Archive for the ‘Compass Newsletter’ Category

Disrupting the Status Quo Through an Innovative Mindset

Monday, May 13th, 2019

Observe an Egan jobsite or walk into our shops, how do you recognize innovation? Whether you see it in the form of tools or technology, safety practices, better processes, posters or signage… we are continuing to change the way we build.

Recently, a customer shared feedback about how they believe their projects with Egan have been successful due to focused service, very fast responses, and innovative approaches. In response, thank you. We’re grateful our customers recognize this. Applying innovative practices happens intentionally. Delivering on this approach takes diligence.

In 2018, we leaned heavily into innovation and Lean practices. If we can provide further value with our trade offerings, increase the efficiency of a service, or shorten timelines all together, it’s our promise to do so.

Our newest Lean practices embrace our futuristic mentality to always be improving while maintaining our aggressive commitment to safety:

  • Implementing 5S Methodology: the 5S system is a Lean manufacturing process designed to improve efficiency through organization; this practice has been most recently implemented in all our shops and warehouses.
  • Promoting My Good Idea: through Egan’s formal innovation program, My Good Idea, there have been over 200 business improvement ideas generated and shared within the first nine months of the year.
  • Eliminating Waste and Applying 30/30: waste is found in everything we do – at work, home, and play. There are eight types of waste we address: defects/ rework, over producing, waiting, not using employee talent/ideas, transportation, inventory, motion and extra processing. Most recently, the 30/30 Rule was applied on our jobsites. 30/30 is a method for eliminating waste that reminds us to have our tools, materials, or equipment within 30 feet or 30 seconds for efficiency.

By disrupting the status quo, we embrace innovation as an essential. Through the development of a continuous improvement mindset and fostering an environment where new ideas and efficiency improvements are welcome, innovation has become a part of the daily value we provide with our work and to our customers.

Building Rooms With a View

Monday, April 22nd, 2019

Downtown Minneapolis continues to grow in size as more high-rise buildings have joined its skyline in the last year. Former parking lots have converted into 20+ story apartment buildings in seemingly expedited fashion.

Egan Company’s InterClad team has played a role in adding to the exterior and interior beauty of multiple new construction high-rises. Last year, the team finished its scope of work on three luxurious apartment and condominium buildings throughout different downtown neighborhoods – and, even more high-rise work is kicking off for 2019.

“High-rise housing is a major draw for us right now,” said Todd Fechner, InterClad Operations Manager. “With our team’s experience, we’ve been able to build some great relationships with a few of our customers who are taking on these projects. In turn, we’re getting to partner with them again and again.”

Though high-rise housing and hospitality isn’t new for Egan, having simultaneous scopes of such massive sizes is – and, has become the new normal. With this, honing in on specialized glass handling equipment like SmartLifts has helped the team execute multiple big projects efficiently and safely.

Over the past year, Egan has invested in six SmartLift glass handling machines that have played a role in reducing soft tissues injuries on the job, as well as help speed up overall installation time.

“Throughout last years’ projects, we’ve learned how valuable these [SmartLifts] are,” said Fechner. “We strive to continue pushing the envelope when it comes to using innovation within our industry and utilizing SmartLifts have allowed us to remain cutting-edge. We’re excited about what the future looks like using them on upcoming projects.”

365 Nicollet

A 30-story, multi-family and retail development located on historic Nicollet Mall. This contemporary, urban living space includes 10,000 square feet of street level retail space and 370 high-end apartment units.  

SCOPE:

  • 16,000 square feet of glazed aluminum curtainwall system
  • 120,000 square feet of pre-glazed windows and terrace doors
  • Custom metal panel system: reveal seam wall panels, flush seam soffet panels, and composite wall panels
  • All curtainwall and metal panels were prefabricated in Egan’s shop

The Legacy

This lavish condominium complex overlooks the Mississippi River in the Downtown East neighborhood of Minneapolis. It is complete with a 17-story tower, eight-story midsection, and 14-story riverfront tower that boasts 374 total units.  

SCOPE:

  • 116,000 square feet of pre-glazed windows
  • 400 terrace doors
  • Custom profile flashing at each opening
  • All curtainwall was prefabricated in Egan’s shop

Rafter (Opening Summer 2019)

Adding more depth to the Northeast neighborhood of Minneapolis, this 26-story apartment building is complete with 283 units and 6,000 square feet of street level retail space.  

SCOPE:

  • 47,000 square feet of pre-glazed windows and terrace doors
  • 7,400 square feet of glazed aluminum curtainwall and storefront
  • 20,000 square feet of insulated metal panels
  • 28,000 square feet of metal siding panels
  • Glass handrails and miscellaneous interior glazing
  • All curtainwall and storefront frames were prefabricated in Egan’s shop.

Putting Trash to Good Use

Tuesday, April 16th, 2019
Complete control system for a trash burner at HERC

During the annual fall shutdown, Egan Company was involved in upgrading the four burners that continually burn trash to produce energy. After 20 years without burner upgrades, Egan controls engineers, electricians, millwrights, and pipefitters were tasked with designing, programming, and installing a newer and more efficient process for the four burners.

“The most challenging aspect of this integrated project was the very tight timeline,” said Randy Kalthoff, Egan Company Project Manager. “We had four weeks to upgrade and connect all four burners so that they were fully operational and continuing to burn and produce energy.”

Fabrication of key components ensured the project was completed on time. Piping components were fabricated in Egan’s Mechanical Shop.

The four control panels, designed, fabricated, and programmed in Egan’s UL 508A Panel Shop, were installed by Egan electricians and can be remotely controlled from GRE engineers in the control room of the facility.

Next up at HERC, Egan electrical and mechanical teams will be partnering with HERC, GRE, and a number of other contractors during the upcoming spring shutdown to replace the large conveyors and the ash handling units.

Egan helped us take a system that was over engineered and more complex than we needed and create an intuitive system for everyone. It’s always great working with Egan and the multiple trades that we utilize every project.

– Eric Freitag, Maintenance Leader at HERC

Core Project Team: Hennepin Energy Recovery Center (HERC), Great River Energy (GRE)

Services Provided: electrical and mechanical demolition and installation, control panel fabrication, field device wiring, design, engineering, and programming of electrical controls, millwright services, pipe fabrication

Refined Initiatives Stimulate Safety Rate Reduction

Friday, April 5th, 2019

To be successful in the construction industry is no different than being successful in any feat, it requires consistency. Success demands day in and day out preparation, proper tools and effective training, equipment, and conditions. When it comes to safety, this recipe for success is the same.

From our company leaders to our field leaders and all of our employees in between, we believe the key to being safe is being proactive and consistently engaging our people with safety in everything we do. At Egan Company, safety is everyone’s job. It’s everyone’s job to make sure our safety policies and procedures are being consistently executed. It’s everyone’s job to help us achieve our goal of ZERO injuries and to come home to our family and friends at the end of the work day.

Through much hard work and a refined focus, Egan achieved its Total Recordable Incident Rate goal of < 2.0 for 2018. Our incident rate for the year was 1.87 (down from 2.42 in 2017) which is substantially below the average rate for specialty trade contractors in Minnesota (4.70). This was accomplished with over 1.8 million hours worked.

“Moving the safety needle in 2018 was a great achievement for us as a company,” said Reid Romer, Egan Company Safety Director. “Our safety incident rate is a direct reflection of the time and energy we’ve invested collectively to minimize risk and protect our people. This progress comes from specific safety initiatives we committed to improving over the past few years and we are now seeing rewarding results.”

An example of one of the changes made in 2017 was within the new employee on-boarding process. This process was specifically addressed after recognizing a pattern that new employees were consistently getting injured within their first six months on the job. Egan acknowledged this, invested in changing it, and elevated it on its priority list. As a result, new employee injuries have significantly decreased.

Though we are proud of this progress in 2018, Egan has no plans of slowing down its drive to be the best-in-class when it comes to safety. Utilizing employee and peer group feedback and experiences from last year, the bar is set even higher for 2019.

“Our goal is to continue to engage with our employees and do everything we can to keep this injury reduction track trending in 2019,” said Romer. “We’ll continue to fill the information and training pipelines, as well as remain diligent with planning in both the pre-mobilization and throughout our jobs. This, along with a team approach, will continue to give us an opportunity to lead the way for safety on our projects this year and in the future.”

Highly Specialized Project Completed in Crunch Time

Friday, September 14th, 2018

High-rise buildings are the distinguishing trademark of cities around the world. And, being the 16th largest metropolitan area in the country, Minneapolis and St. Paul are no different.

As a specialty contractor, Egan has played a role in helping to build, remodel, and maintain many of these high-rise buildings that help shape the Twin Cities’ skyline. While these projects have included scopes of all sizes, this past spring brought forth a very unique high-rise venture.

Egan’s team was utilized for a highly-specialized project in downtown St. Paul, Minn. The scope included the replacement of four massive cooling towers located on the rooftop of Galtier Tower – a staggering 31 stories from the ground.

Galtier Tower is one of two high-rise towers that make up the city block called Cray Plaza. The plaza also includes two other commercial buildings. Together, the block boasts hundreds of apartments and luxury condominiums, a small preparatory school, YMCA facility, and an assortment of other retail space – all of which fully rely on these cooling towers to air condition their buildings.

Overall, the project would require the tallest crane in Minnesota, in-house design and prefabrication, and even more pre-planning and coordination to complete the job within the compressed schedule.

Navigating a Tight Schedule

The project was officially awarded to Egan by Bigos Management in late March. From the start, Egan’s team knew the new cooling towers would need to be “flown” up to the top of the building. To do the “flying”, Egan began coordinating and pre-planning with a local crane company, Vic’s Crane and Heavy Haul.

An in-depth, engineered lift (or often called “pick”) plan was created while Egan’s team began designing the piping and support systems for the towers. A structural engineer was also hired to design the steel platforms for beneath each cooling tower based on the drawings provided by Egan.

Vic’s crane, standing at 410 feet tall, was tasked to hoist these four new cooling towers onto Galtier. However, driving a monster crane into a heavily populated urban city isn’t the most practical of tasks.

In the weeks prior to setting up the crane downtown, the city of St. Paul removed a light pole, cut down a tree, and approved and coordinated road closures. Vic’s also obtained multiple permits, clearances, and police support. Once complete, the crane took 12 hours to set-up on the street.

Another unique aspect of this project was that the new piping system for the cooling towers utilized Aquatherm – a fairly new type of system that is an environmentally friendly alternative to metal. Though extremely lightweight (and vibrantly colored!), Aquatherm pipe is one of the longest-lasting and most chemically inert piping material available.

Egan’s fabrication shop prefabricated all of the Aquatherm piping system for this job. It was also specifically designed so it could fit into the 7’7” elevator and transported to the rooftop of Galtier.

The Race to the Top

Although there was two feet of snow on the ground when the project started, Minnesota’s infamously, unpredictable spring weather found itself over 85 degrees just a few weeks later. With the previous cooling towers entirely off the building, the countdown was on to get the first new cooling tower operational in order to start cooling all of the buildings within the city block.

At the top of Galtier, Egan’s team worked with a subcontractor to set up an extensive amount of scaffolding so the team of pipefitters, electricians, and controls electricians could safely access the work. All of the prefabricated Aquatherm and structural steel platforms were also set before the crane could “fly” the cooling towers to the roof.

The first weekend of May, less than six weeks after being awarded the project, Egan’s team, alongside Vic’s, successfully lifted and installed all four cooling towers onto Galtier. The compressed schedule… accomplished.

Egan installed a majority of the piping after the cooling towers were set and officially completed the project in July.

Core Project Team: Bigos Management, Vic’s Crane and Heavy Haul

Services Provided: Cooling towers replacement, pipe fabrication, pipefitting, electrical controls, electrical installation

Work at U.S. Bank Stadium Leads to a Trip-of-a-Lifetime

Friday, September 7th, 2018

A dream came true for a football fan last April when Jason Lindula, Egan Company Safety Coordinator, was gifted a trip-of-a-lifetime.

Last spring, while renewing his tickets for this upcoming season, Lindula had the chance to enter a members-only drawing to win the ultimate 2018 NFL Draft experience. Not thinking twice about it, he opted in.

A few weeks later, he received a phone call he’d never forget – he had won!

The prize included an all-expenses-paid, five-day trip to Dallas, Texas to view the draft from VIP seating. And, even better, announce the Vikings late-round pick, Devante Downs, on national television.

Lindula joined the Egan team three years ago as Egan’s lead safety professional at U.S. Bank Stadium – home of the Minnesota Vikings. A long-time fan of the game, Lindula was inspired to become a season ticket holder after the time he spent at the stadium throughout the construction process.

 

Lindula particularly enjoyed connecting with fellow football fans from across the country and the opportunity to meet NFL Commissioner, Roger Goodell, and other NFL legends. The experience was truly unforgettable.

For photos and more information on Jason’s trip visit this link: bit.ly/NFLDraftArticle

Evolving With Clean Energy

Wednesday, August 22nd, 2018

SOLAR BOOM

The explosion of the solar industry started after the 2013 Energy Omnibus Bill which mandated large utilities in the state to produce 1.5% of their electricity from solar power by 2020 and allowed for community solar array gardens. This bill also gave consumers an option to utilize solar farms for a portion of their electricity, so the reliance and demand for more solar panel installation and ground-mounted solar arrays skyrocketed.

Egan, having previous experience with the installation of solar panels on high-rise buildings, shopping centers, medical facilities, and business park campuses, recognized the opportunity and utilized our electrical expertise in a way we had never before – installing ground-mounted systems in fields, valleys, and swamps around Minnesota.

“We received a call to complete a 9 Megawatts (MW) solar panel farm in eight weeks, and we knew it was our chance to show what we can do and do it well,” said Carrie Thompson, Egan Company Project Manager.

A CLOSER LOOK AT AN EGAN SOLAR SITE

Egan’s solar site projects vary in size, location, time of year, and type of solar panels – fixed-tilt or tracking. “Tracking” solar panels track the sun’s progress across the sky throughout the day, whereas the fixed-tilt solar panels stay in place. Last summer, 150 Egan electricians were on the 65-acre St. Joseph Solar Farm project to install 28,188 fixed-tilt solar panels.

This was a tight-deadline project, and Egan performed better than we thought possible. We had a contractual obligation to complete the community solar project in 40 days and Egan stepped up to complete the project on time. – Jamie Borell, IPS Solar Chief Operating Officer

 

The St. Joseph Solar Site produces 9 MW of electricity that Xcel Energy distributes to local subscribers of its solar garden program, all of which happen to be local school districts.
Egan had the role of lead contractor on this project and utilized both high-voltage and low-voltage electricians for all aspects of the process. Materials were prefabricated in our shop that provided safe working conditions and a faster schedule.

The 196 inverters were pre-mounted on a strut assembly (or racking system) and underground conduit stub-ups were prefabricated before going on site in St. Joseph.

ENSURING SAFETY ON EVERY JOBSITE

Egan technicians continue to install solar panels year-round, and have installed ground mounts in all weather conditions. The safety of our employees remains our number one priority throughout every project, and Egan has taken measures to provide extra in the less than ideal circumstances — from providing hand warmers and cold-weather approved boots to sunscreen and rain suits.

The installation process also has certain risk factors – the solar panels are actively producing electricity as soon as they’re exposed to the sun, and a solar array farm is erected with multiple moving parts.

“Over the last two years, we’ve completed a large number of solar panel projects in all weather conditions on all types of terrain,” said Thompson. “We’re excited to continue to partner with our customers on these renewable energy projects.

Hiring Heroes

Thursday, August 16th, 2018

For many active duty military members, transitioning out of the service can be daunting. Finding housing, employment, and acclimating back into the routine of daily life is a huge hurdle to overcome. And, although disciplined and highly-trained, many military members still struggle with unemployment.

To help ease this process and address the growing shortage for skilled construction workers, the United Association Veterans in Piping (VIP) Program was created. This 18-week program prepares active-duty military members to leave the service with sought after skills that can lead to lifelong careers in the increasingly high-demand pipe trades.

Specifically, the nationally recognized program trains and transforms heroes into Union Plumbers, Pipefitters, Welders, and Service Technicians.

Ricky Martagon, Egan Company Pipefitter Apprentice, first heard about VIP at an exit seminar he attended was transitioning out of the United States Marine Corps.

Martagon served in the Marines for four years prior to joining Egan and obtained the rank of E5 Sergeant, as well as Shop Chief for his platoon. Though an admirable rank, he’s the first to admit he continually reminds himself his previous title now holds no “authority” on the construction site.

“At times, it is a little confusing for me, but a lot of the habits from the military are still very transferable to my new career,” Martagon said. “I still would do them every day with or without rank.”

Nonetheless, the shift from protecting the country to helping build it has been a natural fit for Martagon and 1,000+ other veterans that have gone through the VIP program since 2008.

“My experience [with VIP] couldn’t have been any better. The people were great, and the instructors were even better,” said Martagon, “By the time we finished the program, we were all good friends. I strongly encourage more service men and women to look into the course.”

Martagon has been with Egan since early this year and is one of two VIP pipefitters currently with the company.

To Drive or to be Driven?

Thursday, August 2nd, 2018

Whether we’re ready or not, autonomous vehicles are becoming less like fictional stories and more versed into our reality. Although Minnesota doesn’t currently have driverless vehicles on its roadways, MnDOT is actively working on a pilot project to prepare for this future mode of transportation when it arrives.

Earlier this year, Roger Walz, Egan Company Technology Systems Manager, was invited to participate in this pilot project. As the current President of Intelligent Transportation Systems (ITS) of Minnesota, Walz was among 11 other people invited to take the driverless vehicle for a ride.

This particular driverless shuttle was fully electric, held up to 12 passengers (six seated and six standing), had no steering wheel, and operated based on pre-mapped lidar and GPS guided routes. Pedal to the metal it could drive at 25mph and was fully equipped with sensors to stop when a person or object was in front of it – which was demonstrated to the group.

The goal for the group was to simply experience the vehicle, provide feedback, and ask questions. This particular phase of the pilot project was to test and monitor the technology during the cold, wintry conditions of Minnesota.

“Before MnDOT can bring autonomous technology to the Twin Cities, many things would need to change,” said Walz. “And, the biggest changes would be within our roadway infrastructure.” 

Adopting driverless technology implies that the current technology within our roadway infrastructure would need to be compatible to move these vehicles. Everything from roadway lighting, traffic signals, fiber optic signage, loop detectors, parking ramps, and so much more would need to function with this technology.

“The hope is that Egan’s role could include an opportunity to furnish and install this electrical- and technology-based infrastructure,” said Walz. “As a company, we’ve always demonstrated an innovative, proactive attitude to embrace new technology and adapt with our marketplace.”

Nonetheless, it’s exciting to think about and consider where this technology will literally take us in the future. The possibilities are boundless. But, in the meantime, our regular vehicles will still be needed to get us from point A to point B.

Thinking Outside of the Trimble Box

Monday, May 7th, 2018

The Trimble Robotic Total Station is a no stranger to the world of construction. Used mostly at Egan for large, new construction projects, the “Trimble” plays an essential part of laying out electrical and mechanical systems.

Its state-of-the-art design was built to verify even the smallest details between the shop and field prior to construction on jobsites. This makes it an ideal tool to accurately lay out underground utility systems, between floor structures, and other flat-plane surfaces.

Though the Trimble has many uses, it had never been used for the glass and glazing industry until Egan Company took on its biggest curtainwall project to date: U.S. Bank Stadium.

“Given the massive size and architectural shape of the stadium, we knew we’d have to get creative,” said Dan Ford, Egan Company Field Services Manager. “However, the task to efficiently and precisely install glass to this 30-story structure was a challenge we excitedly took on.”

This project sparked a unique, innovative Trimble process allowing Egan to accurately lay out anchors directly to a vertical steel surface (different than Trimble’s intended use) and solve two big installation components: risk of human error and efficiency.

In a traditional layout of curtainwall, there are multiple passes that happen before anchors are welded to the steel structure and the glass inserted. A pass includes many provisional tasks that progress toward a more permanent step within a phase of construction; many “passes” are within a phase.

The multiple passes for a curtainwall project include:

  • measuring and marking reference points by hand
  • verifying those references
  • tact welding temporary anchor points onto the building

With Egan’s Trimble process, many of those passes are removed. A digital layout and survey of the curtainwall happen concurrently allowing anchors to be permanently welded in one pass. Therefore, saving an incredible amount of time and labor. The process also allows the team to identify structural flaws early, which allows time for correction prior to installing glass.

Successfully applying this process at U.S. Bank Stadium has led to similar work on other professional sports infrastructures. NBA franchise, the Milwaukee Bucks, will call a new, beautiful arena home beginning this summer. The aesthetically appealing arena is being constructed by M.A. Mortenson who has tasked Egan and its Trimble expertise for the arena’s complex glass and glazing scope.

“Egan’s innovative thinking and usage of Trimble is a perfect example of the versatility of technology,” said Aric Stott, Product Manager at Trimble. “As a result, they’ve run multiple glass/glazing projects with intricate architectural scopes very smoothly — and we [Trimble] have been able to implement several feature enhancements to our product that have helped us stay ahead of the curve.”