- National Security Campus
We were the owner’s engineer and program manager, in collaboration with the General Services Administration and the Department of Energy's (DOE) National Nuclear Security Administration (NNSA), for a new 185-acre campus with approximately 1.5 million square feet of built space in a four-building campus configuration. The NNSA Kansas City National Security Campus (KCNSC) includes approximately 900,000 square feet of manufacturing space comprised of heavy manufacturing, light manufacturing, labs, clean rooms, sensitive instrument areas, and electrical assembly areas, and approximately 600,000 square feet of office, warehouse and support space.
As the manufacturer of non-nuclear components for the U.S. nuclear stockpile, the KCNSC is part of the DOE’s nuclear security enterprise, which is responsible for stockpile stewardship, nuclear weapons dismantlement, and nuclear nonproliferation programs. The more cost-effective, energy-efficient KCNSC will deliver a 25 percent reduction in operating costs and more than 50 percent reduction in the infrastructure footprint from 3.2 million square feet to 1.5 million square feet. Construction and relocation activities were completed ahead of schedule and under budget.
Our team developed the Program of Requirements for the new facility and served as owner’s engineer, providing oversight through all phases of the new facility project, from initial planning phases throughout the three-year design-build process and continuing through area commissioning and building acceptance. We also provided project management and design services for the 19-month relocation phase, continuing through production readiness phases.
For specialty equipment and sensitive equipment, we were responsible for developing requirements for the new facility related to vibration and noise isolation for sensitive equipment areas. We completed three separate yet interrelated studies. The first study involved a Blast Assessment Report and included a subsurface investigation for the proposed site. The second study involved the measurement of vibrations at the existing DOE NNSA Kansas City Plant (KCP). The third study involved the measurement of vibrations at the proposed new building site. Sensitive equipment anticipated to be moved or otherwise located within the facility at the new site was characterized as being either:
- Minimally Sensitive Equipment, measuring/creating detail sizes from 25 to 250 µm, ISO Residential or Operating Theatre criteria
- Moderately Sensitive Equipment, detail sizes 3 to 25 µm, IEST VC-A or VC-B criteria
- Extremely Sensitive Equipment, detail sizes less than 3 µm, IEST VC-C or VC-D
As part of our services, we planned and executed the KCRIMS relocation. One of the largest industrial relocations in North America, KCRIMS moved operations from the existing Bannister Federal Complex to the new KCNSC. The relocation included 130 separate move phases for 24 different functional areas such as:
- Heavy manufacturing-heavy machining, welding and other material production operations
- Assembly and electrical fabrication, which included electronic manufacturing and assembly areas along with inspection and testing of small and medium-sized electrical components; Class 100, Class 10,000 and Class 100,000 clean rooms were included in these areas
- Labs and engineering labs, which included lab furniture, fume hoods ovens and testing equipment for chemical, mechanical, vibration and shock testing
- Paint and heat treat, which involved the preparation of parts for painting; paint processes required special temperature and humidity constraints, and heat treat required media blast booths with dust collectors, heat treat and quenching operations
The relocation included approximately 40,000 moving crates and 2,700 pieces of large equipment in roughly 3,500 truckloads. During this time the M&O contractor maintained dual capabilities at each site, achieving a 99.9 percent on-time delivery record of parts. The relocation finished more than $15 million under budget and one month ahead of schedule, while meeting all targets for quality, safety and security. Top officials, including the Secretary of Energy, described the performance of the project team as “remarkable” and “better than flawless.”Project schedule constraints resulted in a design-build process with multiple construction packages for the new facility. Base facility infrastructure was installed while detailed tenant requirements were still in the design process. Burns & McDonnell worked closely with the developer and contractors to ensure proper integration of stringent owner requirements. This coordination effort allowed the facility construction project to remain on schedule without sacrificing owner functionality required from the final tenant fit out of the facility.