Merit Brass Co., an MCAA member and a family-owned manufacturer of pipe nipples and master distributor of related pipe, valves, flanges and fittings, has been named the 2025 inductee into the prestigious PVF Ring of Honor. The announcement is featured in the December issue of Supply House Times magazine.
Established to celebrate PVF manufacturers and master distributors that demonstrate recent marketplace success through progressive and cutting-edge best practices, the PVF Ring of Honor recognizes organizations that combine operational excellence with forward-thinking innovation while maintaining the highest standards of integrity and customer partnership.
For nearly nine decades, Merit Brass has exemplified these qualities. Founded in 1937 by Louis Schlessinger and now led by third-generation co-CEOs Marc Schlessinger and Alan Lipp, the company has evolved from a Cleveland-based manufacturer of brass pipe nipples into one of North America’s leading manufacturers and master distributors of stainless steel, brass, copper, and carbon steel PVF products.
“Being selected for the PVF Ring of Honor is a tremendous honor that belongs to every associate, past and present, who has lived our values every day,” said Alan Lipp, CEO of Merit Brass. “My grandfather built this company on the simple belief that people come before profit. Nearly 90 years later, that foundation—combined with relentless modernization and an unwavering commitment to our wholesale partners—continues to define who we are.”
Key achievements highlighted in the Supply House Times feature include:
A multi-year enterprise-wide lean transformation that has driven on-time shipping to nearly 99%, manufacturing fill rates to 98%, and dramatically improved throughput and order-processing speed.
Strategic expansion into press technology (carbon, copper, & stainless) known as MeritPressTM and copper tubing, positioning Merit Brass as a complete portfolio provider amid shifting contractor preferences and labor dynamics.
Sustained investment in global supply-chain expertise and long-term supplier partnerships that provide wholesalers with clarity and stability in an era of tariffs, freight volatility, and geopolitical complexity.
Preservation of an extraordinary family-oriented culture that boasts associates with 30-, 40-, and even 45-year tenures working alongside new talent.
“Merit Brass has never chased trends for the sake of change,” added Darren Hilliard, President of Merit Brass. “Every investment, every process improvement, every new product line has been guided by one question: Does this help our wholesale customers win in their markets? The results speak for themselves, but the real reward is the trust and partnership we’ve earned across generations of distributors.”
Read the full profile in Supply House Times to learn more about how family values, operational excellence, and global vision have guided the company for nearly nine decades.
Arden Engineering Constructors used the Belimo Energy Valve™ to reduce chilled water demand in existing buildings so that Providence College would have sufficient capacity to accommodate new developments on its lower campus. As a result, the college avoided buying a new chiller and the extensive excavation to replace existing chiller lines—all while increasing energy efficiency.
Growing Pains
Founded in 1917, Providence College sits on an illustrious 105-acre campus in the heart of Providence, R.I. Since its inception, the campus has evolved and expanded to meet the needs of its enrolled base, which has grown to more than 4,000 students. For example, the college’s Campus Transformation initiative seeks to create a more unified, sustainable, functional campus. As part of that transformation, in 2013, the college purchased Huxley Avenue from the city so that the campus would no longer be bisected by a busy street, offering enhanced freedom of movement for both pedestrians and drivers.
Running beneath one of the recently renovated sections of the school, 12” chilled water lines provide cooling to several buildings on the lower campus. With additional buildings set to come online in the next two years, these lines and the central chiller plant are inching closer to full capacity.
One solution discussed by Providence College and Arden, its main mechanical and controls contractor, involved adding more capacity with the installation of a new chiller. However, this approach would require increasing the size of the chilled water line to handle the higher flows. An alternative was to reduce chilled water demand in existing buildings.
A Simpler Solution
Reducing demand for chilled water on the lower campus would effectively create spare capacity in the chiller plant and reduce water flow through the main line. In doing so, Providence College could forgo the installation of a fourth chiller (the plant already had three 1,000-ton chillers running in parallel). Moreover, the main line would not have to be excavated and replaced, which would have been a significant undertaking.
With around 20 Energy Valves already installed on campus, Arden and Providence College had an established relationship with Belimo and were familiar with the company’s range of products.
“Our plan was to essentially pick off the sections of the lower campus where the demand for chilled water was highest,” said Paul Carter, general manager at Arden’s sister company, Earthwise Energy Technologies, the controls contractor on the job. “Some of the technology in these buildings was very outdated and due for an upgrade. Having seen the advanced capabilities of the Energy Valve first-hand, we were confident it would be able to generate the flow savings we were looking for.”
The Energy Valve is a web-enabled, pressure-independent valve that measures and manages coil energy by using an embedded ultrasonic flow meter, along with supply and return water temperature sensors. With built-in power control and Belimo Delta T Manager logic, the Energy Valve monitors coil performance and optimizes available energy by maintaining delta T.
A key advantage of the Energy Valve is that the delta T setpoint can be matched to the design delta T of the coil. As the temperature sensors start to realize a lower differential temperature across the coil, the valve begins to close and the flow decreases, allowing for more efficient heat exchange and elimination of overflow. When delta T begins to stabilize, the valve increases flow back through the coil, thus maintaining optimal heat transfer.
The Energy Valve comes equipped with a suite of cloud-based services that can be used to benchmark coil performance, analyze glycol concentration, store energy data, send alerts, and commission for optimal performance. In addition to the standard analog signal and feedback wiring, the Energy Valve communicates its data to the building management system via building automation and control network (BACnet) master-slave/token passing (MS/TP) protocol or internet protocol (IP) as well as Modbus remote terminal unit (RTU) and Modbus transmission control protocol/internet protocol (TCP/IP). The built-in web server collects up to 13 months of data that can be downloaded to external tools for further optimization.
After careful evaluation, the decision was made to install 22 additional Energy Valves across the lower campus—with sizes ranging from ¾” to 2½”.
Significant Savings Anticipated
The retrofit project was completed in spring 2023, and now Arden and Providence College plan to begin collecting data to quantify the actual flow reductions. The reduction in pumping will lead to decreased electricity usage, which is in line with the college’s commitment to increase energy efficiency and improve environmental, social, and governance performance.
By allowing their cooling needs to be met with the existing chiller plant configuration, the school saved the cost of buying and installing a new chiller, amounting to an estimated $500,000-$1,000,000 in savings. This figure excludes the millions of additional funds and months of work that would have been needed to resize and replace the existing main chilled water line.
“While the construction of new buildings in the coming years may ultimately necessitate the installation of a new chiller, the Energy Valve will allow us to push that project further into the future and significantly increase the efficiency of the existing system,” said Matt Basile, lead design engineer for Arden.
Basile continued, “Every Energy Valve we install gets a data connection to the cloud and to the campus central building management system. This provides us with visibility down to the individual air handlers, which is crucial for troubleshooting and identifying further opportunities for efficiency gains as we move forward with future capital improvement projects. It is now standard practice to flat spec the Energy Valve for any chilled water device over 10 gallons.”
Successful Track Record
The Energy Valve retrofit is one of several instances over the past three years in which Belimo, Arden, and Providence College have worked collaboratively to conserve water usage and drive energy efficiency.
“Belimo has a long-standing relationship with both Arden and Providence College and is proud to once again be part of a project that will help the college achieve its goal of creating a more efficient and sustainable campus,” said P.J. Qvarnstrom, RetroFIT+ business manager at Belimo. “We are eager to see the results of this Energy Valve retrofit and look forward to supplying cutting-edge technologies for future projects.”
In addition to the lower campus chilled water line, two other main lines come from the central chiller plant and provide cooling to separate sections of the Providence College campus. With additional buildings planned for these sections, the lower campus retrofit will serve as a demonstration project and may potentially pave the way for additional Energy Valve installations in the coming years.
“Belimo’s track record of providing superior products and service has fortified our professional relationship and made them a preferred supplier to the college,” added Steve Basile, supervisor of engineering at Providence College. “We look forward to leveraging innovative products like the Energy Valve in the future as we drive to continuously improve the efficiency of our facilities across campus.”
In today’s data-driven world, data centers have become the new industrial backbone, powering everything from artificial intelligence (AI) and autonomous vehicles to streaming and cloud services. Behind the humming racks of servers, though, is an equally complex mechanical infrastructure working nonstop to manage heat. As rack power densities rise from 15 kilowatts to 100 kilowatts and beyond, contractors are confronting a challenge once reserved for power plants and refineries: removing vast amounts of heat efficiently and safely.
For mechanical contractors, this transformation means opportunity—but also pressure. Projects are larger, timelines are tighter, and the margin for error is smaller. Long trusted in hydronic systems, NIBCO is now emerging as a pivotal partner in the liquid cooling revolution that is reshaping modern data centers. NIBCO INC. is a benefactor of MCAA26.
The Shift From Air to Liquid
Traditional air-cooling systems can no longer keep up with the thermal loads of advanced AI processors and graphics processing unit clusters. To maintain performance and energy efficiency, data centers are increasingly turning to hydronic and direct liquid cooling (DLC) systems.
In these configurations, chilled water or specially formulated fluids circulate through a network of pipes, valves, and control devices, removing heat directly from racks and transferring it to chillers or heat exchangers. Whether this heat removal is achieved through cooling coils, coolant distribution units, or direct-to-chip systems, the integrity of every connection in the fluid loop determines reliability.
NIBCO provides valves, fittings, strainers, and actuators that are critical system components within the circulatory system of these liquid-cooled facilities. They are engineered for precision, longevity, and compatibility with specialized fluids such as propylene glycol and deionized water.
The Next Generation of Cooling
The transition to DLC is not a short-term trend; it is the new foundation of data center thermal management. As processors grow more powerful and energy efficiency becomes a central sustainability metric, DLC and hybrid cooling architectures will dominate new construction.
NIBCO is already prepared for this future. Its valves and fittings are engineered to handle the specific demands of direct-to-chip and two-phase cooling systems. Material compatibility, pressure stability, and sealing performance are critical. NIBCO is well positioned to support these types of installations thanks to their experience in hydronic systems.
Everything Under One Roof
NIBCO offers contractors a complete, integrated hydronic solution. From butterfly and ball valves to balancing and check valves, strainers, air separators, and actuators, every component is designed to work together seamlessly across the cooling loop.
For contractors, this one-stop approach minimizes coordination complexity. All key valves, fittings, and accessories are available from a single manufacturer, simplifying submittals, ensuring compatibility, and consolidating warranties. With domestic manufacturing centers across the United States—including their Butterfly Valve Center of Excellence in Blytheville, Ark., copper foundry in Stuarts Draft, Va., and bronze foundry in Nacogdoches, Texas—NIBCO also guarantees supply security for critical timelines.
With hyperscale data centers under tight delivery windows, delays in material availability can derail entire project phases. NIBCO’s domestic footprint and consistent product availability give contractors confidence that schedules will stay on track.
Reliable, Compatible Products
In hydronic and DLC applications, where fluids run continuously under high pressure, the margin for tolerance is razor thin. NIBCO’s ball and butterfly valves feature corrosion-resistant alloys, high-pressure ratings, and tightsealing designs for long service life. NIBCO’s 585HP ball valve, for example, is rated up to 1,000 psi and backed by a 10-year warranty.
NIBCO’s valves and fittings are built from leadfree copper alloys and low-carbon stainless steel, selected for corrosion resistance and compatibility with glycol-based or deionized cooling fluids. The company excludes the use of materials prone to dezincification or stress corrosion cracking, such as brass with over 15 percent zinc or untreated steel, ensuring durability even under demanding chemical conditions.
A Partner in Performance
NIBCO’s installation-friendly designs help contractors work quickly and efficiently to meet the demands of large-scale data center projects. Consistency across product lines makes prefabrication easier, as contractors can assemble valve stations and pump modules offsite, knowing that connection points will align precisely. Options for press, brazed, or welded joints allow crews to select the best method for their workflow and safety requirements.
Onsite, NIBCO’s regional technical representatives and commercial sales and specification teams provide training, field support, and troubleshooting. That means fewer callbacks, less rework, and more predictable installation timelines. When system adjustments are needed in the field, NIBCO’s representatives are available for onsite consultation, ensuring the installation meets the design intent and operates as expected. NIBCO’s dedicated commercial sales manager team bridges the gap between specification and execution, providing CAD and BIM resources that integrate directly into contractors’ systems.
Mechanical contractors today are at the center of one of the most vital shifts in modern construction, helping build the infrastructure that powers the digital world. Success depends not only on skill and speed but also on the reliability of every component behind the walls and under the floors.
For more information, visit www.nibco.com. MCAA thanks NIBCO INC. for increasing their annual support by becoming a benefactor of MCAA26 and sponsoring the Sunday Pickleball Tournament and convention app.
In commercial plumbing and mechanical systems, material selection is far more than a matter of preference or budget—it directly impacts system performance, longevity, and reliability. Standards offer a framework, but truly effective practice requires that you match the materials to the specific demands of the application.
This article compares the primary materials used for two of the most commonly used valve types—ball and butterfly. NIBCO INC. believes that better understanding these materials can help you specify the right component for the right application, every time.
Understanding Valve Function and Design
A ball valve is a quarter-turn valve used for controlling the flow of liquids or gases in a piping system. “Quarter turn” means the valve handle turns 90 degrees from fully open to fully closed. Usually, a ball valve is bidirectional for flow and omnidirectional for installation, meaning installation is relatively straightforward regardless of orientation within the system. Ball valves can provide a bubble-tight seal. Their compact profile makes them much easier to fit into a system than a gate valve or a globe valve, and the quarter-turn operation makes them faster to operate than a multi-turn valve. Ball valves are a mainstay for isolation service and are more easily automated than gate or globe valves.
A butterfly valve, also a quarter-turn valve, features a disc mounted on a rotating shaft, which turns to open or close flow. Butterfly valves are commonly used where space is limited and affordability is a concern. In most cases, a butterfly valve is bidirectional for flow and omnidirectional for installation. Because of the slim disc profile, a butterfly valve is a suitable substitute for a globe valve for throttling applications, while generating less of a pressure drop. Butterfly valves are also easily automated compared with multi-turn valves.
Bronze vs. Brass: Choosing the Right Alloy
Bronze, brass, and lead-free brasses and bronzes are the primary alloys used in commercial plumbing and mechanical systems. Industry standards, such as the Manufacturers Standardization Society (MSS) SP-110 standard, often do not clearly differentiate between the types of copper alloys used. As a result, terms like “bronze” and “brass” are frequently used interchangeably, despite their differences. Each material has its own set of pros and cons to consider.
Bronze is traditionally a copper alloyed primarily with tin. Because bronze valves are typically produced via casting, they are heavier with thicker walls than forged valves, which contributes to their strength and longevity. They are highly corrosion-resistant, durable, and ideal for demanding applications. However, bronze valves tend to be more expensive and more difficult to machine.
Brass, by contrast, is a copper alloyed primarily with zinc and is often forged. Brass valves are easy to machine, aesthetically pleasing, affordable, and widely available. Forged alloy products may be generally lighter due to thinner wall structures, which can result in a shorter lifespan.
Brass is susceptible to dezincification, in which zinc selectively leaches out, making the brass porous and weak. Factors such as zinc content, water chemistry, and environmental conditions all affect dezincification. Alloys with more than 15 percent zinc are generally at higher risk, unless they contain additives to prevent dezincification.
Application Considerations for Ball Valves
Ball valves are widely used for their quick operation, easy installation, and bubble-tight sealing. Installation is relatively straightforward regardless of orientation within the system. This NIBCO valve is shown open and in service on a potable water system.
When choosing the material for ball valves, consider these factors:
The media being conveyed (e.g., potable water, chemicals)
Water chemistry, including pH, chlorides and total dissolved solids
Installation environment, such as buried service or exposure to temperature fluctuations
System criticality, including whether the application is mission-critical
Cast copper alloys of higher tin content are recommended for high-end, commercial, or mission-critical projects and for systems with harsh media, aggressive water chemistry, or exposure to corrosive environments. Copper alloy of higher zinc content and forged alloys are perfectly acceptable for less-demanding residential systems where cost is a concern and the risk of corrosion is minimal.
Butterfly Valves: Cast Iron vs. Ductile Iron
Butterfly valves are made of cast iron or ductile iron, both of which fall under the MSS SP-67 standard for general-purpose valves. As with ball valves, each material has its own set of pros and cons.
Cast iron is known for its strength and vibration resistance. Composed mainly of iron, it also contains 2–4 percent carbon and small amounts of silicon. Cast iron costs less than ductile iron and is relatively easy to manufacture. However, it is extremely rigid, and virtually any bending will cause it to crack or break.
Ductile iron is similar in composition to cast iron but includes magnesium, which gives it superior impact resistance, tensile strength, and flexibility, so it is less likely to break or crack than cast iron. It also performs better in high-temperature environments and is more resistant to corrosion. However, ductile iron is more expensive than cast iron.
Application Considerations for Butterfly Valves
For most commercial applications where valves are properly installed between flanges and are not exposed to excessive stress or corrosive environments, cast iron is often sufficient and cost-effective. In systems that involve high pressure, frequent cycling, or severe conditions, ductile iron is a superior choice because it can better handle stress and resist cracking under load.
Best Practices
In an industry where failure can be costly or catastrophic, precision in material selection is critical. Look beyond minimum standards and generic material categories to fully understand the alloys you are working with and how they will perform under specific conditions. Consider the operating environment, installation method, and system criticality. This additional scrutiny helps ensure long-term system performance and minimizes the risk of premature failure, saving time, cost, and reputational damage down the road.
Aaron Kilburg, commercial sales manager at NIBCO, contributed the content for this story. For more information, visit www.nibco.com. For additional guidance on specific applications, contact CS-TechnicalServices@ nibco.com.
NIBCO INC. unveiled the Rex Martin NIBCO Interactive Museum on November 12, 2024, coinciding with NIBCO’s 120th anniversary. The museum offers a unique and enriching experience from a historical perspective, interactive learning, inspiration, community impact, and career opportunities. Not just a place to learn about the past, it’s a place to get excited about the future of plumbing and the opportunities it holds. NIBCO INC. is a major sponsor of MCAA25.
The museum is located in Elkhart, IN, where Casper Schweitzer founded Northern Indiana Brass Foundry Works in 1904. The 8,845-square-foot building was completely renovated beginning in 2023. The museum portion of the space is 3,254 square feet, and additional space in the building will be used as a training area for customers, distributors, and NIBCO associates.
A Tribute to NIBCO’s Contributions
Guests are welcomed into the museum by a 14”-copper-fitting water fountain that pumps 50 gallons through its reservoir, along with an interactive hologram feature. A “Plumbing Discovery House” uncovers the intricate systems behind the walls that keep homes running smoothly.
“Our decision to build the NIBCO Interactive Museum and name it after my father is a tribute to his remarkable contributions to the plumbing industry and a continuation of a legacy that began with my great-great-grandfather in 1904,” said NIBCO’s president and CEO, Ashley Martin. “This ambitious project was something I wanted to complete and dedicate on NIBCO’s 120th anniversary to make it extra special. The museum is not just about preserving our history; it’s about showcasing the profound impact we’ve had on the evolution of plumbing and our philanthropic efforts within the community.”
Manufacturing displays with interactive features allow visitors to learn more about manufacturing processes and how products operate. An interactive educational kiosk features NIBCO locations, puzzles, and entertaining games, and a theater area provides seating for visitors to learn more via video programs.
“By making the museum interactive, we aim to create an engaging, hands-on experience that appeals to all ages, especially students. We want to make learning about plumbing, its importance, and the career opportunities it offers both fun and inspiring,” added Martin.
Celebrating 120 Years
Since 1904, five generations of family leadership have driven NIBCO to flourish as a leading manufacturer of flow control products. Even through the toughest times, NIBCO has survived and thrived, a testament to the fact that it consistently provides the best quality products and employs the very best people. In addition, NIBCO adheres to its core values: safety, integrity, teamwork, continuous improvement, and philanthropy. These values have helped shape and promote NIBCO’s culture to what it is today.
From starting out as a company manufacturing parts for musical instruments to becoming a household name in valves, fittings, and flow control products, the NIBCO brand has much to celebrate—today and looking forward to the next 120 years.
“This museum honors NIBCO’s five generations of family-owned leadership dedicated to one of humanity’s most essential innovations—plumbing and the ingenuity, resilience, and creativity that has brought clean water and sanitation throughout the world,” added Martin.
For more information, visit www.nibco.com/museum. To schedule a visit or request a private tour, please contact museum@nibco.com. MCAA thanks NIBCO INC. for being a major sponsor of MCAA25, sponsoring the 4th Annual Pickleball Tournament & Convention app.
Recognizing the need for skilled professionals equipped with knowledge and practical experience, NIBCO, a leading provider of flow control products, has partnered with Chicago Pipefitter’s Local 597 Union to enhance its training programs. This collaboration aims to elevate the level of training and ensure that apprentices are well prepared for the field.
Local 597’s Training Approach
Local 597’s apprenticeship program is a comprehensive five-year course designed to produce highly skilled pipefitters, welders, and HVAC service technicians. With 1,200 apprentices currently enrolled, it is one of the largest programs in the country, with a rigorous curriculum split between classroom instruction and hands-on training. The first three years involve block training, where apprentices spend three months in intensive training before heading into the field for nine months. In their fourth and fifth years, apprentices attend night classes while gaining field experience during the day.
Local 597 Training Director Joe Bonato oversees the main facility located in Mokena, IL, another in Palatine, IL, and a satellite school in Crown Point, IN. Bonato is a firm believer in the importance of exposing apprentices to industry specialists to supplement their learning. NIBCO’s involvement has made a significant impact.
NIBCO’s Role
NIBCO approached Local 597 with a proposition to support the training center by sharing expertise, particularly in copper development and valve technology. Since fall 2023, NIBCO has been providing lectures and hands-on training sessions.
“Our 597 instructors are fantastic and possess great experience from being in the field, but it is a huge benefit to bring in industry specialists [who] can take us to the next level,” explained Bonato.
Kyle Coleman, Local 597 training instructor, highlighted the value of this collaboration. “NIBCO expands on what we can offer in-house. They provide insights into the purpose and function of various valves, which is crucial for our apprentices,” he said.
NIBCO’s Aaron Kilburg, commercial sales manager, and Sean Kelly, area sales manager, bring a wealth of knowledge and practical experience from years of experience at NIBCO to the training sessions. Their approach is twofold—a combination of classroom lectures and hands-on training. The first day focuses on lead-free soldering with valves, where apprentices receive one-on-one instruction and feedback. The second day delves deep into valve best practices, providing apprentices with the tools to make better selections and troubleshoot issues in the field. Apprentices also learn about the vast array of commercial and industrial valves available today.
The Impact of Hands-On Training
Through the NIBCO-Local 597 collaboration, the apprentices gain practical experience. During hands-on sessions, they practice soldering large diameters and working with larger valves, which they might not encounter frequently in the field and are also cost-prohibitive to practice on during normal training.
“The opportunity to solder a 2” ball valve is rare. This training experience is crucial, as it helps apprentices understand the intricacies of working with different materials and techniques,” explained Kelly.
Bonato acknowledged the significant impact of the partnership. “NIBCO has been top-notch in their approach. They are hands-on, engaging, and committed to helping
us produce the best journey workers possible. Their involvement ensures that our apprentices receive the highest quality training,” he noted.
Building Skills, Building Relationships
The hands-on training provided by NIBCO is invaluable for apprentices. “Apprentices get the opportunity to practice soldering larger-size pipes and working with large valves in a controlled environment. This not only builds their confidence but also ensures they are well prepared for real-world applications,” explained Coleman. The feedback from apprentices has been overwhelmingly positive.
NIBCO’s involvement goes beyond mere instruction; the focus is on building relationships with the apprentices. Kilburg explained, “We aim to create an environment where apprentices feel comfortable reaching out to us for additional training or resources. It’s about fostering a sense of camaraderie and support.”
“I think it is genius of a company like NIBCO to invest the time to come here,” said Bonato. “They are meeting and building relationships with the next generation of leaders— the industry supervisors, project managers, general foremen, and potential owners.”
NIBCO has conducted similar training sessions at various union locations in the Midwest, including Local 75 in Wisconsin, Local 166 in Indiana, and Local 130 in Illinois. This widespread involvement underscores NIBCO’s commitment to enhancing the skills of the next generation of professionals in the industry. The training sessions are continually refined based on feedback from apprentices and instructors.
“Every training session is a learning experience for us as well.” Kilburg commented. “We pick up new techniques and insights from the apprentices and instructors, which helps us improve our training methods.”
Looking Ahead
By combining classroom instruction with practical, hands-on experience, the partnership between NIBCO and Local 597 provides apprentices with a comprehensive learning experience that prepares them for the challenges of the field. As the collaboration continues, both NIBCO and Local 597 are committed to refining and expanding their training programs and are dedicated to ensuring that apprentices not only acquire the necessary skills but also develop the confidence and knowledge to excel in their careers.
The NIBCO-Local 597 partnership represents a model for successful industry collaboration. By leveraging the expertise of industry specialists and providing practical training opportunities, this initiative is setting a new standard for apprenticeship programs. As Bonato put it, “It’s about bettering the brand and ensuring that our apprentices represent the best in the industry. With NIBCO’s support, we are well on our way to achieving that goal.”
Kilburg added, “As appreciative as Local 597 is for the training we are providing, NIBCO is appreciative of the relationships we are developing.”
This collaboration not only benefits the apprentices but also strengthens the industry as a whole. NIBCO and Local 597 are demonstrating that with the right support and training, the next generation of mechanical contracting professionals will be well equipped to meet the demands of the industry.
For more information, visit www.nibco.com. To learn more about training, contact Aaron Kilburg, NIBCO commercial sales manager, at kilburga@nibco.com.
A coal-burning power plant in Gallatin, TN, chose Apollo® Valves from Aalberts integrated piping systems for a vital environmental upgrade. Apollo Valves products were selected for their reliability, durability, and precision—crucial characteristics in managing the slurry of limestone that neutralizes sulfur dioxide in flue gasses.
The project involved the installation of scrubber technology. Scrubbers are essential for cleaning gasses emitted from smokestacks. They play a pivotal role in reducing air pollution and curbing the formation of acid rain, which aligns with national efforts to meet stringent Clean Air Act regulations.
Specifically, the project used 1½” through 4” 87A-90X-24, 300 class full port stainless flanged Apollo Valves. These valves are equipped with AS spring return pneumatic actuators.
Approximately 130 Apollo actuated valves were integrated into the scrubber system. The successful implementation of these valves not only ensured operational efficiency but also enhanced environmental compliance, significantly reducing sulfur emissions from the plant.
This scrubber project is a testament to how Aalberts integrated piping systems and its Apollo Valves brand support the power industry’s transition to more sustainable operations. It exemplifies how industrial applications can achieve environmental goals through technological innovation.
Holmberg Mechanical knew Anvil International’s Gruvlok® products would help them meet the quick turnaround time required for the new Colman Dock in Seattle, WA, which will service the largest ferry system in North America. But the job posed another challenge. Because the dock is a publicly funded project (with a price tag of $455 million), Holmberg Mechanical had to comply with Buy America Act (BAA) standards. They needed to secure the right materials on time and with the proper BAA certification.
Anvil’s Gruvlok products met both criteria. Holmberg installed hundreds of Gruvlok fittings and couplings for the first hydrostatic test, which involved more than 1,000 linear feet of 6″ piping. The test was successful, and all Gruvlok products performed perfectly. Randy Hart of Holmberg Mechanical, who has been in the industry nearly 30 years, commented that Gruvlok technology “is a foolproof design that reduces labor when compared to welding.” Anvil International provided Holmberg all the required documentation to comply with BAA standards. Anvil is an MCAA major sponsor.
The combination of Gruvlok technology, excellent communication, and the ability to deliver all materials and documentation in a timely manner made the project a success for Holmberg Mechanical and Anvil International. This five-year project is expected to be complete in 2023.
For more information, visit www.anvilintl.com. MCAA thanks Anvil International for being an MCAA major sponsor.
By using high-density polyethylene (HDPE) pipe rather than carbon steel and pairing it with Victaulic’s HDPE pipe joining system, Shoemaker Mechanical replaced a cooling tower in less time than planned, with fewer people than expected, and avoided potential weather delays. Tulsa Community College’s (TCC’s) system has performed with no issues since it was installed. Victaulic is an MCAA major sponsor.
Attractive Alternative
Ranked in the top four percent of community colleges in the United States, TCC has more than 25,000 students attending four locations spread across the city of Tulsa, OK. Recently, an academic building on the college’s Metro campus, located downtown, needed a new cooling tower to provide water to its HVAC system.
TCC initially favored carbon steel for the tower’s piping system, but after consulting with Shoemaker Mechanical, the contractor responsible for the cooling tower and related mechanical room installation project, as well as considering various other factors, the college agreed to explore alternative pipe materials that could streamline installation without sacrificing performance.
The budget and the timeline for the cooling tower project were tight, so any change in the piping materials selected had to allow for quick and efficient installation. And since the new cooling tower would be located on the roof, the system needed to be durable and withstand the elements.
Shoemaker Mechanical ultimately proposed HDPE pipe, which matched the construction type of the new specified cooling tower and offered compelling benefits. Not only does HDPE pipe weigh less than carbon steel, making it appealing to installation crews, it can be joined with Victaulic mechanical couplings more efficiently and with fewer workers and resources than traditional methods.
“HDPE helped us beat our piping installation schedule, and with Victaulic couplings, we did it with a smaller crew.”
— Richard Shoemaker III, Project Manager, Shoemaker Mechanical
“Looking at the schedule, logistics, and potential weather conditions, as well as seeing they’d previously used HDPE on the cooling tower construction, it made sense to use HDPE and keep everything consistent,” said Richard Shoemaker III, project manager for Shoemaker Mechanical.
After evaluating the labor and material costs and benefits to the overall project by pairing HDPE pipe with Victaulic’s new Style W907 couplings, TCC and the engineer ultimately approved the proposed plan. The TCC cooling tower replacement was the first project in the country to use Victaulic’s new 14″ Style W907 couplings.
Despite Weather, Swift Completion
Victaulic’s HDPE pipe joining system allowed Shoemaker’s crew to quickly and safely install more than 360′ of 4″, 10″, and 14″ HDPE pipe in just two days, faster and more easily than expected.
In preparation for the installation, Victaulic worked alongside Shoemaker Mechanical to review project drawings to integrate their system solution for HDPE pipe into the plan, then the project went to prefabrication. The teams collaborated to amend plans as change orders came in and adjusted accordingly when the timeline was pushed back to limit disruptions to the TCC class schedule.
Once onsite, Shoemaker Mechanical had one weekend to move materials from the street to the roof of the seven-story building without bucket hoists, pulleys, or elevators. The team used a crane to lift parts into position, while crews easily maneuvered the lighter-weight piping into place by hand. Workers then joined the HDPE pipe with hand tools and visually verified correctly installed joints by ensuring bolt-pad-to-bolt-pad contact, giving them confidence in the system’s durability and longevity.
As the installation progressed, winter arrived in Tulsa. Some days were cold and wet, while others were warm and sunny. On snowy days, workers were especially grateful for Victaulic’s couplings, because they did not have to lie in the snow to weld steel pipe together. If Shoemaker Mechanical had decided to fuse the pipe, the snowy conditions would have forced the crew to use tarps during their fusion process, making it even more laborious.
Using Victaulic’s new 14″ Style W907 couplings—for the first time anywhere in the country—Shoemaker cut the number of work hours required to install a new cooling tower by 50 percent over estimated time.
Despite the unpredictable weather conditions, Victaulic’s HDPE pipe joining system allowed the crew to quickly and safely install more than 360′ of 4″, 10″, and 14″ pipe. By choosing Victaulic, Shoemaker Mechanical reduced the number of work hours by more than 50 percent and finished ahead of the original project timeline by 15 percent, all while using a smaller, four- to six-person crew.
“HDPE helped us beat our piping installation schedule,” said Shoemaker. “And with Victaulic couplings, we did it with a smaller crew.”
A Successful Combination
Plastic piping continues to gain ground as materials like HDPE offer greater corrosion resistance at a competitive cost when compared with materials like carbon steel pipe. Victaulic’s HDPE pipe joining system allows you to install plastic piping quickly and in any weather condition compared with traditional methods like fusing.
“Victaulic made multiple visits over to us, the engineer, and the owner to make sure everyone understood Victaulic’s HDPE products and ensured our team was up to date on the proper installation methods,” said Shoemaker. “Their support throughout the project helped make it a success.”
For more information, visit www.victaulic.com. MCAA thanks Victaulic for being a major sponsor.
NIBCO INC. Appreciates the Benefits of Laser Over Other Welding Processes
Many types of welding have been proven performers for a long time. Welding is, at its core, simply a way of joining two materials. While there are other ways to join metal (e.g., riveting, brazing, or soldering), welding has become the method of choice for its availability, high performance, and high strength.
Essentially, all welding processes are the same: melt the metal in a seam so that it can blend, then fuse—forming one piece. This process is achieved (more or less) satisfactorily depending on the materials in the two pieces, the welder’s experience, the method used, and the costs in time and labor. Weld strength and appearance are also factors. NIBCO INC. favors laser welding for its strength and efficiency. NIBCO INC. is an MCAA major sponsor.
Bringing Metals Together, One Weld at a Time
The welding process dates to the Bronze Age (~3300 BCE to 1200 BCE), when copper alloys were heated until the metal softened, then pounded together with a hammer on an anvil to create a forge weld. Now, 5,000 years later, there are three basic welding techniques:
Gas welding
Arc welding
Laser welding
Traditional welding methods (e.g., gas and arc) generate large amounts of heat. Some techniques can create so much heat that the welded pieces can warp and distort, which can ruin the work piece or require a heat treatment or other remedial actions (adding to the cost). Welding requires skill, training, and specialized, expensive equipment.
Gas welding requires bottles of acetylene and oxygen. The acetylene is mixed with the oxygen to create a flame that can be used to melt metal. Gas welding is a slow process.
Arc welding uses closely controlled, high-amperage electricity to form an arc from the electrode to the work pieces. The welding power source is a transformer that modifies incoming AC power so that it can create an arc that melts the work pieces. Filler rod is typically used in this process.
The Future Is Now
Laser welding, compared with forge welding, is a relatively new technology. It is used in many high-tech industries, including automotive, aerospace, and oil and gas. Laser welding uses a high-energy laser beam to melt the materials being joined. The metals then rapidly solidify after the laser moves on or turns off. Laser welding, when used for joining valve components, increases the pressure-containing ability of the valve as compared with a traditional, threaded assembly. The process is repeatable, efficient, and strong, producing high-quality assemblies.
Laser welding is very precise, fast, and clean. Lasers are also flexible. Different operations, such as cutting or drilling, can be accomplished through straightforward machine setup changes. Depending on the types of materials being welded, different welding equipment and supplies are required. Although laser welding equipment is capital intensive, operating costs are low.
Lasers provide the accuracy, repeatability, speed, and confidence modern manufacturers want. Lasers generate more concentrated heat (high-power density) than arc and gas welding. Laser energy can be focused precisely to make the smallest-possible weld seam. Those attributes make the laser ideal for welding thin, heat-sensitive products, as well as for joining dissimilar materials, such as copper and aluminum. Bronze alloys lend themselves well to most welding processes, and laser is no exception.
So, for what types of applications would laser welding offer the most advantages? Laser welding is best applied to production lines where its precision, repeatability, speed, and safety can be controlled. Laser welding consistently repeats the weld from the first part to the final part in the production run.
For more information, visit www.nibco.com. MCAA thanks NIBCO INC. for being a major sponsor.
For those considering open-loop copper plumbing systems, there may be a misconception that bronze valves are the only reliable option for dezincification resistance. However, changes in lead-free requirements as a result of the Safe Drinking Water Act have led to new, viable alternatives to bronze. Heat-treated, dezincification-resistant brass valves are becoming a popular specified product within the engineering community. When subjected to ISO 6509 testing, heat-treated, dezincification-resistant brass valves perform as well as bronze in fighting against corrosion.
What Is Dezincification?
Many forms of corrosion can occur in copper-based alloys. The most common in plumbing systems is dezincification. This process mainly exists in copper zinc alloys that contain more than 15 percent zinc. Dezincification selectively removes zinc from an alloy, leaving behind a porous and copper-rich structure with poor mechanical strength.
Additional environmental factors can also contribute to the acceleration of dezincification. These factors include water with high levels of oxygen and carbon dioxide, slow-moving (or stagnant) water, water with high chloride ion content, and water with high salt content above room temperature.
In some instances, design engineers and contractors are unaware of harsh, preexisting conditions prior to beginning work onsite. However, after completion of a piping system, a number of visual signs might indicate a higher likelihood of dezincification in common copper alloy valves. These indicators include mineral stains on the outer surface of a valve, water weeping from a valve body or stem seal, and the presence of a white deposit (zinc oxide) on the exterior of the valve. A narrowly written valve specification can help minimize these potential failures by simply calling for a proper corrosion-resistant, copper-based alloy.
How Can Brass Become Corrosion Resistant?
Two manufacturing methods can eliminate dezincification in copper-based brass alloys. The first method is to increase the copper content, which results in a reduction of zinc in the alloy. The second practice involves adding corrosion inhibitors to brass alloys. Only through a controlled-heating and slow-cooling annealing treatment can the second method create a stronger material with a realigned molecular structure. Brass alloys typically have two phases to their molecular structure. The first—alpha phase—is dezincification resistant; the second—beta phase—is dezincification susceptible. When brass alloys are enhanced to an all-alpha phase through heat treatment, they perform the same as bronze alloys when fighting dezincification.
The Solution: Heat-Treated Forged Brass
An example of a heat-treated alloy in the commercial plumbing industry is CW511L. This duplex brass is a lead-free brass alloy composed of both an alpha and beta phase. Alpha and beta phases correlate to the solubility between metals in brass alloys, resulting in different colors and structures in each phase. As a result of the temperature changes in heat treatment, elements within the alloy change their liquid and solid states, resulting in a restructured alloy composition.
The alpha and beta composition is resistant to cracking and is extremely malleable at high temperatures. The purpose of heat treatment is to transform alpha and beta phases into a predominately alpha phase (dezincification resistant). After heat treatment, the new composition structure’s alpha-to-beta-phase ratio is less than one percent beta phase, resulting in a dezincification-resistant alloy. At this point, beta phase is now referred to as a residual beta phase, and the alloy structure is 99 percent in alpha phase. This restructuring leaves a brass alloy that is now truly dezincification resistant.
Figure 1 (below) shows the varying phase changes of CW511L during the heat treatment process. These changes are distinguishable by the color and shape of the crystals within the alloy. When the alloy completes its heat treatment process, the color of the brass will appear more gold than bronze under a microscope. However, the valve body surface will appear bronze in color due to the oxidation of brass at 1,000° F (537.87° C).
When CW511L brass is heated to a temperature of 1,000° F (537.87° C), an all-alpha phase is achieved. This alpha state is maintained in the alloy by a slow-cooling, annealing process. The end result is optimal dezincification performance when tested to the ISO 6509 standard for determining dezincification depth of copper alloys with zinc exposed to fresh, saline, or drinking water. The method is intended for copper alloys with a mass fraction of more than 15-percent zinc.
Third-party ISO 6509 testing explored dezincification susceptibility among copper-based alloys, including bronze and brass valves. This testing illustrated the difference in dezincification depths for each valve and corresponding alloy. It was determined that heat-treated CW511L brass showed a dezincification depth of zero microns, which was equivalent to the dezincification depths seen in bronze valves. The remaining non-heat-treated brass valves showed dezincification above 200 microns depth as illustrated in Figure 2 (below).
This level of dezincification is above the acceptable performance level based on the ISO standard, deeming the non-heat-treated brass valves as not truly dezincification resistant. The results of the test prove that not all brass materials are equal and that certain heat-treated brass alloys can perform as well as bronze when it comes to corrosion resistance.
Dezincification in plumbing systems is an ongoing battle, but bronze is not the only solution. New technologies, like Jomar Valve’s heat-treated CW511L brass alloy, can act as a combatant to dezincification while providing an increased level of mechanical strength.
Depending on the application, check valves can get a bad rap. They are blamed for problems such as water hammer, vibration, reverse flow, leakage, or component wear and damage—all of which are harmful to downstream systems. However, the real cause of these problems usually stems from poor sizing and inadequate selection of the check valve for the application.
Most check valves are selected on line size and the desire for the largest valve flow coefficient available. Swing checks require a minimum rate of flow for the valve to function. If the flow is not sufficient to hold the disc in a fully open and stable position, the disc and associated internal parts will be in a constant state of motion (wobble). Insufficient flow results in premature wear, noisy operation, and vibration.
The solution to this problem is selecting a line size that produces sufficient flow. A general rule of thumb for water systems is to maintain a minimum of 7.5 feet per second (ft/sec) flow rate. If the system struggles to maintain that flow rate, it is sometimes recommended that the line size be reduced.
In piping systems containing other types of fluids, the flow requirements vary with the specific gravity of the media. The following formula can be used to approximate the minimum flow rates.
Flowmin (ft/sec) = 60 √V
V = specific volume of fluid (ft3/lb)
Silent check valves such as the Milwaukee Valve 1400 (Wafer) and 1800 (Globe) have slightly different flow requirements. Spring-loaded silent check valves are designed to provide a cracking pressure of 0.5 psi and to fully open at a flow velocity of 4 ft/sec.
All check valves should be installed in a location that has smooth and laminar flow conditions. The following general rules exist for check valve installations:
Downstream of a reciprocating pump or other turbulence-inducing device (elbow, tee, etc.):
Swing type: Locate the valve a minimum of 10–12 diameters downstream of the device.
Silent type: Locate the valve a minimum of 4–5 diameters downstream of the device.
Pipe fittings, elbows, reductions, etc., downstream of the valve:
Swing type: Locate the elbow a minimum of 5–7 diameters downstream of the valve.
Silent type: Locate the elbow a minimum of 2–3 diameters downstream of the valve.
Victaulic Products and Expertise Help Current Overcome Labor Shortage to Meet Tight Timeline
For a demanding new warehouse project with a nine-month timeline, Current Mechanical counted on Victaulic’s experienced virtual design and construction (VDC) team, fabrication services, and grooved mechanical couplings to save installation time even as its workforce was stretched thin. “With the labor shortage, I am not sure we would have been able to complete this project without using Victaulic’s fabrication services,” said Steve Lewis, project manager at Current Mechanical.
Lewis continued, “Victaulic was able to model the room, create 3D installation drawings, and assist with spatial challenges when they arose with other trades as the project progressed. The biggest advantage to using Victaulic’s fabrication services was that we were able to reduce manpower and save critical time by allowing the construction crew to spend its time focusing exclusively on installing the piping system.”
Scaling Up With Control
In 2019, Sweetwater Sound, Inc. planned to expand its Fort Wayne, IN, campus by building a new 500,000-square-foot warehouse. Sweetwater began in 1979 as a recording studio in a Volkswagen bus and has since become the largest online retailer of musical instruments and professional audio equipment in the United States.
“The biggest advantage to using Victaulic’s fabrication services was that we were able to reduce manpower and save critical time by allowing the construction crew to spend its time focusing exclusively on installing the piping system,” said Steve Lewis, project manager at Current Mechanical, of the Sweetwater Sound storage facility project.
Storing musical instruments requires a climate-controlled environment, so maintaining appropriate conditions within the warehouse was critical. High humidity and fluctuating temperatures increase the risk of cracks, corrosion, and broken strings, so precise control is vital to preserving the integrity of the instruments in storage.
The project also had to be completed in just nine months, which was a challenge because of its large scope of work, including six air handling units (AHUs) with humidification; two chillers; a two-cell cooling tower; three boilers; heating, chilled, and condenser water pumps; an air piping system for conveyor systems; a domestic water system; and a reverse osmosis system for humidification.
The system installed also had to be scalable to accommodate future warehouse expansion. The initial concept was to build a giant central plant that answered the immediate needs of the facility but that was constructed so it could be expanded to meet the higher loads required to adequately control humidity and temperature in a larger space as more demand was made on the system.
Making Music Together
The contract was awarded to Current Mechanical, a Fort Wayne-based contractor that specializes in refrigeration, plumbing, HVAC, process piping, medical gas piping, and fire protection services. Current Mechanical had a solid track record with Sweetwater, having previously completed work for two other warehouse facilities, as well as its corporate office in Fort Wayne.
Although Current Mechanical had worked with Sweetwater before, the company had not installed the type of humidification system that was required for this new-build warehouse. Additionally, they were also undertaking this project at a time when their workforce was stretched thin. Current Mechanical needed a partner that could expedite and simplify installation to relieve some of the pressure on its limited crew and provide fabrication to facilitate site work.
Current Mechanical’s successful partnership over the past 15 years with Victaulic, the leading producer of mechanical pipe joining solutions, made the decision to reach out for support an easy one. By joining forces, Current Mechanical would not only have access to Victaulic’s experienced and knowledgeable VDC team, they also would benefit from the company’s fabrication services. And by using grooved mechanical couplings, which are 10 times faster to install than welded joints, Current Mechanical could streamline installation with its limited workforce, which was an enormous benefit on a project that was understaffed from the outset.
Managing Last-Minute Changes
Victaulic’s VDC team proved its value throughout the project, identifying potential issues, working rapidly to address them, and responding quickly to engineering design changes.
Sweetwater anticipated expanding its new warehouse, which would necessitate scaling up temperature and humidity control, so this project incorporated four large AHUs, all of which required triconnection coils. Problem-solvers at Victaulic addressed this requirement by using a series of single-coil AHU drops, which Current Mechanical was able to install in only four days.
“One of the last steps before issuing fabrication spools is to issue preliminary drawings for review and signoff,” said Brandon Horton, territory sales manager at Victaulic. On this project, “we received guidance from the mechanical engineer that required last-minute changes. Our VDC group was able to adapt and make the applicable adjustments needed.”
Once the revised preliminary drawings were approved, Victaulic’s VDC team began the fabrication process, which included spooling, fabrication maps, cutting lists, truck loading logs, and material procurement.
“Making changes, especially during fabrication, can be a challenge, but it’s incredibly important to make sure everything will meet layout and design intent,” said Josh MacMurray, piping coordinator at Victaulic.
Pulling all the pieces together for seamless execution requires a true team effort. “It’s quite a collaborative ecosystem,” said MacMurray. “There are modelers on one end developing quantities, then they pass it on to customer care to allocate and prepare for production. We also work with the fabrication team to make sure the right quantities will be at the right place at the right time.”
Victaulic provided on-site support and allocated all of the materials ahead of time, which was particularly valuable for the large-diameter pipe, which was not stored by the contractor and not available from local distributors. This approach meant materials could be released as needed for each phase of construction, and the necessary materials were onsite to permit construction to continue according to plan.
Innovative Solutions
Because of the size of the warehouse and its eventual expansion plans that would necessitate scaling up temperature and humidity control, this project incorporated four large AHUs, all of which required triconnection coils. Problem-solvers at Victaulic addressed this requirement by using a series of single-coil AHU drops. “This was an example that really showed the flexibility of our product lines,” said MacMurray.
As critical as this solution was, of equal significance was the product’s ease of installation. Although the contractor feared the workaround would be labor- and time-intensive, because of the simple design of the Victaulic catalog item, workers were able to complete the AHU drops in only four days.
Another “first” on this project was the installation of Victaulic’s QuickVic™ SD Installation-Ready™ System for small-diameter pipe. Used on the compressed air system that moves the conveyors that transport instruments through the warehouse, these products featured a thermally diffused zinc coating for improved corrosion resistance.
Additionally, Victaulic’s globe-style balancing valve was a key advantage for this project. Globe-style valves are preferred over ball-style valves because they provide much more accurate flow control of the heating and chilled water through the AHUs, humidifiers, and dehumidifiers.
Working together, Current Mechanical and Victaulic were able to successfully deliver the project on schedule. Even more important, the groundwork has been laid for Sweetwater to continue to grow for future encore performances.
For more information, visit www.victaulic.com. MCAA thanks Victaulic for being an MCAA sponsor.
Renovating an active hospital is challenging in the best of times; to complete a transplant hospital’s new unit in the midst of a global pandemic, Rand Construction needed products that could be delivered on time and installed quickly and safely. Gruvlok® grooved couplings and fittings from ASC Engineered Solutions were the perfect fit. ASC is a major sponsor of MCAA22.
In November 2020, Midwest Transplant Network’s headquarters in Westwood, KS, began major mechanical renovations and minor additions to create a new Donor Care and Surgical Recovery Unit. The Midwest Transplant Network is a nonprofit organization that provides services for organ donation and procurement in Kansas and parts of Missouri. By providing an onsite recovery facility for organ and tissue donors, the Midwest Transplant Network reduces the reliance on local hospital resources and ensures that donors receive highly specialized care.
Rand Construction worked closely with distributor MKS Pipe and Valve, which recommended Gruvlok ductile iron couplings and cast fittings and carbon steel schedule-40 fabricated fittings for the project. “Some of the major equipment, such as the chiller, was already manufactured and shipped with grooved connections. That made it an obvious choice to utilize Gruvlok,” said Fred Thorpe, vice president of Rand Construction. “Gruvlok products were also very helpful in some of the more restricted areas and/or where welding was not an option or permitted,” Thorpe added.
MKS Sales Manager Kevin Aylward noted, “What really makes [ASC] stand out is the large breadth of their product offering, great customer service, and quality products with dependable deliveries.” MKS made sure that the Gruvlok products for the transplant center met the required specifications for mechanical couplings, achieved savings compared with competitive brands, and were available on the requested delivery timeline.
The complete Gruvlok order was delivered on time, in one shipment, boxed and tagged to indicate what materials were enclosed. Thorpe pointed out, “By utilizing Gruvlok products, we were also able to install products made right here, at home in the USA.” Because ASC has domestic manufacturing locations, Gruvlok products were less affected by the prevalent delays in production and shipping that happened throughout 2020 and 2021.
Another key selection criteria that helped secure Gruvlok as the build choice was ASC’s extensive building information modeling (BIM) catalog. All Gruvlok products can be used in digital design projects; ASC provides Gruvlok BIM content in multiple file formats and design program compatibility, including Revit®.
“We were confident the products would work when we incorporated them into our preliminary planning, layout, design, and fabrication,” said Thorpe. “All of the data needed to make an educated decision was readily and promptly available, so that’s clearly why we chose Gruvlok.”
Thorpe added, “MKS and ASC Engineered Solutions were excellent strategic partners on the Midwest Transplant Network project,” citing their cooperation with Rand as a key factor in this project’s success. The Midwest Transplant Network Donor Care and Surgical Recovery Unit is expected to begin taking patients in late spring or early summer of 2022.
For more information, visit www.asc-es.com. MCAA thanks ASC Engineered Solutions for being a major sponsor of MCAA22.
When University Health System in San Antonio, TX, invited Brandt to bid on the mechanical and plumbing contract for their new facility, they requested the same systems and products—including NIBCO valves—that Brandt had used on a smaller project with University Health a few years earlier. “The best sales tool is performance,” said Kyle Holmes, senior vice president at Brandt. In addition, Brandt welcomed the opportunity to use NIBCO pressed fittings for the job, saving labor and avoiding the risks of welding. NIBCO is a major sponsor of MCAA22.
University Health’s planned Women’s & Children’s Hospital is a 521,000-square-foot, 12-story, 300-bed hospital expansion for women, babies, and children. Construction began in September 2019 and is scheduled for completion in July 2023. The project includes the new structure and renovation to the hospital’s central plant, as well as additional shell space for future growth. When completed, 4,000 fixtures will be installed. Headquartered in Dallas, Brandt has established itself as the largest MEP contractor in Texas. The firm’s in-house capabilities range from build/design, construction, and commissioning to service.
Time-Saving Systems
At Brandt, Holmes is responsible for planning, purchasing, and maintaining relationships with manufacturers and vendors. He also has been instrumental in Brandt’s business practices and has worked to establish standards, such as the installation matrix, which ensures that everyone on the Brandt team, from estimation to installation, knows what products are used for different systems, whether domestic water, heating, or chilled water. These time-saving standards are particularly critical for health care projects, which typically have more MEP systems per cubic foot than other types of projects.
Using pressing tools and NIBCO fittings, Brandt made most of the joints inside the racks, which range in size from 20’ to 30’ long so they could be transported. Pressing is especially useful for connecting the joints in a rack system, where insulation can easily catch on fire.
The installation matrix details the specific items required for each system. For example, instead of saying a ball valve will be installed, the matrix specifies a NIBCO PC-585-NS valve. Everything is documented, not only so the building owner can feel comfortable with what is being purchased, but also to ensure that the Brandt team is installing the right items in the right places.
For the Women’s & Children’s Hospital, NIBCO valves were specified for a majority of valves, ranging in size from of 1/4” to 20”, from very large butterfly valves to smaller valves spread throughout the building in the various MEP systems, including hydronic systems, domestic water systems, steam systems for sterilization, and chilled process water systems. A valve matrix was created to designate every valve to be used in every size, in every system.
“Valves are really important, but especially in health care,” explained Holmes. “Valves are actually very complex and have an important job to perform in the MEP system. Often, if you have problems in a system, the valve is likely the issue, whether it is leaking or a function of users not understanding proper use.
“NIBCO does a great job of ensuring that they provide a product that is safe (NIBCO valves are lead-free), high quality, and to spec. They are valve experts!” said Holmes, who has been with Brandt for 22 years and has used NIBCO valves the entire time. “What matters to me the most, is that I know if I have a problem and I call someone at NIBCO, they are going to take my phone call. The relationship is important, so if we need training, I know that NIBCO’s got my back.”
A Pressing Approach
Holmes’ trust in NIBCO led him to choose NIBCO pressed fittings for the Women’s & Children’s Hospital project. Brandt recognized that pressing would help the company save on labor. Also, pressing technology is especially useful for working in existing hospital buildings, where fire watches are required when flames or soldering are involved.
“I was already very interested in NIBCO’s pressing products for the labor savings, but then to not have to deal with flames was a bonus,” explained Holmes. “I knew the buy-in from our organization would be easy if we were working with the same company that provided us with high-quality valves. It also reduced paperwork and increased efficiencies by not having two different suppliers.”
For the Women’s & Children’s project, the general contractor, J.E. Dunn Construction, requested that Brandt prefab the MEP system in large racks. The two companies had successfully developed the racking system for a smaller, previous project.
“In essence, we were building the ‘spine’ of the hospital before the concrete was even poured,” said Holmes. “The racking system is the magical unicorn for us.”
University Health Systems was so pleased with Brandt’s work on a previous project they invited Brandt to bid on their new facility and requested the same systems and products—including NIBCO valves—be used again.
Using the racking system enabledBrandt to prefab the MEP systems in the Brandt Fab Shop, located less than 20 miles from the project site. In coordination with the general contractor and other trades, thousands of hours were invested to build the racking systems efficiently, test them, and tag them in a controlled environment that is not affected by weather or inhibited by working off of a ladder.
Using pressing tools and NIBCO fittings, Brandt made most of the joints inside the racks, which range in size from 20’ to 30’ long so they could be transported. Once the racks were moved to the project site by flatbed trucks, each rack had to be connected, which was done via pressing. More than half of the NIBCO fittings are pressed fittings used on the prefab systems.
“Every time we can, we want to press a fitting,” said Holmes. “Especially in the rack system, where insulation can easily catch on fire.”
Having a high-quality supplier that provides Brandt with efficiency and confidence has been instrumental on this high-profile project—particularly because Brandt’s service division will eventually service the building. “We’re going to get the call when something goes wrong, so for Brandt, using very high-quality products that the manufacturer stands behind is really important to us,” said Holmes.
For more information, visitwww.nibco.com. MCAA thanks NIBCO for being a major sponsor of MCAA22.
Way Engineering, Ltd. partnered with Victaulic to provide the HVAC mechanical work for a new Houston, TX, highrise, saving the contractor money and time throughout the complex project. Thanks in part to Way Engineering and Victaulic, the 1.14-million-square-foot Texas Tower successfully achieved LEED® Platinum status, WiredScore Platinum Certification (for digital infrastructure), and WELL™ Building Standard certification. Victaulic is a major sponsor of MCAA22.
In 2018, Hines, a privately owned global real estate investment, development, and management firm, began planningconstruction of a 47-floor office building in downtown Houston to house their global headquarters. The location (the former site of the Houston Chronicle newspaper) sits at the confluence of the city’s Central Business District, Theatre District, and Historic District. Construction took place throughout 2020 and 2021, with COVID-19 pandemic restrictions in place.
Reliable Partners
Way Engineering already had a long history of working with Victaulic. “Victaulic partners with you in a way that’s more than a vendor selling a catalog number,” said Derrick Williams,
Building the 1.14- millionsquare- foot Texas Tower in the middle of downtown Houston posed challenges, but Way Engineering overcame them— for example, by using Victaulic products that were easy to transport and install.
executive vice president of operations at Way Engineering. “They partner with you to make the job a success and take an interest in the project, not just an interest in the sale of a product.”
Way Engineering and Victaulic started preparation right away, working together on engineering, planning, and scheduling. The timing of this collaboration was fortunate, because it meant the bill of materials was finalized before the industry was affected by pandemic-driven supply chain challenges.
“Victaulic was active in bringing options to the table; not just waiting to receive the order,” said Williams. “Because we used building information modeling [BIM], we knew early on what would be needed for the job. Victaulic took the initiative to review the advanced bill of material and coordinated scheduled, bagged-and-tagged deliveries. This meant when we required material, it only took two to three days to have it onsite, not four to eight weeks. This made a big difference because you need the flow of a job to never stop; you’re always pushing to meet the schedules set by the general contractor.”
Anticipating Challenges Together
The chilled water system for Texas Tower includes four chillers, four cooling towers, 12 pumps, two heat exchangers, fans, filtration systems, duct systems, piping up to a 20” diameter throughout the building to serve the air handling units (AHUs), and risers from the basement to the cooling towers. On the risers, all branches were isolated with Series 761 Vic-300™ MasterSeal™ Butterfly Valves. Then, Series 732 Wye Type Strainers and TA Series 789 Grooved End Manual Balancing Valves accompanied the AHUs to optimize energy efficiency throughout the tower and for ease of installation.
Having enough pressure is critically important for highrise buildings like Texas Tower. Victaulic’s off-the-shelf Series 761 Vic-300 MasterSeal Butterfly Valves eliminated the need for a specialty high-performance butterfly valve, saving costs and allowing more lead-time. “The planning process across the board, through all parties, was exemplary. Since the inception of the project, Victaulic took on a role as a specialized engineering resource in response to high-performance valve requirements,” confirmed Stan Whitfill, Way Engineering’s executive project manager. “They get involved in the BIM process, and they bring value-engineered options to the table. A lot of companies don’t put in that time and risk until they have a purchase order in hand,” added Williams.
Way Engineering and Victaulic collaborated closely on engineering, planning, and scheduling for the new Houston, TX, highrise. Their partnership helped the project meet some of the industry’s highest building standards.
In addition to meeting Hines’ high-performance butterfly valve requirement, Way Engineering eliminated flex connectors at the pumps, using three flexible couplings in a line instead. Mechanical connections also allowed Way Engineering to cost-effectively install a temporary loop on the 27th floor to hydro-test part of the system early and eventually connect the higher floors.
“Being in the middle of downtown Houston is always a struggle for contractors for many reasons, including limited staging and storage areas,” said Corbin Best, territory sales manager at Victaulic. “Aside from a reduction in specialized equipment needed onsite while utilizing mechanical connections, one of the biggest advantages seen at Texas Tower was the ease of mobility and installation when there was one service elevator that all trades had to share to access 47 stories.”
Because of the COVID-19 pandemic, there were limits on how many people were allowed in the building at one time. Way Engineering found that Victaulic products required fewer field connections, and the contractor could fabricate spool pieces offsite, cutting down labor onsite.
Despite the obstacles, Way Engineering and Victaulic’s collaboration upfront and consistent communication—with each other and with Hines—facilitated a successful project.
For more information, visit www.victaulic.com. MCAA thanks Victaulic for being a major sponsor of MCAA22.
With only three weeks to fully replace the riser system at a high-profile residential building, New York-based Fresh Meadow Mechanical Corp. selected Victaulic to win the race against time. Ultimately, they remained ahead of schedule, completing the entire project in only 15 days. Despite spatial constraints at various stages of the project, Fresh Meadow navigated each challenge with reliable engineered solutions that will benefit the building’s tenants and management for years to come.
The existing riser system, original to the decades-old residential building, had degraded over time. A new system needed to be installed before New York’s cold weather kicked in and tenants were left with inadequate temperature control. To accomplish the job, Fresh Meadow needed to first extract the riser that ran from the first-floor ceiling up to the 18th-floor mechanical room. The return riser design also had to accommodate for thermal movement in the existing space. The final and most critical challenge was that the building would remain fully occupied, meaning Fresh Meadow needed to minimize disruptions and maintain occupants’ safety during installation.
Putting People First
During planning of the riser replacement project, Fresh Meadow evaluated the impact of the work on occupants and chose a grooved system over welding. The hot works and fumes generated during welding require a hot work safety program, including restricted work areas, permits, and fire watch. To building residents, welding would raise safety concerns, divert traffic patterns on every floor, and cause a noticeable, unpleasant smell. To mitigate the effect on occupants, Fresh Meadow worked with the Victaulic Piping Movement Design group to execute a grooved system while staying within budget and on schedule.
“We didn’t have to shut down anything and didn’t interrupt the tenants at all. We also knew we wanted to cut down on the noise and could do that using Victaulic,” said Keith McKee, Fresh Meadow’s superintendent for the project. “The only noise was tightening the couplings with an impact gun, which made the building managers happy.”
Tackling a Strict Schedule
Going floor to floor, Fresh Meadow cut the riser out of the wall, rigged it down a 17-story shaft, and then removed the obsolete pieces from the lobby level. The removal used up four days of the three-week timeline, but Fresh Meadow and Victaulic were confident the team would still deliver ahead of schedule.
The Victaulic-patented QuickVic™ Installation-Ready™ couplings installed throughout the riser system are designed to expedite pipe-joining. The two-piece housing design features shift-limiting slant pads that allow for one-touch tightening instead of alternating between bolts, accommodating high-performance impact guns and streamlining installation. On many retrofit projects, standard lengths of pipe tend to be larger than the service elevator. Contractors must choose between cutting pipe lengths to fit on the elevator—which translates to added welding time—and increasing material handling time and coordination of 21’ pipe lengths. Fresh Meadow avoided this lose-lose situation by cutting down pipe lengths to fit in the service elevator, and then joining riser sections within minutes using QuickVic Installation-Ready couplings.
“The pipes were taller than the floor-to-ceiling height, so we cut them in half to get them upstairs. Adding joints may have slowed us down in a different project, but Victaulic grooved connections made it a more efficient installation. We got the building back online much faster than if we had utilized other methods. It was the adaptability we needed for this retrofit,” said McKee.
Additionally, the collective Victaulic team, including the Piping Movement Design group, provided detailed drawings of pipe layouts to the on-site crew and coordinated expedited material deliveries so the project could progress from design to installation without pause.
Space-Saving Solutions
Restricted by the riser shaft’s tight dimensions, Fresh Meadow had to design a dual-temperature system that accounted for sufficient space for thermal expansion and contraction. “There was simply no room to put an expansion loop within the existing shaft,” explained Mike Russo, chief operating officer of Fresh Meadow.
“The owners would need to modify their occupied building, inevitably encroaching on hallway space and evaluating building code, in order to compensate for pipe growth caused by temperature changes using traditional methods like expansion loops.” said Russo. “Instead, using the Victaulic self-contained [Style 155] expansion joint assembly was advantageous because we could work within the existing shaft.”
Fresh Meadow installed two Victaulic Style 155 expansion joints with three Victaulic Style A10 riser anchors at specific levels of the multistory building to accommodate for thermal expansion and contraction. The engineered solution provided the necessary expansion and contraction capability without the need for additional coordination, review, and field work that would have affected the schedule and budget.
Read Victaulic’s white paper, “Using Grooved Mechanical Joining Systems to Accommodate Thermal Piping Movement.”
From Challenge to Triumph
Rapidly replacing an extensive system with minimal disruption to residents’ day-to-day life was a tall order. Attention to detail and thinking ahead during the design phase, combined with Victaulic’s Installation-Ready grooved couplings and engineered motion control solutions, enabled Fresh Meadow to set and maintain a furious pace, cutting a full week off of the project timeline.
To update the HVAC system at the Montgomery County Jail in Dayton, OH, Starco, Inc. relied on NIBCO’s new PressACR™ system to save at least 100 hours in installation time. Initially, press systems were not approved on the specs for the project, but Starco convinced the building owner and the project’s engineering firm, HEAPY, that PressACR would save time and money.
Also located in Dayton, Starco specializes in commercial plumbing, heating, air conditioning, piping systems for steam and medical gas, and sheet metal ductwork. “NIBCO is our ‘go-to’ brand,” said Jonathan Stumpf, project manager at Starco, who led the $2.2 million project. “It’s been that way ever since I’ve been at Starco, and I’ve been here for 11 years!”
Improving Life on the Inside
Originally constructed in 1965, Montgomery County Jail was expanded in 1993 to become a minimal-security county jail complex, which now has a 900 prisoner-bed capacity. The older, original portion of the building required an HVAC system upgrade to improve the efficiency and performance of the system, which consisted of an older chilled heating combination system with unit ventilators servicing areas in the cells where the prisoners reside.
The facility wanted to remove the outdated system and replace it with eight variable refrigerant flow (VRF) systems to serve the same areas. The replacement system consisted of eight condensing units, 46 indoor units, and three make-up air units. Starco, the prime contractor for the renovation, also had to do some rework to an existing air handler to change it from a single heating/cooling coil to have separate heating and cooling coils, enabling two separate systems throughout the building.
“The project was certainly a bit unusual due to it being a jail,” commented Stumpf. “We worked in narrow, three-foot-wide catwalks with the prisoners in close proximity of our installers. Security guards had to be with us at all times, which presented some logistical challenges for scheduling.”
Beginning in fall of 2022, Starco worked in approximately 32,000 square feet of the five-story building, but also had considerable work on the exterior of the building, where all the refrigerant pipe and ductwork was run. The pipe and ductwork ran down the exterior sides of the building due to the narrow catwalks on the interior. Piping ran from the individual indoor units through holes in the wall to the exterior. To access the exterior piping, Starco had to work with scaffolding on one side of the building because it was too narrow for lifts. On the other side of the building, the installers worked off vertical lifts.
Pressing in Prison
To expedite the installation, Stumpf chose NIBCO’s PressACR system, a joining method designed for use in copper tube systems for air conditioning and refrigeration applications. PressACR fittings are approved for use with a wide range of refrigerants and lubricants and create a safer installation, as there is no flame or fire hazard with press technology.
“This Montgomery County Jail project was our first experience with PressACR,” said Stumpf. “I had wanted to try it out for a couple of years, and I thought this would be a great project to try it out on because there was a substantial amount of refrigerant pipe—about 2,800 linear feet.”
Stumpf explained that the estimated time savings with PressACR were key to getting approval for its use. He also noted that “getting copper fittings to 1,100° F to braze in the middle of winter outside on a rooftop is not an easy process. I did a cost analysis comparing my bid actual costs and calculated that it took approximately 100 hours less time to install. It was about $2,500 more for the materials, but we saved about $7,500. Plus, the aggravation!”
Because the bid did not take into consideration that the actual installation would have required extra time for the outdoor winter brazing, the savings were likely underestimated. Also, without brazing, there were additional cost savings from reduced brazing rods, fuel gas, and nitrogen purges.
According to Dave Hirby, Starco’s foreman on the project, “PressACR saved us a lot of grief. It was most definitely easier to slide fittings together, press a button and crimp, versus brazing, in the winter, on a roof. And I appreciate the consistency and reliability of the joints.”
Due to logistics, each VRF system required short pieces to be brazed into the wye fittings before using a press coupling to join them as they were installed down the wall. The only two leaks in the entire system of the eight VRF systems installed occurred in the brazed joints. To install the PressACR fittings, Starco used a NIBCO PCR-20M Press System®battery-operated, mini pressing tool designed to create a leakproof connection with the correct pressure. Starco conducted its main pressure test of the system at 550 psi (the fittings are rated for 700 psi), after the installation was completed.
Starco began using pressing soon after it was introduced to the United States 20 years ago. “We press any time we can on a project, if it is allowed for,” said Stumpf. “If it’s not specified, we even push for it after the fact, using RFIs [requests for information] to see if we can obtain acceptance to use pressing for domestic water and hydronic piping.”
NIBCO is Starco’s preferred brand for solder fittings, press fittings, and valves for all its projects. On the Montgomery County Jail project, for the chilled piping, heating piping, and condensate drains, Starco used a variety of NIBCO press fittings, including more than 100 90-degree elbows, more than 90 flare adapters, and 60 couplings, in sizes ranging from ¼” all the way up to 1 3/8”. Starco also used NIBCO ball valves in the heating and chilling system.
If your team is tired of callbacks because of a lack of hot water at the point of use and the labor required for manual balancing, thermostatic balancing, a more efficient domestic hot water balancing method, is now an option. Thermostatic balancing recirculates the hot water loop based on temperature, as opposed to pressure or flow.
Balancing a domestic hot water line is often a challenge because it is an open-loop system that is constantly changing in relation to user demand. Once a system is up and running in the field, it can easily fall out of balance. Thermostatic balancing ensures that all fixtures maintain the minimum desired water temperature constantly.
Manual vs. Thermostatic Balancing
Manual balancing is the most common type of balancing in plumbing. It is based on pressure, and often results in customer dissatisfaction. It is also labor-intensive, because it involves having a person at each point of use as well as a person at the balancing valve adjusting the valve to ensure hot water is available at every fixture for every line throughout an entire system. Additionally, manual balancing is an ongoing challenge, because when one balancing valve is adjusted, it affects the entire system, instantly putting the system out of balance. Maintenance teams often adjust the valves in response to users’ complaints about fixtures not receiving hot water.
Thermostatic balancing eliminates the need for a person to be at the point of use during the installation, eliminates callbacks due to flow adjustment, and increases customer satisfaction. You simply install the thermostatic balancing valve at the end of each hot water supply line before the recirculation loop and then turn on the hot water to balance the system. Because you no longer need contractors in the field to turn on every fixture to ensure hot water is in the line, you can direct workers to the projects where their skills are most needed.
How It Works
The technology behind the product uses a thermostatic cartridge that adjusts flow based on temperature. The valve will modulate open as a line cools and closes as a line achieves its desired temperature, using water’s path of least resistance to ensure adequate flow throughout an entire system. The valve never fully closes, which prevents deadheading the recirculation pump.
The thermostatic cartridge in Jomar Valve’s RecircSetter™ eliminates the need for pressure ports to balance a system. By selecting the same temperature at each valve, a uniform temperature is ensured in every branch. Designers select the design temperature within the range of 95° F to 140° F (the factory setting is 125° F), and the temperature is set in the field by the contractor using the presetting hand wheel.
To learn more about how thermostatic balancing works, watch this video.
Site-Specific Options
Jomar Valve offers three different models of the RecircSetter that address different installation needs. The standard thermostatic balancing valve balances domestic hot water lines from 95° F to 140° F. The thermal disinfection model has an added thermal disinfection cartridge that is particularly useful in health care settings that need to avoid the proliferation of bacteria in a potable water system. The RecircSetter with an actuated thermal disinfection valve allows the end user to choose the thermal disinfection temperature, duration, and frequency through a building maintenance system.
The RecircSetter has a temperature sensor port that allows for remote monitoring through a building maintenance system, so it can be easily integrated. The standard drywell thermometer on each valve allows for easy identification of the water temperature flowing through each unit. Drywells are located on each side of the RecircSetter for orientation flexibility. The assembly models have fewer connections, shorter assembly lengths, and an integrated check valve option, which saves costs, takes less space, and makes installation seamless. The valve can be adjusted in the field to accommodate design condition changes without valve replacement.
For a new, state-of-the-art medical school campus, Maxair Mechanical saved valuable time by installing “miles of piping” using Victaulic products rather than welding and relying on Victaulic’s 3D models of the mechanical space to anticipate potential pitfalls and avoid costly delays. Streamlining processes at every opportunity, Maxair completed the project on time, despite labor and supply chain challenges. Victaulic is a major sponsor of MCAA23.
Thanks to Victaulic’s VDC team, Maxair was able to optimize the mechanical room layout for the School of Medicine, so each component is easy to access and can be disassembled without welding or flanging, simplifying maintenance and service.
The new Mercer University School of Medicine in Columbus, GA, boasts 77,000 square feet of classrooms, research facilities, and office space. To support it, Mercer University needed a sophisticated, reliable mechanical system that would keep students and faculty comfortable and safe while also providing temperature control to critical areas, such as a gross anatomy laboratory and vivarium.
Mercer University tasked NBP Engineers Inc. and Maxair Mechanical with installing four mechanical spaces at the new site, which included three boilers, chilled and heating water piping and pumps, a condenser system, and five dedicated air handling units for the laboratories.
Working under a tight completion deadline, Doug Polley, Maxair’s senior project manager, knew they needed to incorporate strategic solutions to compress their schedule and mitigate risk. Victaulic was the ideal partner for the job.
Setting Up for Success
The mechanical rooms required precise layouts to fit the necessary equipment and piping. Optimizing the spatial design was also a priority, as it would simplify the initial installation and facilitate future maintenance and servicing for Mercer University. The Victaulic Virtual Design and Construction (VDC) team was fundamental to meeting the project’s demands.
Victaulic’s VDC team worked to optimize the layout and design of the entire mechanical system at Mercer University which, combined with the efficiency of Maxair’s new fabrication shop, enabled workers to keep pace despite delivery delays.
“Victaulic used their expertise to create 3D models of the mechanical spaces, which proved hugely advantageous in the BIM [building information modeling] process,” Polley said. “The 3D modeling enabled us to optimize the room layout, identify potential issues ahead of time that might have wrecked the schedule, and put solutions in place during the design phase that avoided costly rework.”
Dale Heiring, principal at NBP Engineers, Inc., added, “We were pleased with the consistent support Victaulic provided. The team reviewed all our specs—which are extremely thorough—and they made sure every detail was accounted for.”
Navigating Challenges
When Maxair Mechanical first bid on the project in the fall of 2020, they were prepared to work through a certain degree of uncertainty. Globally, the COVID-19 pandemic affected the available skilled labor pool and caused supply chain disruptions that directly affected construction schedules.
“It was constantly a race to keep up on the project. It was quite challenging. There were moments that seemed impossible,” Polley said.
Challenges ranged from finding sufficient staff to substitute workers when outbreaks spiked to delayed material arrivals because delivery drivers struggled to locate people at drop-off locations on the large campus. But Maxair was determined to complete the work on schedule—and they did.
Maxair Mechanical used Victaulic grooved couplings, fittings, and valves to tie in two boilers inside the first-level mechanical room at Mercer University’s School of Medicine, saving time compared with welded solutions.
The thoughtful and clear design and layout of the mechanical space, combined with the efficiency of Maxair’s new fabrication shop, enabled workers to keep pace despite delivery delays. Onsite, pipefitters worked off of a detailed spool map, developed by the Victaulic VDC team, that streamlined installation, while the grooved couplings, fittings, valves, and equipment modules proved easy and fast to install.
“If we had welded everything, it would have been very challenging to maintain the schedule,” Polley said. “We had miles of piping to install throughout a large, two-story medical building, and we were working with many complex systems.”
“Once the materials and units arrived, it didn’t take long to install the Victaulic product, the mechanical rooms were laid out well, and the designs were easy to follow,” said Guy Cozzolino, Maxair’s pipefitting coordinator.
A Productive Partnership
Despite unfavorable supply chain conditions that complicated this highly sophisticated mechanical installation, Maxair Mechanical and NBP Engineers, Inc. delivered the full scope on schedule. By partnering with Victaulic and engaging its VDC services, the engineers and mechanical contractors streamlined the entire process before materials were even purchased.
Mercer University School of Medicine at Columbus welcomed its inaugural class of medical students to the new campus in December of 2021. “It’s a win for Mercer that their students got this state-of-the-art facility that is well thought-out from the design phase to the final product,” Polley said.
For more information, visit www.victaulic.com. MCAA thanks Victaulic for being a major sponsor of MCAA23.
The Impact of Hands-On Training 
Laser welding, compared with forge welding, is a relatively new technology. It is used in many high-tech industries, including automotive, aerospace, and oil and gas. Laser welding uses a high-energy laser beam to melt the materials being joined. The metals then rapidly solidify after the laser moves on or turns off. Laser welding, when used for joining valve components, increases the pressure-containing ability of the valve as compared with a traditional, threaded assembly. The process is repeatable, efficient, and strong, producing high-quality assemblies.
