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Cover Story - November 2003
Project Called Third Largest for Hospitals in Illinois
Prognosis Good for Central DuPage Hospital Expansion

by Jeffrey Steele

The construction team undertaking the enormous expansion of Central DuPage Hospital in Winfield had to figure out how to keep the acute care facility in full operation 24 hours a day, seven days a week.

One of the first steps was establishing an interim exiting program, said Robert Garrison, president of Garrison Inc., the project's Chicago-based development and construction consulting firm. Garrison is perhaps best known for its work on the Prudential Plaza project from 1986 through 1996.

"If you're going to tie new buildings into existing ones, you need to close off certain exit corridors and provide new ones that meet all applicable codes and are in accordance with the requirements of the Illinois Department of Public Health," Garrison added.
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But the interim exiting program was only part of the answer. Garrison, general contractor Pepper Construction and other team members also had to address phasing.

"That meant vacating certain areas of the hospital, reconstructing them, relocating certain departments within the hospital, all in consequence with the new construction total project schedule," Garrison said. "Almost everything within the existing hospital ends up being rebuilt under the final plan."

Montie Garrison, executive vice president of Garrison Inc., said the phasing during construction evolved from month to month. He added that the contractor, architect and affected hospital departments worked together with the owner's representative to create successful solutions.

And then there was the staging, which required extensive and intricate logistical planning because the hospital was surrounded by construction on virtually all sides, said Jim Guyette, Tinley Park-based senior vice president with Chicago-based Pepper Construction Co.

"Two inspectors from the Illinois Department of Public Health called it the most intricate construction phasing plan they've ever seen," Guyette said. "They come to our jobsite once a month. Because the phasing is so complicated, it's their job to make sure the safety of patients is never compromised."

The expansion project, the third largest hospital construction project in the history of Illinois, involves a construction cost of $140 million. The Certificate of Need came to $188 million, including soft costs, medical equipment, telecommunications, fixtures and signage.

Three Major Project Components

Expansion at Central DuPage Hospital, which was originally built in 1964, will involve three major components:

  • An entirely new 425,000-sq.-ft. ambulatory services pavilion, which will include 137,000 sq. ft. of office space for almost 100 physicians.
  • An expansion of the maternal-child care facilities, which will add 135,000 sq. ft. and include modernization and expansion of physician office space, pediatric services, pediatric intensive care beds, labor and delivery. It will also add 36 private rooms.
  • An expansion and modernization of ancillary services and the surgery department in the hospital's North Tower. Included in this work is expansion of the hospital's surgical suite, cafeteria and kitchen, as well as pharmacy services.

    Work on the entire project began in October 2002 and is expected to be complete by the first quarter of 2005.

    Dick Rouse, vice president of facility services for Central DuPage Health, hospital owner, said the expansion will be a major step forward for the hospital. "It will conveniently provide centers of service around patients and visitors," he added. "It will obviously modernize our existing impatient and outpatient and ancillary services.

    "This is our attempt to redesign and modernize our facility, to reflect advances in technology. We are adhering in this project to a continuing shift from inpatient services to an outpatient setting."

    Building Over Busy Areas

    Pepper Construction's Guyette said one of the most difficult pieces of the project has been building new hospital floors in the maternal-child care area directly over occupied areas.

    "We're building three floors of new construction on top of patients," he added. "All the lifts for steel work had to be coordinated and select areas of the floor vacated. There's extreme care taken to leave the existing roof in place to keep the lower floors watertight. You come later on after the building is complete and remove that roof."

    He said the substantial mechanical equipment housed on the old roof had to be relocated to the penthouse, a mechanical enclosure on the roof that houses pumps and other mechanical equipment.

    Limited staging area has also necessitated the use of four tower cranes. The cranes were needed to provide the dramatic lifts required by the small staging areas, Guyette said.

    The mechanical, electrical and plumbing design conforms entirely to all existing codes, as well as Illinois Department of Health requirements, Garrison said.
    Information services will be upgraded with new equipment, and an entirely new data center will be constructed on the hospital campus.

    Designed for Care

    The expansion also presented a number of challenges for the design team, said J. Todd Robinson, senior designer and principal-in-charge for Earl Swensson Associates, the Nashville-based firm providing both architectural and interior design services. One of the design priorities was providing "portals of care" that would integrate inpatient care, outpatient care and physicians in an operationally efficient and user-friendly design.

    To achieve this, designers created a vertical outpatient mall within the ambulatory services pavilion, with convenient access from parking. Patients headed to the cardiology floor can park on the same level as cardiology services, then walk directly into the mall to obtain outpatient cardiology services. All cardiologist offices will be located on that level. The outpatient mall is adjacent to an outdoor courtyard.

    "A lot of times, when you go into a building, you get lost within a maze of corridors," Robinson said. "With this building, though it's very large, you're able to orient yourself to the courtyard and know where you are within the building itself. Not only does [the courtyard] allow natural light to flow into the building and provide a healthy environment, it also allows visitors to not totally rely on signage."

    Another design hurdle came because the floor-to-floor heights in the existing hospital weren't adequate for current-day practices.

    The response from Swensson Associates was to call for flat-slab construction, which took the structural depth out of the space to provide adequate floor-to-floor heights.

    "Within the existing structure was post-and-beam construction, with a beam depth and a slab integrated but on top of [the beam]," Robinson said. "We eliminated that beam depth through flat-slab construction. That depth allowed us additional plenum space that permitted us to run our mechanical ductwork and lighting fixtures above the ceiling in adequate space."

    Designers also had to provide architecture that enhanced the facility while meeting Winfield village officials' call for a traditional look. Efforts were made to blend new brick with existing brick.

    In addition, a man-made cut-stone-like product called Arristcraft was used for roof cornices to provide some of the required traditional appearance. And a liberal use of curtain wall was incorporated to somewhat offset the enormous scale of the building.


    KEY PLAYERS
    OWNER: Central DuPage Health, Winfield, Ill.
    OWNER'S REPRESENTATIVE DEVELOPMENT AND CONSTRUCTION CONSULTANT: Garrison Inc., Chicago
    GENERAL CONTRACTOR : Pepper Construction Co., Chicago
    ARCHITECT: Earl Swensson Associates, Nashville, Tenn.
    MECHANICAL ENGINEER: Robert G. Burkhardt & Associates, Chicago
    CIVIL ENGINEER: Bollinger, Lach & Associates, Oak Brook, Ill.
    STRUCTURAL ENGINEER: Structural Design Group, Nashville, Tenn.

    'Two inspectors from the Illinois Department of Public Health called it the most intricate construction phasing plan they've ever seen.'
    - Jim Guyette, Pepper Construction Co.


    'This is our attempt to redesign and modernize our facility, to reflect advances in technology.'
    - Dick Rouse, Central DuPage Health

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