A Beautiful Church – A Wonderfully Dry Building!

2014 St. Francis by the Sea Building Construction Project, Phase I Summary Report

-Submitted by David Decrow-

North Wall – BEFORE

Construction Contract – Planning and Work Scope

On June 13, 2014, a construction contract agreement was signed by St. Francis by the Sea and general contractor E.L. Shea, Ellsworth, Maine. The contract work scope was based upon architectural plans and specifications prepared by Lewis & Malm Architecture, Bucksport, Maine. The contract sum was structured as “cost of the work plus contractor’s fee” with a guaranteed maximum price (GMP) not to exceed $ 394,003.00 with a substantial completion date of September 26, 2014. Construction work commenced on June 16, 2014.

North Wall AFTER!

North Wall AFTER!

The GMP contract arrangement was chosen for the following reasons:

  • The existing structure had serious water leakage problems along the north masonry wall of the undercroft. The underlying causes of the leakage were complicated due to previously existing design and construction defects, which added risk to a successful project outcome and somewhat limited the project design choices and remedies. The GMP approach was a fair approach for the client, contractor, and the contractor’s subs (subcontractors) because of the existing building condition.
  • Since this renovation / repair project resulted from problems created with a previous renovation project and due to magnitude of the expense involved, it was felt that the project had to “get it done right”; therefore, it was paramount to have qualified, experienced trades people performing the work, particularly, for the roofing work. The GMP approach allowed for selection of qualified, competent contractors.
  • The contract arrangement also provided flexibility throughout the building process to work through and resolve design and construction details. Weekly construction meetings functioned well to solve emergent issues in a productive, cost effective manner, which benefited the project outcome.

Essentially the construction contract work scope included: 1) Correct the water leakage along the undercroft north wall, 2) Protect the north wall masonry, 3) bring the building exterior shell into good repair condition, and 4) provide additional insulation at the undercroft north wall and roof area.

Careful Removal of Sod Roof Overburden

Careful Removal of Sod Roof Overburden

The existing “sod roof” was removed along with approximately three feet of the upper parapet portion of the undercroft north masonry wall.

A cloister roof extension and supporting columns were installed along the north undercroft wall.

Cloister Column Foundation

Cloister Column Foundation

North Wall View with Upper Parapet Wall Removed, Blue Sub-Roof Installed, Start Framing Cloister Roof Extension, Stone Masonry Cement Joints Ready for Re-Pointing.

North Wall View with Upper Parapet Wall Removed, Blue Sub-Roof Installed, Start Framing Cloister Roof Extension, Stone Masonry Cement Joints Ready for Re-Pointing.

A low-slope EDPM (premium grade rubber membrane) roof, and drain system replaced the existing undercroft roof and continued out over the new cloister roof extension. Upgraded insulation was installed under the roof membrane area over the undercroft.

EDPM Membrane Roof & Roof Drains

EDPM Membrane Roof & Roof Drains

Roofing Detail, Clapboards Removed, Water Protection Membrane (Blue) and Metal Flashing Installed, Roof Membrane Wear Mats in Place

Roofing Detail, Clapboards Removed, Water Protection Membrane (Blue) and Metal Flashing Installed, Roof Membrane Wear Mats in Place

Other work included in the base contract included: re-flashing of windows and doors

Detail, Zinc Coated Copper Flashing, Lower North Wall Openings

Detail, Zinc Coated Copper Flashing, Lower North Wall Openings

throughout the building, repairing and/or replacing exterior wood trim (about 100 feet of wood trim was replaced on the steeple in addition to other trim on the main building), re-roofing the entire wood shingle roof with architectural grade asphalt roofing, re-pointing cement joints and water proofing all masonry walls, replacing the sacristy window including replacement of rotten wall framing at the window opening,

Detail, Sacristy Window Replacement, Rotted Sub-Framing Below Window Opening

Detail, Sacristy Window Replacement, Rotted Sub-Framing Below Window Opening

painting the building exterior & steeple, installing foam insulation along the undercroft north interior wall cavity, and replacing dry wall in the undercroft.

Newly Installed Upper Roof

Newly Installed Upper Roof

Additional Work – Contract Change Orders

A total of six (6) work change orders totaling $17,362.00 were added to the base contract work scope during construction:

  1. Re-roofing “skirt” roofs on the steeple.  This work was not contemplated originally.

    Detail, Re-pointed Masonry and Renovated Back Wall

    Detail, Re-pointed Masonry and Renovated Back Wall

  2. Additional stone removal and flashing at the north wall. This detail was finalized during this construction.  It could not be evaluated prior to construction.
  3. Rebuild trim at front entry.   It took addition work to replace old,rotted trim and replace flashing rather than repairing the existing trim.

    Detail, Rotted Trim at Front Door - Typical of Window,  Door & Trim Board Replacements

    Detail, Rotted Trim at Front Door – Typical of Window, Door & Trim Board Replacements

  4. Re-route lightning protection wiring.  This issue was discovered during construction.
  5. Secure loose masonry wall stones, another issue discovered only because of the construction.
  6. Install new interior wood trim.  This was additional work.

Project Completion – Budget & Schedule – Conclusion

A certificate of Contract Substantial Completion was issued October 17, 2014. The project was completed approximately as proposed at the start of the construction process with a four-month estimate for completion of the work. The October 17 date is beyond the contract September 26 date, however, additional work was completed during the construction. The actual GMP cost total was $ 3,689.01 below the original contract amount of $ 394,003.00, with the contract and change order sums totaling $ 411,366.00, or an approximate 3.5 % increase over the original GMP price.

Completed Cloister

Completed Cloister

Within the contract total sum listed above, there is a small “hold-back” of monies outstanding for lawn re-seeding and exterior painting to be completed spring 2015 as weather conditions allow.

In conclusion, beyond budget and schedule issues, the design and construction work accomplished during this project was completed carefully, in a thorough, professional, detailed manner to produce a good result allowing continued use of the building.

The Project Participants

Dan McGraw,  Atlantic Engineering, Surry, Maine, Structural Engineering, Owner’s  Representative

Rick Malm , Lewis & Malm Architecture, Bucksport, Maine Architect

Charles Earley, Senior designer

Rob Shea, E.L. Shea, Ellsworth, Maine, General Contractor

Jotham Pierce, Pierce, Atwood, Portland, Maine, Legal Advisor

William Waterston, Wiss, Janney, Elstner, Boston, MA, Architectural  & Engineering Consultant

Walter Barschdorf, Independent Roof Consulting, Pownal, Maine, Roofing consultant

David McGaughlin, Hahnel Brothers, Bangor, Maine, Roofing contractor

Dwayne Norwood, L.E. Norwood, Bar Harbor, Maine, Masonry contractor

Jeff Clarke, Clarke Construction, Ellsworth, Maine, Excavation contractor

Tim Sphar & Jason Kane, E.L. Shea, Site foremen

In addition to the participants listed above, there were many talented trades people in the general contractor and subcontractor crews working diligently throughout the project.

St. Francis Building Project Committee:

Pam Siewers

Ray Yardy

David Decrow

Additional Construction photos are available. Please refer the building project committee for questions regarding this report or the construction project.

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