The Building Of Many Chimneys - General Discussion - Contractor Talk

The Building Of Many Chimneys

 
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Old 02-05-2019, 09:58 AM   #1
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The Building Of Many Chimneys


Back in June I was invited to bid on a decent sized commercial project. The client PM held a pre-bid meeting including me, a few competitors, and the EOR.

Turns out my competitors weren't very interested in the project and I was awarded the contract.

SOW for the project entails a few different things.

1. Install new electrical service. Nothing special. Single phase, 200A, underground from a pole out in the parking. Build an equipment rack, mount the meter and disco, run conduit thru grass median, thru concrete retaining wall, into basement, up thru building, onto roof, up and over roof peak to the customer equipment. There will be some other conduits needed for a remote generator plug, a 4/0 ground wire to the basement, and fiber optic cable all following the same path.

2. Provide and install an equipment platform. Platform is galvanized steel, 12x20', W12x20 main beams, heavy grating, handrails, steps. 4 support columns thru roof deck. Anchor to existing W18x40 beams below.

3. Install customer equipment. AC panel board, surge supression system, auto transfer switch, DC power plant, rectifiers, fuse panels, DC battery cabinet, fiber patch panels, router, etc. etc. There will be several conduit runs that spider off the main equipment location out to the corners of the building for remote equipment.

4. The main concern of everyone, chimney replacement. The building has 2 chimneys/ corner, 4 corners, 8 total. We need to demo 3 of them. I know they have a limestone veneer and, that's about it. Install a faux chimney. Install antennas in the faux chimney. No one knows what the chimneys are made of, what is inside of them, can we work on them during normal hours, can we bring a crane in on weekdays, etc.

5. All the other stuff which is running power and fiber out to each antenna from the equipment platform, installing lightning rods, grounding everything, installing lighting, convenience outlets, wiring all the equipment up, walk pads across the roof, and the most curious of all, demo the chimneys and rebuild them without getting water in the building. It rains a lot in western PA.
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Old 02-05-2019, 10:05 AM   #2
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Re: The Building Of Many Chimneys


Only letting me upload 3 pics @ a time.

Here's a couple more shots before starting construction. PVC flat roof with a 60 degree peak in the middle. Surrounded by 10' parapet and faux slate on the other side. I've not seen a roof like this before.
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Old 02-05-2019, 10:20 AM   #3
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Re: The Building Of Many Chimneys


Sounds like a fun and complicated project.

What's it's future use, EOC?

It almost looks like an old "insanitarium".


Why are they demo'ing the chimneys, and then building faux ones instead?
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Old 02-05-2019, 10:52 AM   #4
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Re: The Building Of Many Chimneys


Kind of an odd building. Maybe the peak down the middle is due to a triangular truss - who knows...
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Old 02-05-2019, 11:11 AM   #5
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Re: The Building Of Many Chimneys


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Originally Posted by Seven-Delta-FortyOne View Post
Sounds like a fun and complicated project.

What's it's future use, EOC?

It almost looks like an old "insanitarium".


Why are they demo'ing the chimneys, and then building faux ones instead?
The building isn't very old. 80's I'd guess.
The faux chimneys are "RF Transparent"
We will be installing cellular antennas inside each one so folks can use their phones even more than they do.

Other than the chimney work, its fairly typical for what we call a stealth project.

We've done quite a few big rooftop projects lately with concealed antennas on the roof.
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Old 02-05-2019, 11:30 AM   #6
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Re: The Building Of Many Chimneys


If they are solid masonry, it should be evident on the interior of building. Given the age, I would think it's likely they are framed with a 4-6" veneer of stone. Around here that sheet metal cap would indicate frame construction. Do you have to demo below roof level?

I wonder if the antennas are the new 5g equipment. Someones spending a bunch of money on that.
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Old 02-05-2019, 11:37 AM   #7
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Re: The Building Of Many Chimneys


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What's it's future use, EOC?
Nothing more than an office building.

Quote:
Originally Posted by hdavis View Post
Kind of an odd building. Maybe the peak down the middle is due to a triangular truss - who knows...
The peak is there so they can be fancy and vault the ceiling on the top floor.

No trusses in that area. Its all W12x35 beams cut, welded, bolted. I've attached a snip off the original roof framing design. The EOR sent that to me to prove there SHOULD be (2) W18x40 beams directly under our equipment platform. There is only one. We proved that when we opened the ceiling.

We ended up installing additional support columns thru the roof deck for our equipment platform. 4 of them landed on some flimsy bar joists. The EOR had us reinforce the bar joist under each point load.
All this had to be done in the evenings. We opened up the ceilings and did all that from underneath. Luckily, it was drop ceiling in this area. Unluckily, it was in a lawyers office. They were quite particular but so far, not problematic.
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Old 02-05-2019, 11:45 AM   #8
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Re: The Building Of Many Chimneys


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If they are solid masonry, it should be evident on the interior of building. Given the age, I would think it's likely they are framed with a 4-6" veneer of stone. Around here that sheet metal cap would indicate frame construction. Do you have to demo below roof level?

I wonder if the antennas are the new 5g equipment. Someones spending a bunch of money on that.
You are right on. My first step was establishing power.
Step 2 was digging into these chimneys and opening the ceiling so I can get measurements and buy all the steel.

The chimneys are indeed a limestone veneer, approximately 6" thick. There are some heavy beams in the roof holding it all up. The beams were reinforced with a wide top plate welded on and 2.5x2.5x3/16 angle welded from underside of flange to the web.

We have to drill a bunch of holes in existing steel to bolt on the new chimney supports. It takes a mag drill with a 4" long bit to get thru all the layers.

This is being built as a 4G site. Believe it or not, Dish TV is spending BILLIONS to try and build a 5G network. I think they will try to build it as cheap as they can and sell a POS to an existing cell carrier. I've seen pricing on the sites. Its not favorable to contractors. https://www.fiercewireless.com/5g/di...-towers-for-5g
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Old 02-05-2019, 11:57 AM   #9
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Re: The Building Of Many Chimneys


One thing that's changed since those were built is the advent of thin veneer saws. Might be worth considering going that route although I'd say your call-back risk would probably go up. Main advantage would be 1/4 of the material going up there.
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Old 02-05-2019, 01:04 PM   #10
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Re: The Building Of Many Chimneys


Never mind, I forgot about the rf signal part. What are you cladding the chimneys with?
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Old 02-05-2019, 04:16 PM   #11
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Re: The Building Of Many Chimneys


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Never mind, I forgot about the rf signal part. What are you cladding the chimneys with?
My client employs this firm to build custom enclosures for this type of situation. https://www.stealthconcealment.com/

We take field measurements. They engineer and pre-build. We install.

We are building a small steel platform inside each chimney. On top of each platform we will have a FRP structure. Cladding will be thick foam sheets with a proprietary faux coating to mimic the original stone.

We've done a few similar jobs this year. We always make it work but it's never a smooth process.

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