Barton Malow Industrial Construction

IndustrIalConstruCtion serviCes

building innovative solutionswww.bartonmalow.com

http://www.bartonmalow.com

ii w w w.bar tonmalow . com

IndustrIal ConstruCtIon

Marisa Varga, CPSM, LEED APProject Development Manager

248.436.5512 p248.436.5513 f248.331.6716 [email protected]

Barton Malow CompanyIndustrial Group26500 American DriveSouthfield, Michigan 48034

Barton Malow’s Focus on Industrial ConstructionBegins with a specific understanding of the demands in your market as well the needs of the companies we build for. Companies like General Motors, Detroit Edison, Consumers Energy, A123 and Severstal Steel have taken Barton Malow beyond typical construction techniques, practices and implementation through preconstruction, integrated project delivery, design-build, fast-track general contracting and construction management, Building Information Modeling – from presentation to implementation on the ground, in the field.

Expectations of the highest quality and safety standards push our project management as well as Barton Malow’s work performance in civil, concrete, resteel production and process equipment installation.

In working over 10 years throughout the industry, including six years for Barton Malow, I have never found a company culture to have as much dedication, integrity and care for the clients we serve. Those companies we find with similar cultures we work with as partners in the construction process.

There are several projects throughout this package that I am personally close and dedicated to – Severstal, Bosch, DTE Monroe and Heritage/DTE Wind Farm. They are excellent examples of all of our services and teams in action, working together. I would be happy to arrange a site visit if any projects take your interest.

Our people value the relationships we build over time with you. The representative projects and clients found here demonstrate 5-10 years of working relationships individually. Please feel free to contact me and allow us to demonstrate how we may Build Innovative Solutions for you.

Sincerely,

Marisa Varga’s focus on project development with Barton Malow Company centers on the best way to provide unique value to the company’s clients. Beyond delivering construction projects safely, on time and within budget – our team really looks to provide new, innovative solutions in order to get our client’s products to market quickly and efficiently through their facilities.

With 10 years in the A/E/C industry, including years in marketing, preconstruction & estimating and now project development, Marisa understands that design and construction is one of our greatest opportunities for continued growth and success in our country and economy as entrepreneurs innovate and develop new products, markets and industries.

Click here to connect with Marisa on LinkedIn.


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B u i l d i n g I n n o vat I v e S o l u t i o n S

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table of ContentsIntroduction .......................................................................................2Safety .......................................................................................................3Quality ....................................................................................................4Building Information Modeling ............................................5Services ..................................................................................................6Self Perform Expertise .................................................................8Project Experience .....................................................................10

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Founded in 1924, Barton Malow provides construction services nationwide with a focus on heavy industrial contracting including manufacturing, automotive, energy, renewable and other industrial facilities.

Barton Malow employs approximately 1,400 full-time staff, including 700+ trades personnel. In Michigan, Barton Malow is considered the largest employer of trade labor and has been recognized as one of the “Best Places to Work” in the State.

Whether general contracting, construction management, design/build or integrated project delivery, our delivery process is built on integrity, trust and our people. Our professionals bring extensive experience performing and managing industrial construction from small equipment relocation projects to large-scale production, manufacturing and energy facilities. Thinking about your facility in its entirety, from the anchor bolts down to the building shell to the process equipment, provides a focused approach on reducing first cost as well as long-term ownership cost.

Our Preconstruction Group, which has grown to 56 full-time engineers and architects and supports the Company with a reliable estimating system. Their expertise also includes all facets of project planning, value engineering, project phasing/logistics , scheduling, manpower planning and Building Information Modeling.

Building innovative Solutions for clients like you for 89 years.

CorporAtE oVErViEW • SAfEty








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At Barton Malow – safety, productivity, and quality are equal components in supporting our overall success. As such, our culture and philosophy stress the importance of planning our work safely, minimizing hazards, training our people, and striving for continuous improvement toward an incident free environment. Barton Malow employs a three-pronged approach to safety – awareness, training and reinforcement. Awareness is the first step in performing a job properly and safely. Through regularly scheduled meetings, toolbox talks and jobsite signage, employees are made aware of their place in Barton Malow’s overall culture of safety. Each task is critical and every employee is aware and accountable. All operations personnel are required to achieve and maintain a certain standard of job-specific safety training. To aid in this, Barton Malow rolled out an enhanced training program with the purpose of providing meaningful, hands-on safety training, which covers OSHA 30-Hour topics plus additional topics specific to Barton Malow projects. Upon completion of the “30 Plus Program,” participants will have earned their OSHA 30-Hour card, along with a specialized Barton Malow “30 Plus” designation. One way Barton Malow reinforces the safe work acts and practices of our people is by means of our “Whatever it Takes…” program. This program recognizes employees for their planning, acting, and overall emphasis on proactively working safely. The goal of this program, through positive reinforcement, is to instill proactive behavior when it comes to safe work practices. Barton Malow’s philosophy and corporate value system stress safety as an absolute. Our commitment to safety education and performance reinforce the importance of this message.

We start with safety. We end with safety... and it’s everywhere in between.



Quality control in the construction industry can be looked at as having three elements: to deliver a project which satisfies the client, to deliver a project where quality is in line with the price, and to deliver a project in the desired time frame. At Barton Malow, we take quality control to the next level. Our standard is based on our abilities to continuously exceed our clients’ expectations from start to finish with regard to a safe jobsite, a hassle-free process, and an excellent end product.

Barton Malow’s core values of leadership, commitment and integrity are the basis of our practice and the origin of our quality control approach. We understand the importance of planning to ensure quality. For us, quality control management includes developing a project specific quality manual that takes into consideration the individual needs of each owner, project and process; selecting the most qualified team members based on their relevant experience and knowledge base; leveraging technology, resources, manpower and schedule control to build the project right the first time, on time; implementing a successful safety plan on every jobsite; and having methods in place to proactively address issues and correct deficiencies.

from start to finish, building our reputation on Quality Construction.

QuAlity • Building inforMAtion ModEling








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The majority of our construction projects include the integration of Building Information Modeling (BIM). BIM provides the ability to verify and provide accurate estimates, confirm and monitor the project schedule, simulate design and construction, and eliminate field-driven change orders. Fly-through BIM models are used early in the process to identify field element collisions before fabrication and installation begin. Our collaborative team approach has been enhanced with BIM with past project successes including a 1,000,000+ square foot project being delivered to substantial completion in just nine months.

from preconstruction to punchlist, BiM is a member of our team.

CLICk hErE to wAtCh A VIDEo hIghLIghtIng BIM utILIzAtIon.

CLICk hErE to rEAD MorE ABout BIM In ACtIon on thE SEVErStAL DEArBorn ProjECt.

http://www.youtube.com/watch?v=hw50X9hkd5w

http://issuu.com/bartonmalow/docs/bmc_sna_autodesk_article



to MEEt ALL our CLIEntS' nEEDS, wE oFFEr:

Construction ManagementDesign-BuildEngineer/Procure/Construct (EPC)General ContractingIntegrated Project DeliveryFacility ManagementProgram Management

projECt dEliVEry








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With client needs so varied, Barton Malow offers a choice of project delivery methods and a full complement of in-house services. From preconstruction through project close-out, our innovative solutions bring value to our clients on every project.

Because we are a full-service firm, we also offer a host of in-house services, such as: architecture/planning, interior design, preconstruction, facility audits, facility services, mechanical equipment installation, technology consulting, interiors trades, concrete trades and Building Information Modeling.

full service construction capabilities to meet your complete facility needs.


IndustrIal ConstruCtIon SElf pErforM trAdEWork








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Civil and ConcreteFrom the anchor bolts down, we understand that some of our best work is never seen, and that’s okay with us. Our goal is to provide you with a solid foundation on which to build your project. Providing comprehensive civil and concrete services from heavy foundations to high-strength floors, Barton Malow’s skilled self perform workforce includes carpenters, ironworkers, laborers, finishers and operators.

Barton Malow’s concrete trades are active members of the American Concrete Institute, American Society of Concrete Contractors, the Associated General Contractor’s and the Concrete Reinforcing Steel Institute. They regularly attend educational programs designed to keep them up-to-date on methods used to ensure the best placement and finishing of concrete installations.

One of the largest concrete contractors in Michigan, Barton Malow is ranked #30 in the nation on Concrete Construction’s Top 100 concrete contractor’s list. Our professionals’ depth of experience gives us the ability to accelerate project schedules while maintaining the highest quality and safety standards.

Mechanical InstallationOur experience in the installation of machinery and equipment in industrial facilities spans over 30 years. Barton Malow offers our clients the ability to bring together building systems, equipment and services into an integrated and functional facility. We manage initial feasibility studies and concept engineering, carry through design and construction to start-up and, if desired, continuing operational maintenance. Barton Malow can schedule and install all machinery and equipment on a turnkey basis, including the delivery and unloading of equipment as well as machinery setting, leveling, piping, and wiring. We can test, de-bug, and cycle all installations to ensure that the equipment is operational. This service can also include establishing appropriate maintenance procedures, training owner maintenance personnel, and ensuring that all warranty documents, maintenance and operating manuals, and other pertinent data are turned over to the client at project completion.

Adding value through self perform services.

CIVIL / ConCrEtEexcavation, Backfill,

earth RetentionFoundations, Flooring,

Architectural ConcretePost-tension system InstallationsParking structuresResteel estimating, Detailing,

Fabrication and Installation

MEChAnICAL InStALLAtIon storage, Delivery and Unloadingsetting, Leveling, Piping

and Wiringtesting and De-Buggingturnkey InstallationPlant and Facility Maintenance and

shutdown Work



The $30 million hot Strip Mill (hSM) involves a complete modernization of the mill’s steel handling operations through increased automation and quality control. All of Barton Malow’s work on the Hot Strip Mill has been completed in cooperation with the mill’s hours of operation and periodic down time outages, making scheduling, manpower and task completion crucial for project success.

The $450M Pickle Line tandem Cold Mill (PLtCM) program will provide Severstal an expanded product capability which will include dual phase, TRIP and high-reduction interstitial free steel products in delivered widths of up to 72 inches. With this expanded product range, the Dearborn facility will increase its total output of cold rolled sheets from 1.65 million tons to 2.1 million tons per year. The new PLTCM equipment consists of a five-stand, six high mill that links pickling and rolling in one line, which is the newest and most productive cold rolling technology in the world. The project includes 320,000 square feet plus 180,000 square feet of band staging area.

The $220 million hot Dip Coating Line (hDCL) is a high-speed continuous line, capable of applying a precise coating of either zinc or zinc alloy to the surface of the steel strip. The project consists of 271,000 square feet, 19,450 cubic yards of concrete placed, and 2,300 tons of resteel fabricated and installed.

IntEGratED sErvICEs, PrEConstruCtIon throuGh CoMMIssIonInG

Severstal nA Mill Modernization programDearborn, Michigan

CLICk hErE to wAtCh A VIDEo FEAturIng thE SEVErStAL DEArBorn ProjECt tEAM.







http://www.youtube.com/watch?v=JV7rh6PzHI0


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ProgrAM hIghLIghtS135,000 Cubic Yards of Dirt Excavated

and Backfilled

6,500 tons of resteel Installed

52,000 Cubic Yards of Concrete Placed and Finished

750 Major Equipment units Moved, set and Installed

475,000 self Perform Man-hours

10-week schedule acceleration

$10 Million Cost savings through BIM



ProgrAM hIghLIghtSMultiple Delivery Methods

Design-Build, Integrated Project Delivery

BIM utilization Led to schedule and Cost savings

Self Perform Concrete, Mechanical Installation and Interiors

Flint global V6 selected as Design-Build award recipient, Design-Build Institute of america; aIa taP (technology in architectural Practice, american Institute of architects

BuILDInG CustoMEr rELatIonshIPs throuGh InnovatIvE aPProaChEs








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Barton Malow, with Ghafari Associates, designed and constructed the new 442,000 square foot global V6 Engine Facility in Flint, Michigan. The design-build team, along with the GM project team, was co-located in the Barton Malow Headquarters to expedite the design and decision-making process. More than 4,000 design and construction interferences were avoided by the use of BIM, and the facility was constructed in less than a year. Additionally, Barton Malow’s sustainable concrete solution saved tons of demolished concrete from ending up in a landfill.

general Motors transmission & Assembly programsMultiple Locations

A mere six months after breaking ground on the 1.1 million square foot San Luis Potosí Assembly Complex in San Luis Potosí, Mexico, Barton Malow began equipment installation. A commitment to Integrated Project Delivery and lean construction principles made this possible. Innovations in the process included co-locating the team at Barton Malow’s Southfield Headquarters, primary contractors joining the team early on to have input during the design process, and fly-through BIM models to identify field element collisions before fabrication and installation. Through value engineering, the team implemented an inventive and efficient design plan for repetitive steel. The team also adapted to seasonal heavy rains by using a sifonic roof conductor system.

The 750,000 square foot 6-Speed rear wheel Drive transmission Plant, located in Toledo, Ohio is North America’s most productive rear wheel drive transmission plant. The entire facility was built virtually utilizing BIM, to resolve interferences in the structure, mechanical, electrical and plumbing systems before construction. As part of the IPD approach, the design-build team co-located at Barton Malow Headquarters to expedite the design process. The schedule was also incorporated into the BIM process, providing a working 4D model for the project.



Chrysler global Engine Manufacturing AllianceDundee, Michigan

Barton Malow’s commitment to lean construction falls right in line with the lean manufacturing goals and accomplishments at Chrysler’s global Engine Manufacturing Alliance (gEMA) plants in Dundee, Michigan. In just eight weeks, Barton Malow completed the installation of the process lines for assembly, head sub assembly and piston assembly at the complex’s South Plant; bringing the 4-year dormant facility back to life. At the North Plant, upgrades to the plant and utilities are in progress to accommodate the Tiger Shark Program. This plant will remain in operation throughout construction, requiring a phased construction plan coordinating all trades on site.

FuLFILLInG a wIDE ranGE oF autoMotIvE CLIEnt nEEDs








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honda transmission Manufacturing localizationRussells Point, Ohio

honda transmission Manufacturing in Russells Point, Ohio tapped Barton Malow Company for a $35 million construction management project. The project includes an assembly/manufacturing building addition, a tank farm and new trestle, a connector building and a power house addition. The assembly/manufacturing building will house a large clean room as well as high bay spaces for an automated storage and retrieval system (ASRS).

Barton Malow was selected to meet Honda’s aggressive schedule because of the company’s track record with similar work and its detailed, phased construction plan to allow the existing facility to remain operational throughout construction.



Barton Malow is playing an instrumental role in bringing battery production (and jobs!) to Michigan. A123 Systems selected Barton Malow to build a new facility to mass-produce lithium ion batteries in Livonia, Michigan. The existing CBS/Fox building is being completely renovated to house this high tech manufacturing process as well as to showcase A123’s Michigan Headquarters. The 291,000 square foot building is the first of its kind in the United States.

Given the critical nature of dry/clean rooms in the lithium ion battery manufacturing process, Barton Malow created new protocols in the construction plan to provide environments with low dew points, low pressurization leak rates, and a minimum number of envelope penetrations. Additional specialized spaces in the facility include formation areas, aging rooms and chemical storage space. Excellent project coordination and sequencing has kept the project on schedule despite long lead times on process equipment coming from Asia and delays in code approvals.

Barton Malow’s services include:• Construction Management• Concrete• Equipment Installation• Miscellaneous and Structural Steel• BIM

A123 Systems lithium ion Battery plantLivonia, Michigan

LEaDInG EDGE In rEsEarCh, DEvELoPMEnt anD tEChnoLoGY








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robert Bosch Corporation technical CenterPlymouth Township, Michigan

Known as one of the auto industry’s great innovators, robert Bosch Corporation had high expectations for their new Technical Center. Barton Malow built the 225,000 square foot facility to house Bosch’s research, development and engineering activities including predictive safety systems and driver assistance technologies. Additionally, the new facility was built with an eye on sustainability, utilizing a closed-loop system for heat and a unique storm water management system. The environmentally responsible Technical Center was completed with zero change orders on the project and the final construction cost came in 3.5% less than the guaranteed maximum price.



As general contractor, Barton Malow is playing an important role in DTE Energy’s major clean air effort. Current work includes installing Flue Gas Desulfurization (FGD) Units 1 & 2 at the Monroe Power Plant to reduce sulfur dioxide and particulate emissions from the coal-fired plant. A previous contract with DTE included the installation of FGD Units 3 & 4 as well as the infrastructure for Units 1 & 2.

One of several Barton Malow projects utilizing a MIOSHA Partnership, the project has seen a measurable improvement in safety performance on-site, achieving a high level of overall worker safety and health.

DtE Energy flue gas desulfurization programMonroe, Michigan

soME oF our BEst work wILL nEvEr BE sEEn








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City of Detroit oakwood CSo and Control facilityDetroit, Michigan

Located in Southwest Detroit, the oakwood Combined Sewer overflow (CSo) Stormwater treatment Plant and Control Facility includes a pump station, control room, chemical facility, screen facility, basis and storm pump discharge pipe encasement, along with various supporting out-structures. Replacing an existing facility that became operational in 1940, the new plant is built to withstand a 30-year storm.

The skilled trade intensive project included 345,000 lineal feet of formwork and over 30,000 cubic yards of concrete placed and finished and was completed without a single lost-time incident.

CLICk hErE to rEAD MorE ABout thE ProjECt In CAM MAgAzine

http://issuu.com/bartonmalow/docs/oakwood_cso_cam_article



Calpine Power otay Mesa generating plantSan Diego, California

otay Mesa is a sate-of-the-art, highly efficient, environmentally responsible combined cycle power plant, fueled with natural gas and fitted with advanced air emissions control equipment. It is the largest air-cooled power plant in the state of California, conserving precious water by eliminating the need to use ground or potable municipal water to cool recirculated steam.

This project highlights Barton Malow’s commitment to environmental preservation and green building principles. Our team was not issued a single violation on this environmentally and archaeologically sensitive and highly regulated project.

Self perform construction included: civil sitework, concrete, structural steel, piping, centerline erection and combustion and steam turbine generator erection.

sELF PErForM work DrIvEs EnErGY anD EnvIronMEntaL IMProvEMEnts








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Black & Veatch/Barton Malow, a joint venture, was the design-builder of this reliant Energy Combined Cycle facility. The plant is natural gas fired with capacity rating of 839 megawatts. Special features included massive concrete columns to support a 9-foot thick pad for operation and engineered formwork to accommodate the weight of the concrete, ensuring the final finish met specifications. This project was recognized with the 2002 Governor’s Award for labor management cooperation in construction.

reliant Energy Hunterstown Combined Cycle plantHunterstown, Pennsylvania

EnErgy ConStruCtIon hIghLIghtS

national BoP / EPC Constructor

over 7,000 Megawatts of new Generation Experience

Dedicated Labor Force self Perform Civil / Earthwork, Concrete, rigging / Millwright services, Centerline Erection, Piping, heavy haul, structural Erection

Delivery Method Versatility General Contracting, Design-Build, Engineering/Procurement/Construction ( EPC)

Project type Diversity utilities, wind, Biomass, Environmental, outage, Maintenance



In July 2007, Barton Malow negotiated a design/build contract with Heritage Sustainable Energy to install (2) 2.5 MW Fuhrländer FL2500 wind turbines at the Stoney Corners Wind Farm, McBain, MI. They are the first Fuhrländer wind turbines to be erected in the United States. The location of the turbines was based on optimum wind resources and site accessibility, with consideration also given to minimizing the impact on the local farming community. Barton Malow provided civil sitework, complete foundation installation and tower / turbine erection services on the project.

Stoney Corners - Phase 1 Completion includes seven (7) REpower MM92 wind turbines. Each unit carries a capacity of 2MW and sits atop an 80-meter tower. This is the first wind project in Michigan to be erected under the state’s Renewable Portfolio Standard (RPS). The RPS legislation mandates that Michigan electric utilities provide 10% of their power from renewable resources by 2015.

The second phase of the project includes (9) MM92 REpowers on 100-meter towers, (1) 2.2 MW Northern Power prototype on a 100-meter tower, and the expansion of the existing substation to support the additional turbines.

Civil roadwork for Phase 3 of the project is now underway. This phase will include an additional 9 REpower MM92 units on 100-meter towers.

heritage Sustainable Energy Stoney Corners Wind farmMcBain, Michigan

rEvItaLIzInG LoCaL EConoMY whILE BuILDInG GrEEn








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ProgrAM hIghLIghtSSelf Perform Civil sitework, Concrete

Placement, Complete turbine Erection

Manitowoc 18000 used Exclusively by BMC for wind turbine Construction

2 Fuhrlander turbines on 100M towers

7 rEpower MM92 units on 80M towers

18 rEpower MM92 units on 100M towers

2 northern Power Direct Drive units on 100M towers

Barton Malow CoMpany • IndustrIal Group26500 american Drive • Southfield, Michigan 48034

www.bartonmalow.com


Documents

Barton Malow Industrial Construction