US EPA AWBERC Infrastructure Replacements - Project Highlight

AWBERC Infrastructure Improvements | Cincinnati, OH

PROJECT FACTS: Owner: US Environmental Protection Agency Services: Space Planning, Architecture, Engineering, Planning, Interiors

The original US EPA Andrew E. Breidenbach Recearch Center (AWBERC) building was concrete brutalist construction from the 1970s. The 10-story building is home to over 400,000 SF of governmental offices, laboratories, vivarium and common areas. Since the 1970s, the building had undergone minor renovations and retrofits, but was in need of a complete systems overhaul by the 2000s.

For more than 10 years, Elevar worked with the US EPA on the engineering and design of the infrastructure improvements at AWBERC. This multiphased, decade-long renovation project was complicated and complex.

Thoughtful phasing and prioritization of work was planned to ensure that no lab was ever without access to necessary equipment or services.

Extensive planning and programming with researchers and staff was completed early on to design for the unique needs of each laboratory.

This project entailed a state-of-the-art HVAC building infrastructure for the AWBERC building. The improvements allowed for an increase in the labto-office ratio and added flexibility / reduces redundancy to the existing system. During this project, concurrently, a majority of the annex additions (the first phase of the project, also designed by our team) were used as swing space to accommodate this major infrastructure renovation project which took place in the existing laboratory building.

The original building was renovated in five phases, but with just four waves of temporary relocation of staff and space required. With new swing space constructed, the annex buildings absorbed approximately one-fourth of the building’s population during each of the four phases. The building was segmented into quarters, with a quarter of the building renovated, and its personnel temporarily relocated to the annex, in each phase.

Work was performed with the following phasing strategy: Phase 1: North side of the east wing Phase 2: South and east side of the east wing Phase 3: West side of west wing Phase 4: Into three phases - a. lobby, auditorium, computer room and library, b. south side of west wing, c. east side of west wing

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AWBERC Infrastructure Improvements | Cincinnati, OH

Phase 5: 7th floor of vivarium (housing chickens, gerbils, mice, ducks, and fish).

These phases included the renovation of 200 labs, replacement of all 126 fume hoods with high performance low velocity fume hoods, replacement of all Air Handling Units, replacement of all supply duct work, replacement of all exhaust duct work, replacement of all exhaust fans, implementation of a new VAV supply system for offices and laboratories, installation of a new run around glycol loop from the roof to the basement for energy recovery, installation of a new process water system for heat pumps, chillers for mass specs and other sensitive research equipment, Complete overhaul of ceiling plenum space to organize wiring, gas lines, telecom, etc.

Through effective and efficient project management tactics, we minimized research shut down time and interruption to ongoing research during construction. Work included phasing analysis; complete replacement of all seven (7) air handling units from 10,000 to 90,000 cfm, supply, return and exhaust ductwork; multiple variable speed exhaust fans serving a manifolded exhaust system; laboratory exhaust and renovations of existing lab spaces over a multi-year schedule. As part of the infrastructure replacement project, all ceilings, lighting, and HVAC were removed and replaced. All units were equipped with energy recovery run around coils to reduce cooling and heating costs of high percentage outdoor air units.

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AWBERC Infrastructure Improvements | Cincinnati, OH

“During my tenture as a Director, there are two projects of great significance that must be recognized. The first being the construction of the AWBERC Annex buildings. This project’s innovative architectural and mechanical systems design resulted in the award of a LEED Gold Certification from the USGBC. The other project was the renovation of the AWBERC Lab building which was completed over several years. One of the significant challenges of this project was the need to completely seal off the construction area from the remainder of the lab facilty where research activities continued. Noise, vibration, material deliveries, debris removal, etc were closely monitored and controlled. All system shut-downs and tie-ins (i.e. mechanical, electrical, and plumbing) were performed after hours and coordinated with ongoing 24/7 research. The team’s attention to detail, understanding of the culture, working relationship with all contractors and construction oversight led to the success of this unprecedented project.”

- Richard Koch, BSME, MBA | Retired Director of the US EPA

The Elevar team started the project with several pre-design and planning meetings in both Washington, DC and Cincinnati, OH. Phase One (annex addition) took a year to design and another year to construct. While Phase One was in construction, we were busy working on designing Phase Two (infrastructure replacements) and overseeing the construction of Phase One. During longer construction periods, our team also worked with the EPA to replace a 600 ton chiller and perform an perform an in-depth boiler study.

Through implementation of the above items, the EPA was able to achieve a 45% reduction in energy overall. The above completed scope items allowed the EPA to achieve success and fulfill all of its aforementioned project drivers. The newly renovated facility had a 45% energy reduction, sophisticated laboratory space and became a safer, more desirable place to work.

As a result, the facility is now a state-of-the-art, flexible and energy efficient building providing the foundation for 21st century research. There has been reduced maintenance resulting from the new systems, improvement in AWBERC environmental conditions, and increased lab and fume hood utilization.

Throughout the delivery process neither our team nor the Lead Contractor ever missed a date of significant completion. Early on programming meetings with maintenance personnel, onsite staff, laboratory researchers, and administrators were held weekly. In these meetings the design staff collected and recorded vital information regarding the procedures and needs of each department. Toward the end of the design phase these meetings evolved into verification sessions in which the designs were examined and tested by the users.

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