Thursday, August 1, 2013

50 Years of Setting the Standard

‘The Kinsley Way’
Left to Right: Tim Kinsley, Pat Kinsley, Jon Kinsley, Anne Kinsley, Rob Kinsley, Bob Kinsley and Chris Kinsley
Companies are defined by their reputation, culture and values. At Kinsley Construction, we call that “The Kinsley Way.” With guiding principles that emphasize quality, accountability, a sense of urgency, employee empowerment and achieving results, Kinsley has been setting the standard for construction excellence for 50 years. Today, Kinsley is proud to have developed seven separate business units that are fully capable of operating independently but that have the ability to join forces and provide more cost-effective, efficient and coordinated projects for its clients. The business units also provide stability for the company as market forces vary within different market sectors. The day-to-day activities at Kinsley are managed by second-generation family executives and personnel who “grew up” in the business. Bob Kinsley, founder and CEO, remains involved in all aspects of the corporation on a daily basis.

Apprentice Program

Appalachian Trail Museum in Pine Grove (Pine Grove Furnace, PA)
The Kinsley Apprenticeship Program has an articulation agreement with Harrisburg Area Community College.  This program has met and exceeded its original expectation, giving the apprentice an opportunity of a lifetime to also obtain an Associates Degree.

Presently there are several apprenticeship programs at Kinsley.  Four-year programs include Commercial Building and Highway & Bridge.  There is a three-year Ironworking apprentice program as well.  Our apprentices come from York, Adams, Lancaster, Dauphin, Perry and Gettysburg areas and more recently, Baltimore.   At the completion of their apprenticeship, students receive their Journeyperson status from Labor and Industry.

Deb Rohrbaugh, Associate Director, spends many hours each year meeting with students and parents to share information and inspire them to prepare for acceptance in this program.  Each year applications are accepted in January and February; March brings testing and interviews and decisions are made for the August class.  Instructors for the apprenticeship program are Steve Taylor, Gary Schaeffer and Rich Miller who work very closely with the apprentices in the Building Division.  They provide classroom instruction and on the job training as well.  Kinsley supervisors, foreman, and lead men are a huge part of the apprentice program – they provide training on the jobsites.  We are looking forward to another quality year of working with our new apprentices.

This group of first- and second-year Apprentices teamed up with the Site Division for construction of a grass walkway at the Appalachian Trail Museum in Pine Grove Furnace, PA.  This walkway provides public access to the upper- and lower-level grounds outside of the Museum.  In order to keep the natural look of the trail, the access walkways were seeded to allow for grass to grow.  The Museum handrails are made of wood and have replaced the white rails as shown in the photograph.

In closing, I want to say that I am very happy to be here at the Kinsley Education Center and feel fortunate to be working with such a great group of people.  My first few months have been very busy and challenging as I become accustomed to the duties of my position.  It has been a pleasure meeting new co-workers and I look forward to many more years as a Kinsley employee and being part of this wonderful team.

Carol True
Director of Eduction

A new associate, Carol True, was hired to assume the Director of Education position in April.  Carol brings with her many years of assisting co-workers in the steel industry who took classes to enhance their abilities both on the job and in their personal lives.  Carol welcomes this opportunity and is eager to assist Kinsley associates and its affiliates in their education experiences.  In addition to training required in the construction industry, the education center has classrooms available for your training/meeting needs.  Please contact Carol at (717) 851-1053 with any questions you may have.

Leadership Mentoring

(Back Row) John Sivulka, John Diehl, Jerry Caslow, John Clemons, Jan Wagner (Front Row) David Muehling, Wanda Peatross, Bob Kinsley, Kayla Holdridge (YC), Norman Rathborne (YC), Matt Jovineli (YC), Stephen Przybyszewski (YC) and John Kotchish
Kinsley Construction has always been a supporter of York College of Pennsylvania.  This past semester, we had the privilege of participating in a Mentor Program and teaming up with four senior YCP students (Matt Jovineli, Kayla Holdridge, Stephen Przybyszewski and Norman Rathborne) as part of an Integrated Business Experience course led by Professor Chris Meisenhelter.

The students were able to gain first-hand knowledge of several of the Kinsley Companies as well as taking a more in-depth look at one of the Kinsleys current educational construction projects at York College, the Willman Business Center at the Graham School of Business.  Under the leadership and guidance of Jerry Caslow, Kinsley Vice-President of Finance, the students were able to meet with multiple Kinsley employees and participated in various aspects of business development, marketing, accounting, human resources, estimating, safety, steel fabrication and project management to highlight just a few.

The program recently concluded with the students giving a professional presentation to about a dozen Kinsley employees, including Robert A. Kinsley, CEO and several YCP faculty members.  The students summarized what they had learned about the company through their time spent with us over the past several months.  They also shared with us suggestions on ways that we may improve the integration within our company.

It is wonderful to see such bright and talented young men and women preparing to graduate and enter the business community.  It was a privilege for us to share some of our time with the students and to continue the relationship between York College and Kinsley.

Jan L. Wagner
Project Executive

Energy Modeling

Energy modeling is a tool used by Kinsley Construction during the design, pre-construction, and construction phases of a building project to assist owners in decision making.

Energy modeling is used throughout the design process to provide life cycle cost analysis of various energy efficiency measures and alternatives to aid in making design decisions.  Everything from schematic level decisions such as building placement and orientation within a given site, to HVAC system selections, to the quantity of insulation to include within exterior walls can quickly be assessed and summarized to aid a building owner in making a decision.  The end result of this series of informed decisions is a high performance, optimized building with little money wasted on features or equipment that won’t offer a favorable payback.

Sample Results from Building Energy Modeling - Annual Utility Usage
One benefit of Kinsley’s participation in this building optimization process is the potential for mechanical and electrical systems to be reduced in both capacity and space requirements.  Smaller ductwork, piping, conduit, and equipment can help alleviate conflicts during construction and limit scheduling delays.

One of the biggest advantages for Kinsley when performing life cycle cost analyses is the generation of reliable and accurate capital costs for various options.  Kinsley has a wealth of previous project cost estimates and subcontractors that they can rely on to get quick and accurate cost estimates for all energy conservation measures.

Energy modeling is not limited to new construction.  Many owners have existing buildings in need of substantial renovations and upgrades.  One service offered in these circumstances is a thorough walkthrough and audit of the existing building envelope and engineering systems.  The intent of the audit is to develop a comprehensive list of all energy use within an existing building and to use that list to generate a calibrated energy model and help determine the most effective capital improvement options.

A calibrated energy model uses the results of the building audit, and then adjusts equipment, building envelope, and scheduling variables in order to get the results to closely match actual utility bills.  Calibrated energy models can be used to benchmark an existing facility in order to compare its energy use against similar facilities across the country.  This relative energy score can then be used to target the worst offenders on a campus or the worst performing buildings in a client’s portfolio for renovation.

Another application for energy modeling is the documentation of compliance with federal grant, rebate, and financial incentive programs.  Alternative sources of funding for construction projects is available, however a large number of these government programs are beginning to require independent, third party energy modeling to validate the energy savings of a proposed building in order to qualify for the incentives.  The requirement that the energy modeling be performed by a third party, not a representative of the owner or design team, opens up an avenue for the construction manager to step in and fulfill a need.

Much like Building Information Modeling (BIM), energy modeling requires a collaborative effort of all project team members to be a successful and worthwhile exercise.  The results of the energy model are only as good as the inputs, and extensive communication and coordination is required across all design disciplines in order to ensure the accuracy of the model.  For this reason, it becomes a natural fit for a construction manager to offer these services.  Historically, it has been our responsibility to ensure the coordination of all parties throughout the construction process.  The spirit of sustainable design is the idea that all building systems and components work together and complement one another to function in the most efficient way possible.  Energy modeling is one tool available to the design and construction team that can provide an approximation of that final product.

Kyle Flanagan P.E.
MEP Coordinator

Fall Distance

Falls are the number one cause of construction related fatalities and have been for many years.  This is why Kinsley has a zero tolerance fall protection policy for employees that are exposed to a fall hazard of 6 feet or more.  Guardrails, warning lines, and personal fall arrest systems are some of the ways employees can protect themselves from fall hazards.

Personal fall arrest systems (PFAS) are made up of three different components; a harness, an anchor point, and a lanyard.  The OSHA standard 1926.502(b)(16)(iii) states that a PFAS must be rigged so an employee may not free fall more than 6 feet or contact a lower level.  In many instances a 6-foot lanyard may not be an effective method of fall protection.  When using a 6-foot lanyard you need a clearance of 18.5 feet from the anchor point to the floor below (View the diagram to the right).  Tying off overhead is the ideal anchor position but may not be possible in some scenarios.  If the anchor point is lowered and a fall occurs, the chances of an employee striking the ground is greatly increased.  Therefore, a 6-foot lanyard device, if used incorrectly, can give employees a false sense of security.

With new safety products coming out each and every day, Kinsley Construction has found a safer more effective way of “tying off”.  With the use of a double legged retractable we are able to reduce our fall distance from 18.5 feet to 11 feet from the anchor point.  The double legged retractable stops an employee within two feet after a fall, decreasing the free fall from 6’ to 2’.  Also, the retractable device does not have a deceleration pack, therefore eliminating the 3.5 feet of stretch from a 6-foot lanyard.

Double legged retractable devices will greatly reduce the chance of an employee striking the ground in the event of a fall, and that is the main purpose of a PFAS.  Kinsley Construction has already started phasing these products into the company to allow employees to work safer every day.

Rick D Brooks

Front Street (Harrisburg, PA)

Kinsley Heavy Highway/Bridge currently has a PennDOT project in Harrisburg PA, at the interchange of Front Street and SR 81.  This $1.4 million project consists of two single-span structures, both of which require the performance of the same scope of rehabilitation work.  The biggest challenge so far has been getting started on this project.  The first delay was due to the incompletion of the George Wade bridge contract.  Complicating matters was the tanker fire that took place in early may; the ramp that was affected by the fire - and closed due to instability - was on our detour route, requiring PennDOT to redesign a detour plan before we could start.  The project schedule was very tight to begin with; now we have even less time to complete the work this year. The first ramp to be done is the North Front Street to SR 81 Southbound ramp, then we’ll switch to the off-ramp from SR 81 to the South Front Street ramp.  The work items consist of: detouring the ramp, milling one-fourth inch off the existing deck, demolition of the back walls, remove and replace a three-foot portion of the deck and parapets  at the existing joints,  jacking of the structure to remove and replace the bridge beam bearings, set new dams, tie rebar and pour them in place, hydro demolition one-half inch off the deck and the placement of one and one-half inch of latex modified concrete on the deck within seven days, and reconstructing approximately  800 feet of shoulder on each side of the structure with asphalt and concrete patching of the existing ramps.  This work needs done in under 90 calendar days or it’s a $5800 fine per day.  We are maintaining an aggressive schedule, keeping PennDOT well- informed of potential delays, and the crews are beating aggressive productions.  This formula will keep us on schedule to have the first bridge completed within 90 days. The last items to be completed do not fall under the 90-day time limit and include structural steel repairs, removal of the lead-based paint, and application of a new paint system on the beams of both structures.

York County Cool Creek Road

The Cool Creek Road Reconstruction Project was one of PennDOT District 8-0’s initial design/build projects that were let in October 2009 and finally progressed to physical construction this year.  The anticipated construction timeframe was originally conceived to occur between October 2010 and October 2011.  The expected duration for design, permitting, Right-of-Way acquisitions and utility relocations was 10 months; however, due to numerous issues, the actual duration became 32 months.

Last August, once the last utility had been relocated, Kinsley Construction, Inc. was prepared to begin the project in mid-August.  The project was to be constructed while Cool Creek Road was under a detoured condition and the signs were in place, but before the detour implementation, Kinsley received a phone call from PennDOT directing that the detour not be implemented until further notice.  It had been determined by PennDOT that because local residents and businesses were already impacted by at least two or three other construction projects, one of which had a detoured condition, they would postpone the construction of this project until the Spring of 2013.  Should the project progress as planned, the anticipated completion date is June 14, 2014.

The project consists of a variety of construction work including demolition of existing buildings and structures, excavation, storm sewer installation, construction of two post-tensioned box culverts that replace two bridges, roadway widening and reconstruction.  The existing alignment is being adjusted to soften some of the more drastic curves both horizontally and vertically.  Additional improvements include the installation of guiderail, signing and delineation.

I-83 Exit 10 (LOGANVILLE, PA)

This $11.4 million PennDOT project was awarded to Kinsley via the traditional design, bid, build method. This project involves improvements to the I-83 Exit 10 interchange, with construction items including replacement of the existing SR 3100 over I-83 with a 2-span continuous composite pre-stressed concrete bulb-tee beam structure, approach roadwork including the realignment of SR 3100, widening of SR 3100, upgrading and widening the interchange ramps to provide enhanced acceleration and deceleration lanes, re-alignment of the interchange ramps, concrete pavement, guiderail, fencing, milling, paving, pavement markers and other miscellaneous operations. Also included is the removal of the existing SR 3100 over I-83 bridge structure after the new bridge is completed and traffic is utilizing the new structure over I-83. This project is scheduled to be completed in the summer of 2014.

Heavy/Highway Division Overview

2013 is all about positive change for the highway and bridge division.  Our marketplace has been very challenging over the past few years, and we’ve experienced our share of turnover.  We’ve responded to these challenges by re-tooling operations and changing our mindset with respect to how we execute our work.  When the market is so tight that every move you make counts, you have to be prepared to make them all count.  The most impactful change occurring within the group is our shared understanding that we are working towards common goals - not individual interests.  As a result, we are experiencing increased pre-performance planning, greater communication, and sharper execution; with these things will come success.

Our estimators continue to work hard to maintain our competitive edge and to stay at the top of what remains a very competitive marketplace, and we have recently been awarded 4 new projects.  SR 116 from Broadway Street in Hanover towards Spring Grove is a safety and resurfacing project that will start next Spring.  In Lancaster County we have a new three-span bridge project over Amtrak that will start after existing high-tension power lines are relocated.  In Lehigh County we have a bridge project starting this summer that includes the rehabilitation of two bridge superstructures.  Most recently, we have been awarded a four-year maintenance contract for various repairs to 28 PennDOT bridges within District 8-0.  This contract includes up to three additional years of T&M work throughout the District to keep bridges at serviceable levels.  Maryland Bridge has recently been awarded a sizeable project in Clarksburg, Maryland from a repeat client.  Construction is just getting underway, and we’re excited about the opportunity to deliver another quality bridge project ahead of schedule to meet the Owner’s needs.  

Changing how we look at or think about the work we do is instrumental in staying ahead of the curve.  Our project managers and supervisors have the difficult challenge of meeting the owners’ wants and needs while ensuring each project is successful for us as well.  To see us emerging from the recession with such a high-quality highway and bridge team is a testament to the resolve of the Kinsley employees, and it all starts with a “can-do” attitude.

Fred Thompson
Division Coordinator

Mount Vernon Mill

Before Construction
After Construction
The renovation of the 263,000 SF century-old Mount Vernon Mill has come a long way since its start, much like the mill itself. Spanning the Jones Falls Waterway, the property was first the home of a flour mill, which utilized the Jones Falls to power its milling operations. Like several other flour mills in the area during the mid-1800s, the facility became part of the Mount Vernon Company, a leading maker of cotton duck cloth for ship sails and canvas cloth for tents. Soon the Mount Vernon Mill will enjoy its new life as a mixed-use complex that includes 93 apartments, an interior parking garage, retail space, commercial office space, and two restaurants.

Kinsley Construction is the Construction Manager of this historic adaptive reuse project. The pictures capture the Kinsley steel erectors constructing the clear span pedestrian bridge over the Jones Falls and also rigging the historical weaving loom back to its original home after being an artifact at the Baltimore Museum of Industry for many years.

Dollar General

Kinsley Construction is building the new regional distribution center for Dollar General in Bethel Township, PA. The facility will have the capacity to serve over 1,000 Dollar General stores in the northeast.

The project includes nearly 1 million SF of warehouse and office space, as well as a truck maintenance facility. As part of Dollar General’s commitment to the Green Portfolio Program, this facility incorporates features designed to reduce greenhouse gas emissions through LED lighting and energy management systems that automatically control lighting and climate. This climate control along with quality branded interior finishes,
is one way that Dollar General provides a pleasing work environment for their associates. Dollar General collaborated with the Minneapolis office of Leo A Daly to design the facility. Construction is scheduled for completion by late 2013.

York College Business Administration Building

Kinsley Construction was selected to provide Construction Management services for the addition and renovations to the Willman Business Center at York College. Features include a two-story lobby with a new outside entry leading to the auditorium and a renovated main entrance from the academic courtyards.
The new, generously-sized lobby is designed to reflect a corporate environment and includes soft seating, a coffee bar, department and faculty offices, and a conference room. The existing main entrance will be clad in contemporary materials to update the look of the facility. The additions and renovations are tied to the existing campus through the use of the York College standard brick on the lower portion of the building.

Volvo Construction Equipment

Volvo Office Building
Volvo has been a valued Kinsley customer since 2008. As a part of our continued relationship with the construction equipment manufacturer, Kinsley recently completed a series of projects at the company’s Shippensburg campus.

Volvo Office Addition
To permanently accommodate the move of Volvo’s sales staff to the Shippensburg campus, the company needed additional office space. Kinsley was engaged to construct a new 32,000 SF, two-story office building adjacent to their existing facility. The two structures are joined by a connector bridge/walkway on both floors. Volvo is deeply committed to sustainability and has incorporated it into their own real estate and design standards. These standards, along with some innovative design and construction practices employed by our team to achieve LEED points, puts this project on track to reach its goal of LEED Silver Certification.

Challenges on this project included a high level of pedestrian traffic and a rock-filled site. To overcome these challenges, Kinsley worked closely with Volvo’s safety and security team to ensure that employees and visitors were kept safe and clear of construction activities. Rock excavating and blasting had an approximate 6-week impact on the project schedule and occurred close to neighboring communities, requiring careful communication and coordination with Volvo and their neighbors.
PDI Facility

Recon/PDI, Maintenance Facility, and Test Track
In order to free up space in the manufacturing facility for future potential equipment assembly lines, Volvo  ngaged Kinsley to build new facilities for the company’s Recon/PDI shop and Maintenance Building for the facility maintenance staff. At the same time, we worked to extend their equipment test track so that Volvo could conduct expanded testing of graders and loaders.

Maintenance Facility
Maintaining the project schedule was the greatest challenge on this project. Rock excavation, the holidays and winter weather all threatened to impact the project schedule, but by developing construction alternatives to those challenges (like the installation of a mechanically fastened roof in lieu of a fully adhered roof, which isn’t conducive to cold weather application), we were able to deliver the project to meet Volvo's required completion dates.

PDI Facility
Kinsley continues to enjoy an excellent relationship with Volvo. We are already engaged in the renovation of the existing office facilities and we look forward to working on their new Customer Care Center which is currently in design.