caused by inaccurate documentation. This often happens when someone is referencing the wrong set of documents. It is critical to commercial construction project success to have one and only one set of documents that everyone is using. Utilizing or not utilizing centralized plans, photos, revision management and other important documents will make or break your projects.
Document accessibility on job sites is important. Equally important is having the correct documents while on site. What happens when changes are made due to site conditions and the Project Planner does not update the correct set of drawings? Rework.
Rework causes longer construction schedules that push occupancy dates and cost overruns that can be between 2%-20% of the project value. This percentage comes from the Construction Industry Institute of Texas. Could your project absorb a $400,000 rework on a $2,000,000 project? Rework not only affects your bottom line, but it can also cost companies their reputations and sway decisions regarding future work with a customer.
Throughout a project lifespan there will be multiple drawing revisions. Ensure that your document management system implements some type of version control. Some companies use in house developed document management systems. Some companies use out of the box software such as Procore, Textura, BIM 360, Plangrid and Blue Beam. These cloud based systems can assist with subcontractor communication. For example a millwork contractor gets the plumbing submittals that include sink cutouts and faucet information that is needed to fabricate the tops.
The bottom line is that if you do not have control of your documentation, you have a much lower chance of successfully completing your projects on time and in budget.
Commercial construction projects rarely progress exactly as planned. Wikipedia defines scope creep as changes, continuous or uncontrolled growth in a project’s scope, at any point after the project begins. This can occur when the scope of a project is not properly defined, documented, or controlled. It is generally considered harmful. Scope creep will happen when Project Managers fail to address changes as they occur. Failing to remain in control of project scope/schedule is a runaway train and will result in a financial train wreck.
What are some causes of scope creep? Poorly defined project scope. This usually begins with your preconstruction team. Failure to stick to change practices. If a customer asks you for a change, no matter how small, document it. Because one of our goals a satisfied customer, when asked for a change, we may agree without first initiating a change process. Any change in requirements, large or small, becomes a new feature (scope) that was not part of the original agreement.
Recently a large addition to the millwork scope was added to a healthcare project we were managing. This happened because the owner had overlooked it in the original design and therefore it was not part of the original contract. Our team immediately assessed how this would affect our responsibilities to complete this project on time and in budget. We did request additional material and labor cost to the added scope via a change order. In this case, we were ahead of schedule and did not have to work overtime to ensure that the work was completed on time. No overtime labor costs were passed on to our customer.
Another example is when a customer informs you that the owner would like the color of the solid surface countertops to be a complex patterned color that just so happens to be the most expensive group of coloring offered by the manufacturer. Your preconstruction team priced the material at a cost that is half that of what is now being requested. If your team did not clearly define what material was included in your proposal, you may be at odds with your customer about changing the scope/cost. This is a great example of scope creep that is caused by requirements or material not clearly defined.
There are many things you can do to help prevent scope creep. Make sure that your project is clearly defined. Something as simple as the color of countertops can make or break a project. Make sure that everyone on your team is aware that ALL changes to project scope are documented and go through the project management team. This includes employees that are handling submittals and installers. Let’s say that your submittal coordinator receives a phone call from the customer and they let them know what pulls they want on all of the casework and what company to use. The submittal coordinators thanks them for making their day just a little bit easier as they don’t need to dig through the specifications to find this information. They submit the pulls that were requested via the phone call not knowing that they are completely different from what is in the spec and costs 25% more. Your project costs just increased and no one even knows it. Another example is when your installers have a plan to go floor-by-floor installing tops. On a few floors, the trades before you are behind and the customer lets your site supervisor know that the schedule for installation has to be changed. If your site super does not let you know that you are delayed because of another trade you may be asked to keep your schedule. When this happens, it needs to be documented. Make sure that you have a clear process for dealing with changes. If there is no process then your team members have no guidelines for what has to be done with scope changes and will most likely assure scope creep. Make sure that changes are addressed immediately. It may become a problem if you go back to your customer with a change request for something that you have already completed.
In February 2022 the Bradley Corp conducted a survey and 51% of Americans stated that an unclean lavatory shows poor management. COVID brought a heightened sensitivity to the cleanliness of public spaces and even more so in public restrooms. There is a sense of fear that some people have when entering a public space that may be contaminated. That fear is a direct reflection of how a person feels about the owner of the building.
Traditional plastic laminate vanity countertops and drop-in sink bowls provide an opportunity for moisture to destroy a particle board substrate. This creates an optimal environment for bacterial growth. We have all witnessed public countertops with laminate surfaces that have swelled from exposure to water.
To address these common problems, ASST developed a wall hung solid surface vanity system. The 30” wide modular units utilize a sturdy aluminum and polyethylene support structure with a removable solid surface front panel allowing for easy access to plumbing. The Modular Vanity system™ is available in 30” wide increments and includes a solid surface top, backsplashes, side panels and your choice of an integral mounted sink. The system is available in all solid surface sheet products. Without wood that can rot and grow mold, the system is perfectly designed to handle rigorous public restroom environments.
As of 2020 there were 5,139 community hospitals in the United States (www.aha.com). New healthcare spaces today are no longer the institutional hallways that instill desperation and smell like antiseptic. Thanks to pioneers like Esther Sternberg, we now know that there is a direct correlation between the environment that we occupy and healing. Healthcare providers are looking to offer a space that provides hope and healing. To make this happen, new healthcare facilities are now offering premium finishes that include custom solid surface nurses’ stations and reception desks.
Times are tough in commercial construction. We are all dealing with supply chain issues (see our article about this here), labor shortages, logistic shortages and turbulent markets. When a GC buys out the millwork, are they buying from the same subcontractor? Are they buying the wall panels from the same supplier as the cabinets? Are they buying the flat top solid surfaces from the same subcontractor as the custom thermoformed nurses’ stations? Is the casework sub communicating with the tops sub? What happens when the tops show up and the casework is not there because of a delay in material procurement for the cabinets? Handling multiples subcontractors for a single millwork package is a sure way to endure cost overruns, scope creep, project delays and many change orders (queue the cash register drawer).
Why add more moving parts than necessary? At ASST, we have been providing Division 6 and Division 12 millwork, casework, solid surfaces and quartz for large healthcare projects for 24 years. We understand that to become a beacon of hope for an entire community, the healing space must be innovative and constructed with the highest standards. We have the experience to provide project scope on time, in budget and we do it safely. Whatever you need, ASST can build it to the exact specifications, in a safe manner and to the finest quality standards, you expect.We look forward to Going Beyond for your exciting project! Contact us today at firstname.lastname@example.org or visit our website at www.asst.com.
Did roofers show up to install the casework for your large commercial project? If you have worked in large commercial construction, you have either suffered the consequences of bad installation or heard the stories of it happening. Did the PLAM on the wall cabinets not match the PLAM on the base cabinets? Often times this happens when materials are ordered with a large time span between procurement. Did your millworker not inform you that they were delayed because of a material shortage until the day of installation?
These are just some of the ways your large commercial construction project can come off the tracks. We are all acutely aware that we are at the tail end of a pandemic that has rocked commercial construction. We are dealing with supply shortages, employee shortages, and unheard-of escalations. Coupled with owners that may not understand how this affects schedule or cost and you have a recipe for disaster. How are your millworkers dealing with this? What happens to your project when your millworker is ill-equipped to maneuver in these difficult times of commercial construction? Will your project be delayed? Will occupancy dates get pushed?
At ASST, we know that materials are in short supply. We know that there is a serious shortage in labor. We know that times are tough all around. What are we doing about it? We have always been willing to provide VE options when bidding a project. We can also offer material options when we know that a material may be difficult to procure. We are ordering further out than we ever had before and we are storing materials that we know are being delayed. We are using multiple shipping companies to ensure that if one cannot provide a mobilization for our project, we have a backup that can. These are just some of the ways we are handling the current issues in commercial construction. At ASST, one of our core values has always been innovation. We continuously generate new ideas and methods to ensure success.
Would you and your team like to do a virtual shop tour of one of our facilities? It only takes about 25 minutes and we demonstrate how we successfully plan and complete large millwork projects on time and in budget. Email us at email@example.com to setup a virtual shop tour.
Solid surface is one of the most versatile millwork finishes. There are some guidelines when specifying solid surfaces to keep your design intent. Below are a few of those guidelines.
Solid colors and colors with small particulates will either show no seam at all (solid colors) or be difficult to see (small particulates). Solid surfaces colors that will show a seam are any color that has movement (swirls, large particulates, etc.). Keep in mind that most solid surfaces come in 30” X 144”. If your project has a surface area larger than this, there will be a seam. The last thing you want is your best work to have, what might be considered, a flaw that is painfully obvious. If you have any reservations about how a seam will look, contact your fabricator and ask them to send you large seamed samples. Any good fabricator will do this at no cost to your firm.
Color and Finish Level
Solid surfaces come in hundreds of colors from different manufacturers. While solid surface is a versatile surface with few limitations, there are some guidelines when specifying light and dark colors. When you are choosing color selection for a working surface (transaction ledges, tops, etc.) stay away from dark colors. Dark colors will show every little scratch and although they are easy to repair, it will have to be done often to keep the aesthetic you have designed. Light colors don’t show scratches easily and most often will only require basic cleaning. Dark solid surfaces are great for vertical applications such as die walls or wall cladding. When specifying a dark color, make sure that you specify the finish level. A matte finish on a black solid surface will actually look grey. With very dark colors you will want at least a semi-gloss finish. Keep in mind that the higher the finish the higher the cost as there is more labor involved.
Thermoforming solid surfaces gives you the ability to remove the chains and take your design to a whole new level. Solid surfaces are no longer just the flat countertop in a well-appointed kitchen. Thermoformed solid surfaces can be used for anything from an eye-catching nurse’s station to the radius corners in an operating room and beyond. When specifying a thermoformed solid surface project, make sure that you specify the fabricator of choice. Don’t let your best work be doled out to the cheapest millworker.
At ASST, we have been fabricating healthcare solid surfaces for 23 years. We have a solid surface fabrication facility in McSherrystown, PA and a quartz fabrication facility in Corry, PA. Whatever your needs, ASST can build it to the exact specifications, in a safe manner and to the finest quality standards you expect. Contact us online or call us at 717-630-1251. WWW.ASST.COM
If you work in commercial construction, you know that getting building material right now can be difficult. It does not matter if you are talking about MDF, steel, or even portable toilets for workers. What is causing this? There are many reasons such as COVID-19, worker shortages, extreme weather and even shipping container shortages. While we don’t have individual control over extreme weather or worker shortages, there are actions that companies can take to ensure project continuity.
Know your schedule and get in front of ordering materials early. This should go without saying and if you do not do this, you will certainly risk not being able to get materials on time. If you have the space, order your material early and store it. In the time of JIT (just in time) manufacturing/production this seems counter-intuitive. However, this could be the difference between a delayed project and being the hero during tough times.
Make sure you have multiple distributors for the same material. Don’t wait until the distributor you normally use is out. Having multiple accounts setup with sales representatives ahead of time will help speed up ordering material. When getting material pricing, ask your sales representative to guarantee pricing past the time you will need it. Make sure you get confirmation in writing. A verbal “don’t worry about it” won’t do. Pay your vendors on time per the net terms of your agreement. Your company is not the only company that ranks customers by how fast they pay as one of the metrics. That may make the difference between you getting the material ahead of the customer that decides to pay on their terms. While none of this is a guarantee for project success, it may be the difference between project delays and successfully completing on time and in budget. Not being prepared is a guarantee for failure.
Inova Loudon Hospital
What does it take to successfully manage the millwork package for a $200M+ healthcare project? There is no single ingredient that defines a successful large millwork project. The overall process has to be complete and well-defined. From initial contract to project completion, there are many steps in between. These steps will define whether the project is successful or not.
Hershey Children’s Hospital
Have you ever received a submittal and asked yourself “is this company looking at the right specifications”? Have you ever received shop drawings and wondered “do these people even know what an AWI standard is”? Every General Contractor has been in a situation where they have received shop drawings for approval and the casework is on the wrong side of a wall or something similar.
On every large project, the schedule is one of the most difficult things to control for a project manager. It can be difficult to fabricate when the time between field measuring and installation is compressed. When this is not planned correctly other trades can get pushed as well as occupancy deadlines. What happens when your millworker cannot meet the deadline for completed installation?
At ASST, our process for success is well-defined and is continuously reviewed. We have a team of Submittal Coordinators that will push to get approvals back in a timely manner. Our Project Planners have the right tools for field measuring and handle site verification. They handle machine programming and fabrication scheduling. Our Project Managers have decades of experience and the ability to handle dynamic environments. Our shops are set up to handle the most unique custom projects as well as very large high capacity projects. All of our employees have the tenacity to be successful.
Did you know that it costs between $400 and $700 per square foot to build a hospital depending on the geographic location (Becker’s Hospital Review)? For example, in Los Vegas the cost to build a hospital is between $285 and $455 per square foot. While in New York City the cost is between $475 and $700 per square foot. When a health network spends this kind of money they want to make sure that it will be done on time and in budget. An operating room costs the health system around $2,200 per hour for direct and indirect cost (American Journal of Managed Care). Hospitals charge between $3200 per hour and $10,000 per hour per operating room (Journal of Clinical Anesthesia, Stanford). The sooner the health system can take occupancy the sooner they can start recouping that investment.
One of the most important decisions that General Contractors and Owners can make is the selection of subcontractors. What happens when the subcontractor does not have the capacity to complete the project in the schedule required? Usually the General Contractor will have to hustle to find another subcontractor to supplement the work that cannot be completed by the awarded sub. This is painful and a deduct change order ensues or worse the performance bond is engaged and a replacement subcontractor has to be contracted. After this the GC usually will have to explain why schedule is not going to be met to the owner.
Some of the questions that have to be answered for any successful General Contractor and owner are as follows: Does this subcontractor have experience with this type of work? Does this subcontractor have the capacity to handle this type of work? Does this subcontractor operate safely? Does this subcontractor provide the quality of work to meet and exceed the expectations of the owner? Is this subcontractor financially sound? If the answers to ALL of these questions are not a resounding YES then your project is at risk.
At ASST, we have been successfully providing millwork, casework and solid surfaces on large health care projects for 23 years. We have the capacity for large projects, the processes to keep schedule, we do it safely, we are financially sound and we have the Project Managers that know how to be successful. We look forward to Going Beyond for your exciting project! Contact us today at 717-630-1251/ firstname.lastname@example.org or visit our website at www.asst.com.