by John Crowley | Oct 22, 2025 | Uncategorized
Residential: Big Build, Bigger Challenge SMACNA contractors do approximately 75% of all new residential construction in the St. Louis, Missouri, market, so Welsch Heating and Cooling of Maryland Heights, Missouri, had an edge when it was time to bid a unique single-family home. “One of our contractors was the successful bidder for the project and assigned the work to us. Knowing our background and knowing that we could handle such a large project, they were glad that we bid it and glad that we could participate in the work,” says Paul Heimann, Vice President and Comptroller of Welsch Heating and Cooling. The massive 14,300-square-foot, ranch-style home has 28 tons of cooling, about seven times as much as a typical St. Louis home. Welsch took part in every step of the job, joining the complex planning process in June 2021. “We sat through several meetings with the owner, the general contractor and the architects,” Heimann says. “They even had a mechanical engineer. Our portion of the HVAC planning process was to go over how they wanted the house zoned, where they wanted the duct work to run, what kind of equipment they wanted to use, as well as energy efficiencies.” The owner prioritized energy efficiency, so they decided on geothermal heat pumps. Welsch used two water-to-water units for the radiant in floor heating and four water-to-air units for the forced air systems. “We got that bidding and pricing done to make sure that we met the homeowners’ expectations,” Heimann points out. The high CFM kitchen range hood in the luxury kitchen required careful consideration. “Those hoods can suck all the air out of the house, so we installed a heated makeup air fan as well as an Energy Recovery Ventilator for fresh air ventilation,” Heimann says. “Sometimes we see how the air will be extracted from the house and how it’s coming in, and we have to provide for that.” Welsch also compensated for extreme humidity changes. “In St. Louis, we have very dry winters, so we install humidifiers to keep the air moist in the winter, but we have humid summers, so we dehumidify the air to mitigate moisture problems. In the summer, if you’re bringing in outside air, and not treating that air accordingly, you’re bringing very moist air to very cold ductwork. It’s going to make everything sweat.”Welsch purchased round pipes and elbow for the project but fabricated all duct in house. “The gauge we use depends on the size of the ductwork, because if the metal is too big, it gets floppy and makes noise,” Heimann says. “We use anywhere from 22-gauge to 28-gauge galvanized steel, depending on the application. It’s like a jigsaw puzzle. We measure and fabricate every piece to our specifications, so it fits properly, and it looks great at the end.” Welsch custom fabricates 8-foot joints to save time on site. “We use 8-foot joints instead of the usual 5-foot joints, because that means fewer joints to connect as we’re doing a house,” Heimann says. “To comply with local codes, we have to seal all of those joints, so the fewer seals we have, the less time we spend sealing.” For most residences, the huge HVAC system would have been Welsch’s biggest responsibility, but the owners wanted a unique exterior for their dream home. “Not only did we do the HVAC, but we also put a complete metal roof on this house, and the siding of the house was all made of metal,” Heimann says. Welsch fabricated and installed a 22-gauge Rhein Zink metal roof and siding on the home. “We basically wrapped the entire house.” Welsch organized the work as two separate jobs. “We bid on the heating and cooling, and then we gave them a separate bid for the architectural sheet metal,” Heimann says. Two Welsch foremen attended the planning meetings. “We had one foreman in charge of the heating and cooling aspect, and we had another foreman in charge of our architectural department. He understands roof pitches and flat roofs, and how water drains.”Welsch purchased a specialized double seamer for the architectural side of the project. “We needed a smaller seamer than any we could rent,” Heimann says, “so we did some research and bought one, which saved a lot of work hours in the field.” Welsch often completes new homes in nine to 12 months, but this project took about 18 months. “We put our first person on the jobsite in February of 2023, and we finished it at the end of last year,” Heimann says. “We had 4,000 work hours on this project, 3,300 architectural hours and 700 HVAC hours. Only about 100 of those hours were in the shop.” “With any project of this size, the biggest challenge is coordinating with all the other trades,” Heimann says. “We don’t want to be in their way, and they don’t want to be in our way. With the exterior sheet metal work on this particular home, the weather was also a factor. It’s always a challenge to tackle such a big job, but one we take great pride in accomplishing.”
by John Crowley | Oct 21, 2025 | Uncategorized
Industrial: Driving Fabrication Innovation Founded in 1988 in Austin, Texas, Dynamic Systems, a Quanta Services Co., has grown from a small local contractor into a formidable player in precision fabrication and mechanical contracting. “We started here in Austin, Texas in 1988,” says Jay Rohan, Senior Vice President of Operations at Dynamic Systems. “We do piping, plumbing, sheet metal; we’re a full-array contractor.” Most of the company’s locations are in Texas, but they also have offices in New York, North Carolina, Massachusetts and Utah.The company designs and constructs energy-efficient, health-conscious environments across a wide range of specialty sectors, including those in the industrial space. These places face unique challenges, such as high-occupant density, food service proximity and noise pollution — complex environments that need innovative solutions, including energy-efficient underfloor and displacement air systems, CO2 monitoring and pressurization control and code-compliant delivery of outside air. Dynamic Systems has built its reputation on industry best practices that fuse advanced technology, safety-first culture and a focus on customer dedication.MAXIMIZING EFFICIENCY WITH FABRICATION FACILITIESDynamic Systems optimizes project outcomes by focusing on off-site fabrication. The company has 535,000 square feet of fabrication space in the Texas cities of Burlington, Buda, Houston, Dallas, McKinney and College Station, as well as Salt Lake City, Utah; Poughkeepsie, New York; and Boston, Massachusetts. This fabrication focus maximizes cost effectiveness, safety, labor efficiency, material control, logistics, quality and schedule adherence, while minimizing waste. The facilities utilize cutting-edge technologies, including laser cutters, plasma cutters, automated coil and spiral line systems, ED virtual design software, and a comprehensive tracking system that bar codes every item to guarantee traceability and accountability. “One of Dynamic Systems’ claim to fame is that we track, monitor and measure every single aspect that we can of our business,” Rohan says. In 2023, the company started using a new software program called Stratus to digitize its fabrication processes. The software helps integrate data from models, connects to manufacturing tools and creates digital workflows to reduce manual effort and improve efficiency and profitability. The program, “gives us all the pertinent job data. Once that information is given to a superintendent, he can build a job out electronically,” explains Doug Smith, the company’s Director of Technology and Innovation. “It tracks the entire process digitally, so no papers are printed out, no drawings are printed out. It saves on revision control. The model is the revision, the single point of truth.”With Stratus, “we can run regular status reports on projects,” adds Adam Nichols, the company’s Director of Virtual Design and Construction. The employees “on the shop floor are fed their work data in Stratus and it shows them what’s on their plate for the day. As they complete a task on the list, they check it off and it’s done. It also designs and builds the criteria they need for a job on the screen, so they can see how something needs to be built in the program.”More than half of the company’s clients were asking for something like Stratus, Rohan says. “They like the verifiability aspect of tracking every part that’s being put on their job,” he explains. “We even give clients a log-in to our model, so they can see how the project is coming along at any time,” Smith adds. EMPHASIZING SAFETY AND QUALITY AT EVERY TURNThough the company started out small and has grown considerably, it tries to keep a fun culture intact. The company has very little turnover in its management ranks as a result. “The hardest thing has been to keep that culture as we’ve grown, but I think we’ve done a pretty good job of it,” Rohan says. “We always wanted to make it fun. We started out as a little bitty mom-and-pop shop, and now we’re a larger contractor, but we still have the same attitude. We want to have people work here because they enjoy it.”Embedded deep into that culture is the safety aspect. Safety is foundational to Dynamic Systems’ operations. The company culture ingrains safety in every employee because protecting its people and customers comes first. The company’s robust protocols and continuous training programs reflect in their exemplary safety records, enhancing client confidence.“We’ve been able to improve our modifier rate significantly over the years,” Rohan says. “And we’ve gotten better and safer over the years, which is good for us, good for the company and good for the employees.”
by John Crowley | Oct 21, 2025 | Uncategorized
HVAC: More Than Just Another Office Project Sustainable. Eco-friendly. Green. The Farmington Hills, Michigan, campus of Japan Solderless Terminals (JST) Corp. was designed to go beyond typical labels. The 10-acre, six-building property takes in its surroundings in a way unlike most corporate campuses. Instead of replacing native vegetation with grass, it preserves and expands the plants. As opposed to buildings that feature huge glass panes, JST’s structures make extensive use of natural materials like wood and stone. Drywall is forbidden. Paint is banished. And synthetic, commercial carpeting is nowhere to be found. It’s not what you might expect for a multinational manufacturer of electrical connectors used in industries such as automotive and HVAC. But it’s keeping in line with Osaka, Japan-based JST’s Asian approach to design, which aims to create spaces in harmony with the environment and that respect nature. Cunningham-Limp, the project’s Construction Manager, calls it “the most holistically sustainable project ever seen in Michigan.” When completed, the JST campus will encompass six buildings: a test lab, sales center, engineering center, annex, center circle loop, and a “tree nest.” The buildings will not disrupt the animals or natural habitats of the heavily wooded site, which sits in the heart of metropolitan Detroit. DEE CRAMER AWARDED PROJECTCunningham-Limp awarded SMACNA member Dee Cramer of Holly, Michigan, a $3-million contract in 2021 to handle HVAC construction for this holistic sustainable building, including duct fabrication and installation, at the campus test lab. The lab, which is an evaluation site for the critical electronic components that JST manufactures, was the first campus building that was erected. Aaron Montgomery, Dee Cramer Project Manager, explained that his company’s work began where the geothermal system tied into the piping (installed by a subcontractor) and the HVAC system. The piping entering the lab connects to 30 ducted fan coil units and numerous branch boxes that help condition the lab’s corridors. “Piping goes into four condensers and then numerous heat exchangers,” Montgomery says. “There’s also dedicated outdoor air systems (DOAS) — three of them just in the test lab alone.”In addition to the condensers and heat exchangers, the project has a lot of ductwork — 3,390 linear feet in all. “There’s a ton of small duct,” Montgomery says. “All of the latent energy is transferred from the geothermal system into the water-source VRF system and through the heat exchangers.”The test lab used approximately 23,000 pounds of internally lined duct, all of which was fabricated at Dee Cramer’s Wixom, Michigan, facility, about 11 miles from the jobsite. Most of the ductwork was rectangular, with some spiral. AN EDUCATIONAL EXPERIENCEJST’s commitment to sustainable construction presented a learning curve for Dee Cramer and some of the other contractors involved. “It was a bit of a struggle on everybody’s end because it’s a timber-frame building,” Montgomery says. “There’s not much timber-frame construction and carpentry experience here in the local Detroit area. It was such a trying process sometimes.”Nick Seraphinoff, the Vice President of Project Management at Dee Cramer, says the use of timber-frame construction made the project more complicated. “It affected the types of fasteners and hangers that we could use, as well as the coordination with other trades,” he says. The lab was completed in 2023. Officials with Cunningham-Limp and JST were pleased with Dee Cramer’s work. The contractor was hired to perform the HVAC work on four other campus buildings, bringing the total contracts to around $7 million in value. Dee Cramer’s work on the sales building is now underway. Seraphinoff says the JST project is unique. “We’re pretty excited about this job,” he says. “It’s really an honor to be a part of it.”
by John Crowley | Oct 21, 2025 | Uncategorized
Architectural: Shining Symbol of Strength When IBEW 48 upgraded their training center in Portland, Oregon, they chose a unique look, three copper signs with the IBEW logo and three interior walls covered with copper panels. Two 23-foot by 10-foot copper walls accent the hall’s training room, with large TV screens to display lectures. The third wall is in a conference room where IBEW leaders meet with elected officials. “The conference room is their showpiece,” says Shane Crunchie, project manager for General Sheet Metal (GSM) in Clackamas, Oregon. “And its 23 feet by 11 feet copper wall was the architectural focal point. It had to be perfect.” IBEW’s aesthetic gave General Sheet Metal an advantage in the bidding process because other contractors suggested using aluminum panels that had been coated to look like copper. “You can buy many prefinished architectural panels out there, and, basically, they’re all versions of laminate, where they’ve applied a finish to either stainless steel or aluminum,” Crunchie says. The electricians preferred a material that is more authentic to their lives. “Electricians work with copper all day long. We won the project because we could provide real copper.”The architect’s original plan suggested 16-ounce copper, which concerned GSM. “We worried that 16-ounce wouldn’t hold up over time in a room with people walking by the wall and bumping into it,” Crunchie says. Early in the design process, which started around May 2023, GSM recommended moving to a more durable 48-ounce copper. GSM also designed the custom support structure for the panels. “There’s an aluminum clip system behind the copper. The finished copper is glued to aluminum panels, and they’re hung in sections. Wherever we had aluminum panel joints, we glued a piece of copper in place in the field.The green patina that forms when copper is exposed to air stabilizes the copper chemically, making it easier to handle. “Copper starts to oxidize almost immediately after you sand it,” Crunchie says. “But in the submittal process we learned that IBEW 48 didn’t want the patina finish. They wanted to see the brightness of the copper. That created a level of complexity for the project because of the finishing technique.” The owners also wanted a hand-sanded finish to bring out the metal’s natural color variegation. “You had to finish it very carefully to get it to work.” GSM worked closely with the customer throughout the design process. “We did multiple phases where we started out with various samples with patina,” Crunchie says. “That’s when we discovered their desire for a bright finish. We produced more samples with the bright finish with appropriate clear coat.” Before starting production, GSM fabricated a full-sized demonstration panel for the owner’s approval. “When we brought out our first panel, we hung it and did our first in place inspection before we went further down the road. The client was in lockstep every step of the way. We always try to make sure there are no surprises.” GSM developed a quick process for finishing the panels because the clear coat had to be applied while the copper was freshly sanded. “We set up equipment specifically for this project,” Crunchie says. “Anytime you’re doing that, I would advise that you spend the money on what you need and be prepared to make adjustments mid-process to your plan, fabrication or installation method based on something that nobody saw earlier in the process.”The team did the preliminary sanding in the open shop, then wrapped each piece in brown paper for moving to the coating tent. Throughout the project, other teams were fabricating duct in different parts of the busy GSM shop, so the coating tent was pressurized to mitigate dust. “We had a four-step cleaning process before we were able to apply the coating to the panels,” Crunchie says. “Finishing the panels was a white-glove process, and everybody had to be trained and brought up to speed.” Only experienced people touched the sanded copper. “You have to have a group of people who know how to navigate the different variables, because sometimes you’re learning in real time,” he says. In this case, “a single fingerprint could cause a chemical reaction on the face of the copper that would create a blemish.” The clear coat was allowed to dry and harden before the team mounted the copper onto the aluminum panels. The copper walls were the most technically challenging part of the project, but GSM also installed roofing panels, gutters, downspouts and a stainless-steel rail. The company fabricated everything except the roofing panels in their own shop. The project required 2,887 pounds of 48-ounce copper sheet, 2,432 pounds of 5052 aluminum and 200 pounds of stainless steel. “It was labor-intensive,” Crunchie says. The $250,000 project ran from July 2023 through February 2024 and brought GSM 600 work hours in the shop and another 600 work hours in the field for a total of 1,200 work hours. “Ultimately, the client was very happy with us, and the general contractor was very happy with us,” Crunchie says. “They said they couldn’t have hired anybody else to do this project.”
by John Crowley | Oct 21, 2025 | Uncategorized
How Getting Involved Can Make a Big Difference During my time as president, I’ve made it a priority to stay active in every part of our association. Getting involved in politics is a powerful way to make a real difference for your business and our industry. I know politics can feel tiring these days but connecting with lawmakers from any party really does help us make progress on the issues that matter.During my time with SMACNA, I’ve made it a point to get to know our members of Congress and help their staff understand our issues and how they can support the skilled trades. I’ve met with legislators, including Congresswoman Shontel Brown, Congressman Dave Joyce and Congresswoman Emelia Sykes, at events ranging from golf tournaments to tours of our training centers and shop floors. These experiences have been key in helping our allies in Congress see what’s happening in our industry. We’ve discussed important topics, such as registered apprenticeships and how our field offers a path to a debt-free, well-paying career. I also highlight our commitment to workforce development and to creating a welcoming environment where everyone’s skills are valued. Our industry offers both men and women opportunities to grow, advance into management and even become owners. Regardless of your political views, I believe we can all support these goals. But achieving them depends on us. We are the experts, and our legislators rely on us for the information they need to make good decisions for our future. I encourage everyone to reach out to Stan and our legislative affairs team to learn about opportunities for getting involved.As my term as president ends, I hope I’ve made a positive difference for our association. By the end of my term, I’ll have spent over 150 days traveling. It’s been amazing to visit new places and take part in so many great events. I’ve met contractors and chapter leaders from across the country, all of whom are dedicated to supporting SMACNA and our industry. Along the way, I’ve made new friends, listened, offered support and helped tackle challenges when needed. I’ve enjoyed presenting and joining local meetings, and it’s been an honor to keep everyone informed about what’s ahead. Thank you for your trust this past year. It truly has been a remarkable experience. Tom MartinSMACNA President
by John Crowley | Oct 21, 2025 | Uncategorized
SMACNA’s Legacy of Government Relations Government relations have always played a key role at SMACNA. I first met Stan Kolbe and Dana Thompson from the National SMACNA staff back in 1993. After my freshman year at the University of Rochester, I interned with the National Roofing Contractors Association. Thanks to Stan and Dana, SMACNA remains as strong now as it was in the 1990s. The relationships they built then still matter today. Being consistent and knowledgeable about policy, as well as attending meetings, are all essential for success. When I served as a chapter executive, government relations was one of the biggest ways I added value. Like Stan and Dana, I spent years in New York building relationships that made a difference for our members. Managing several groups helped us share costs, but what really mattered was being a trusted policy expert and always being open to conversation. Working with great partners like Denise Murphy McGraw, who supports SMACNA’s state and local programs, has also made a significant difference.Some of you joined a recent webinar we hosted with my friend, New York State Assemblyman Harry Bronson. I’ve worked with Harry for almost 20 years, starting when he was counsel to the Assembly Labor Committee and a top staffer for a member I knew well. Today, Harry chairs the Labor Committee, which is especially important for SMACNA members. We didn’t always agree, but we always discussed issues and policy openly. Together, we achieved a lot for our community and union contractors. One highlight was a $1 billion school renovation program that improved city schools and created significant work for our members, all with clear and transparent PLAs.I also worked with another assembly member who later became the majority leader of the New York State Assembly. Joe Morelle is now a leading Member of Congress and a strong supporter of union contractors. We first started working together on insurance issues in 2004. That work then moved to economic development and project funding and was very successful for our community. Building relationships with great members of Congress like Morelle takes years of effort and partnership at the local level!Many of our chapters are actively engaged in state and local issues. Some states have already passed indoor air quality legislation, and others are considering it. Labor and construction bills often arise, and we don’t always agree with all of them. Permitting can be a challenge for projects, but we can help make it easier. Chapters can also support economic development and get involved early in new projects that need political backing to succeed.SMACNA will continue to support state and local efforts, just as we have in recent years. I’m also happy to share that SMART is now investing nationally in state-level work. This will help us work together more effectively on shared issues and create more opportunities for our members.If there’s an issue that matters to your chapter, please let us know. Small local issues often grow into bigger national concerns. SMACNA wants to be involved early and do everything we can to support our members.I look forward to seeing you at the convention and hearing about the work you are doing! Aaron HilgerSMACNA CEO
