Introduction
Northwell Health’s South Shore Hospital in Bay Shore, NY is undergoing a significant expansion with a new six-story addition. This expansion is designed to house state-of-the-art private inpatient rooms and advanced operating rooms, enhancing the hospital’s capacity and service quality.
Donnelly Mechanical was awarded the contract to manage both the modular plant and the core and shell portions of this ambitious project. Collaborating closely with Systecon, Donnelly’s sister-company, a leading modular utility solutions company, Donnelly will ensure the seamless integration and functionality of the central utility plant (CUP) for the new pavilion.
Scope Review
The project encompasses a comprehensive scope of work, focusing on the modular plant and the core and shell construction of the new pavilion. Key elements of the installation include:
- Modular Plant – A critical component involving the procurement and manufacture of the central utility plant (CUP) by Systecon. This includes the installation of essential HVAC systems tailored to meet the hospital’s high standards for climate control and air quality.
The prefabricated central utility plant (CUP), which will be assembled in Ohio, broken down into 19 sections, and shipped to New York for installation. The CUP includes four (4) 6000 MBTU duel fuel boilers, three (3) 500 Ton chillers, heat exchangers, emergency electrical and normal electrical rooms, 5 Marley cooling towers and a fuel oil system to ensure reliable climate control and energy efficiency for the hospital.
- Core and Shell – Donnelly is providing the infrastructure required to facilitate the heartbeat of the new pavilion, including the installation of a fuel oil header, chilled water, hot water, and glycol pumps. The team is also installing roof-mounted fans, unit heaters, and a Mitsubishi VRF system.
- Base Building Modular Air Handling Units – Donnelly is installing five custom-built rooftop AHUs designed to provide optimal airflow and efficiency. These Temtrol AHUs feature fan wall systems with air tunnels, conjoining the units into one massive system with extremely tight tolerances—with only 8 inches between units and bases only 1 inch apart. Each unit measures 43 feet in length, 24 feet in width, and 20 feet in height, with a total weight ranging from 85,000 to 120,000 lbs
- Fuel Oil & Generator System – Below-grade fuel oil piping and pumps are being installed to supply fuel to the boilers within the rooftop central utility plant, as well as three rooftop generators that will provide emergency backup power.
- Piping & Duct Risers – Donnelly is installing riser piping and duct risers spanning six (6) floors, with take-offs on each floor to allow the fit-out contractor to connect to the system as the hospital expands.
- Structural Engineering & Rigging – This project includes the largest rigging operation in Donnelly’s history, utilizing the biggest mobile hydraulic crane in NYC. Donnelly custom-built the AHUs to accommodate future engineering modifications and coordinated the steel dunnage that supports the rooftop units. The team engineered crane drawings to lift 120,000 lbs for the AHUs plus welded dunnage bases, pushing the crane’s capacity to 98%.
- Wind Load Structural Design – Donnelly collaborated with external engineers to develop structural steel supports capable of carrying the load of the rooftop ductwork while withstanding wind loads of up to 140 mph.
- Future-Proofing the Structure – The central utility plant will be rigged into place with 12-foot structural steel columns penetrating the plant in five locations. These columns will later serve as the base for future building expansions, allowing for additional floors to be added to the structure.
The installation and integration of these systems are critical to maintaining optimal conditions for both patients and medical staff, emphasizing the importance of precise and efficient HVAC solutions in healthcare environments.
Donnelly's Response
Donnelly Mechanical has been involved in every aspect of the engineering, design, and execution of this complex healthcare infrastructure project. The team worked closely with outside engineers to develop solutions that accommodate the intricate layout of the mechanical systems, ensuring seamless integration with the hospital’s expanding needs.
The prefabricated central utility plant, manufactured by Systecon, was strategically designed to streamline the installation process. Once shipped to New York, Donnelly will oversee the rigging and precise placement of each section, followed by the interconnection of all MEP’s between the sections ensuring structural integrity and alignment with the hospital’s operational requirements.
For the rooftop AHUs, Donnelly engineered a highly complex rigging plan, utilizing the largest mobile hydraulic crane in NYC. The team designed and coordinated the steel dunnage to provide secure support for the AHUs and developed a custom-built design that allows for future modifications. The steel structural framework supporting the rooftop ductwork was engineered to withstand extreme wind loads while optimizing space for duct routing.
The fuel oil system, which provides fuel for the boilers and rooftop generators, was carefully designed and installed to ensure long-term reliability. Riser piping and duct risers spanning six floors were strategically placed to allow for future connections, reducing the need for major structural modifications as the hospital expands.
Through meticulous planning, innovative engineering, and flawless execution, Donnelly Mechanical is delivering a world-class mechanical system that not only supports the hospital’s current operations but also ensures scalability for future growth. This project stands as a testament to Donnelly’s expertise in executing complex, large-scale healthcare projects and reinforces their reputation as an industry leader in HVAC solutions.
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