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How Prefabricating Headwalls Reduced Installation Time at Meriter

Posted By Tiffany Scuglik On November 13, 2017

JP Cullen is currently engaged in a project at UnityPoint Health-Meriter Hospital in Madison, Wisconsin. The scope of the project consists of the interior renovation of the North, Center, and West Wing of the facility to expand the Women and Infants Center. This expansion is to accommodate additional births.

At JP Cullen, we are always looking to find new, creative ways to prefabricate at our jobs. Our Prefabrication team took on the task to prefabricate the headwalls of these new patient rooms.

The Process
A collaborative effort was initialized by JP Cullen to work with the customer and sub contractor to brainstorm ideas for the easiest way to go about prefabricating the headwalls. JP Cullen worked with the millwright supplier to prefabricate the units in their shop and ship them to the job site with minimal final assembly required onsite.

To ensure the prefabricated headwalls would meet the hospital requirements, weekly reviews were held onsite. The reviews were conducted by Meriter’s construction manager and members of the hospital staff to review location and layout of all hook-ups and outlets.

The construction manager and the architect conducted a review of the first headwall in the suppliers shop to make sure it would meet their requirements.

The team had to overcome a demanding, mission critical, schedule to turn the rooms over in time to accommodate new patients. Prefabricating the headwalls allowed work to continue in each room while the headwalls were being constructed. One of the challenges of this can’t miss schedule was the multiple types of headwalls on multiple floors; but the biggest challenge would be exceeding the customers expectations for prefabricated headwalls as their past experience with other contractors have not yielded their expected results.

One of the biggest reasons this project was such a huge success and part of the reason for such great satisfaction from the client was the buy in and interaction from the customer. Having those weekly meetings with the individuals who will be using this equipment and facility on a daily basis, allowed us to get important feedback on the design that we wouldn’t have had otherwise. JP Cullen continuously received feedback and incorporated it in the design until the final layout was agreed upon.

By prefabricating these headwalls, JP Cullen enhanced customer satisfaction with the precision of layout and quality of work. JP Cullen carpenters build and install time was reduced by 61%, the electricians reduced their install time by 50%, and the plumbing connection time was reduced by 66%.




Key Team Members Included:
Hillcraft | Millwright Supplier
Plunkett Raysich Architects | Architect
JP Cullen Carpenters: Derek Deniger, Tim King, Barry Woodrick

Filed Under JP Cullen