Struc’tur’al Headquarters Renovation and Power Systems Study

BKM provided MEP design services for this 80,000-square-foot renovation serving as the Struc’tur’al headquarters facility located in Columbia, Maryland. Struc’tur’al, a Structural Group company, is the largest specialty concrete repair contractor in the United States and is in the top 100 of Engineering News-Record (ENR) magazine’s list of Specialty Contractors.

The facility was designed to provide the owner with various needs, including an office region with a courtyard, warehouse/production spaces, and concrete materials R&D laboratories. The spaces have an industrial concrete and rebar décor throughout to embody the firm’s identity and highlight the concrete products they develop.

Because the original facility was aging and had water damage, the design team was responsible for initially abating hazardous materials, addressing HVAC infrastructure, and installing a new roof. The mechanical design new rooftop units with gas-fired heating and DX cooling utilizing a ducted VAV system with electric re-heat for the office area. In addition, new exhaust fans were provided for lab exhaust toilet rooms and breakrooms. Gas-fire unit heaters were also provided in the warehouse. Steam humidifiers required special design considerations for the IT room.

The plumbing design incorporated the redistribution of sprinkler heads in the office, domestic water, sanitary and vent piping distribution for new core toilet rooms, shower rooms, and pantry. Natural gas distribution was provided to gas-fired unit heaters located in the warehouse and six (6) rooftop AHUs with gas-fired heating. A clean agent fire suppression system (FM200) was provided for the client’s data center.

Electrical design work included an existing electrical service & switchboard analysis, existing propane generator load analysis, power riser design, new power distribution, lighting design & controls, branch circuit & wiring device design, a new fire alarm system, laboratory fit-out, and mechanical equipment connections.

A power system study was completed including fault current, coordination, and arc flash analysis. Over 70 buses were analyzed including two separate electrical services and 4 MW of power. BKM worked with DEL Electric in a design/build style effort for the study. During analysis, the gear submittal package was streamlined. The study was integrated into the electrical design for one cohesive Power System Infrastructure Product, requiring extensive research for Legacy Switchgear on-site. BKM teamed with SKM to develop new library data for Legacy Westinghouse Switchgear used on site. Special challenges included legacy Westinghouse switchboards with unavailable replacement circuit breakers.