Wyoming School Facilities Commission School Bus Maintenance and Parking Facility Design Guidelines
Prepared by OZ Architecture, Inc. and Engineering Economics, Inc.
In collaboration with Wyoming School Facilities Commission Wyoming School Facilities Department Wyoming School Districts
March 2013 Updated June 2013
Table of Contents INTRODUCTION
1
OVERVIEW INTRODUCTION
2
1. Purpose of Report
2
2. Executive Summary
2
3. Methodology
3
4. Project Goals
3
FACILITY PERSONNEL
5
1. Titles and Roles
5
SPACE DESCRIPTIONS INTRODUCTION
6
1. General
6
2. Repair Bays
6
3. Work Area
8
4. Tool Crib
8
5. Parts Storage
9
6. Tire Storage and Repair Rooms
9
7. Fluids Storage
10
8. Wash Bay
10
9. Locker Rooms
11
10. Break Room/Assembly
11
AREA REQUIREMENTS 1. Estimating Building Sizes
12 12
a.
Mechanics per Mile and Bus
12
b.
Mechanics per Bay
12
c.
Bay Size to Overall Building Size
12
•
Space Tabulation Tables
EQUIPMENT LISTS 1. Equipment Matrix
13 17 17
ALTERNATIVE FUELS
18
1. Fill System
18
2. Gas Detection
18
3. Exhaust and Makeup Air
19
4. Electrical
19
5. Architectural
19
SITE
20
1. General Considerations a.
Access
20 20
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b.
Security
20
Safety
20
d. Durability
20
c. 2.
Design Parameters a. Parking
21
i.
Standard Uncovered Stalls
21
ii.
Standard Covered Stalls
21
iii.
Standard Enclosed Stalls
21
•
Space Tabulation Tables
22
b.
Block heaters
23
c.
Fueling
23
d.
Fueling Dispenser Requirements
23
CODES & DESIGN STANDARDS 1.
21
Regulatory Requirements
SUSTAINABILITY
24 24 25
1.
Site Strategies
25
2.
Building Strategies
25
SAMPLE LAYOUTS
26
•
Small
27
•
Medium
28
•
Large
29
APPENDICES A. Bus Data
A
B. Questionnaire
B
•
Equipment Checklist
C. Wyoming Transportation Report
C
D. Comparison of CNG to Diesel
D
E. Wyoming Transportation Building Needs List
E
F. Acknowledgements
F
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Introduction The Wyoming school bus systems served almost 38,000 students in the school year of 20112012. A fleet of over 1700 standard and MPV buses traveled around 79,000 miles a day accounting for over 19 million miles that year. This clearly represents a substantial investment in the students of Wyoming. This report - compiled with the help of Wyoming School Districts, Wyoming Department of Education, Wyoming Department of Administration and Information, and the Wyoming School Facilities Department - analyzes the needs required to maintain these buses in the best practical working order for a safe and long life. Every facility encountered has its own unique factors of size, location, population dispersion, access to private resources and more, but all facilities have much more in common than not. This report lays out a baseline to provide the necessary tools to properly maintain the fleet. Included in the report are basic floor plate layouts. These are not meant to be a final layout but are to be used to develop an understanding of what spaces need to be incorporated to help determine facility costs. The actual designs should use these diagrams only as guidelines to help determine the size and arrangement of the spaces. The selected site and operations of each facility will determine the final layouts. This document includes the required guidelines for the design of new and remodeled school bus maintenance facilities in the State of Wyoming. As noted, this document is a guideline and not a standard or construction specification; however, some design or construction standards are included in this document. The design or construction standards are highlighted in gray throughout the document and are associated with the terms “will” and “shall”. In some instances, sections are highlighted in gray. In these instances, the entire content under the highlighted section is a design or construction standard and shall be followed. More stringent requirements shall be used when required by the current State of locally adopted building codes.
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Overview 1. Purpose of Report This report is intended to provide a basis for future design, construction, and modification to public school bus facilities in the state of Wyoming. The report sets out guidelines for best practices in design and planning that will allow Wyoming to chart a road map for the future, a basis to initiate new design, and a means to assess bus facilities built in the past. The report is meant to augment a thorough design effort as it cannot cover every variable of site, community goals, local practices, and intuitive common sense. In doing this report we estimated the overall building size based on the number of miles traveled, the number of mechanics, and the number of buses. We do not regard this as an exact science only as a guide for funding and planning. Final facility size and many room sizes will vary based on local condition. This was due in large part to the many variables of each site, including weather, remoteness from supplies, work performed, and miles traveled. 2. Executive Summary The School Facilities Department, at the urging of the School Facilities Commission, was asked to provide a study of the optimum facilities to provide a current standard of care for school bus facilities. Through a series of questionnaires, interviews, meetings, and comparison of other facilities a standard layout for three sizes of buildings based on the number of buses served by the facility was developed. The report includes descriptions of the spaces within the facilities as well as the areas required for the building site. Also included are equipment lists, sustainability guidelines, alternate fuel options and code requirements. Conclusions include: • • • • • • • •
•
A small facility needs 3 repair bays, a medium facility 5-7, and a large 9 or more. Facilities need wash bays for proper maintenance and functioning of the fleet. The size of the garage support area is about ½ the size of the repair bays and wash bays. The size of the office and dispatch area is about ½ the size of the repair bays and wash bays. The overall facility area is about twice the area of the repair bays and wash bays. A bay is between 20’ and 25’ wide by 55’ deep; the area of a bay is about 2500 SF. Small facilities are 10,000 SF; Medium are 20,000 SF: Large are 27,000 SF. Building costs can vary widely depending on site conditions, equipment, and materials. Average 2012 costs for similar facilities are between $150 and $225 per square foot. The facilities should be designed for energy savings through efficient equipment and building envelope. Natural lighting should be utilized as much as possible.
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• • • • •
Areas in and around the building should be designed for the optimum safety and efficiency of the staff and visitors. Fuel islands shall provide diesel and unleaded gas. All facilities should be designed to be adaptable to servicing and fueling alternative fuels, especially compressed natural gas. All buildings shall be secured from vandalism via a fence. A small facility should have enclosed bus parking; a medium and large facility should have enclosed parking for 50% to 75% of the buses.
3. Methodology • A group of four users selected by the State were sent questionnaires and interviewed to establish the existing conditions and their requested improvements. • Common meetings were held to discuss similarities and differences in the systems. • Results of the questionnaires and interviews were compared to industry metrics. • The facilities were evaluated by size and services to determine natural groupings of facilities. • Local and State Officials were contacted for regulatory requirements. • The work was reviewed by the users for accuracy and completeness. 4. Project Goals • Provide general designs for productive facilities that include all the necessary parts to operate a fully functional facility. • Provide the necessary code information for the future designer of the facility. • Provide three sizes of facilities to match the natural division of the school systems. o Commonality between facilities will determine where the division between small, medium and large occurs. o Each size will be assigned standard features that are deemed necessary to perform tasks practical for that size. • Safety o Efficient use of space o Clearly defined work and circulation zones o Tool and equipment storage adjacent to work areas o Good lighting o Good drainage and slip resistance • Lighting o Plenty of natural and artificial lighting o Capture morning light o Light source at work area o Reflective flooring o Energy efficient light fixtures and occupancy sensors • Ventilation/Temperature o Required air changes with heat recovery o Heat at floor (radiant floors)
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•
•
•
• •
o Overhead doors set up for cross ventilation o Vehicle exhaust systems o Specialty equipment exhaust Noise o Separation of bays and office space o Sound absorption in bay areas o Quiet areas for meetings Break Area o Dedicate for getting away, not multipurpose area o Bright clean space o Outdoor access o Views if possible Shared Office areas o Library/research type space o Data access, weather access Crisis Rest area o Quiet, dark, rest area Sustainability o A sustainable site and building o Energy efficiency and environmentally friendly
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Facility Personnel 1. Titles and Roles • Facility Manager o Director of the Facility o Assistant managers in larger facilities o Office located near reception area • Maintenance Shop Supervisor/Foreman o Supervises garage personnel o Office overlooking bays • Garage Personnel o Mechanics o Other o Need storage of tools and uniforms, locker space • Receptionist/Administrator o Executes office functions o Receives Visitors o Near reception & work/copy areas • Parts Manager o Assistants in larger facilities o Maintaining parts inventory o Office within parts room o Office near Bays • Dispatch/Driver Area o Dispatcher o Scheduler o Trainer o Drivers o Offices near reception
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Space Descriptions 1. General The optimum size and function of each facility is determined by the amount of work required to maintain the buses. The number of vehicles maintained is a strong determining factor in sizing the facility but not the only one. The size also can vary greatly by the type of work performed at the facility as well as offsite by contracted labor. In developing these guidelines, we have attempted to identify the optimum facilities to perform the work on site unless it is more cost effective to do so offsite. The smaller the facility the more work is done offsite as it is impractical to outlay funds for the increase in size and equipment. 2. Repair Bays The heart of any Maintenance Facility is the repair bays. They need to be sized for efficiency, close to all other spaces that augment the work in the bay, well lighted, and heated and ventilated to promote a good working environment. We also believe natural day-lighting is an essential part of a good working environment and increases productivity. The number of bays has historically been determined by the number of mechanics which is determined by the work load. With the changes in the technology of vehicles and the tools to maintain them, there is no standard or optimum ratio of mechanics to fleet size. This issue is currently being addressed by the Transportation Research Board with a national study of public transit fleet systems to develop a guidebook for determining optimum maintenance technician staffing levels for different sized fleets. This study is scheduled to be completed in the summer of 2014. Currently in Wyoming a mechanic can maintain about 20 buses, including routine preventative maintenance (PM) work as well as common unscheduled repairs. A current rule of thumb is to have at least one and one half bays per mechanic for most common work. In the smaller districts at least two bays per mechanic and sometimes three are required due to the inability to schedule unexpected work and/or get parts quickly. The 20 busses per mechanic is a common factor in other school districts. This assumes that on average two to three buses are serviced each day by a mechanic. This number will be less in the smaller facilities due to inherent inefficiencies and multiple tasks required of the mechanics. Repair Bays are best arranged in pairs end to end to allow a “drive through” bay to facilitate towing and allow a center work aisle between parked vehicles. The sides of the bays also are used for work areas. The typical central bays for a bus up to 40’ long are 20’ x 55’, allowing 6’ on either side, 5’ at the rear and front with a 5’ aisle between. When bays are not adjacent to other bays an additional 4’ to 5’ is necessary to an end wall. Bus heights vary, with the buildings needing at least 18’ clear to obstructions. The lowest structural element should allow for lighting, mechanical, and some equipment to
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be placed below without interfering with the 18’ clear space and is generally set at 20’ above the floor to the bottom of structure. The area surrounding the busses is used for portable tools and small equipment storage. Hose, electrical, and exhaust reels are also located in the side areas and shared by adjacent bays. Compressed air is piped to the surrounding walls and internal columns if any. Bays are accessed via overhead doors from 12’ to 14’ wide and 16’ tall. Doors should be equipped with electrical operators and glazed at about 5’ above finished floor. Six inch minimum concrete pipe bollards should protect the door jambs inside and out. A 25’ concrete apron is recommended if the site has asphalt paving. North facing doors should be avoided. Site conditions, especially wind, need to be factored into the door locations. The bays need to be drained. It is impractical to slope the floor as the overall slope can approach a foot or more and drain unnecessary water where work occurs. An 8” to 12” wide trench drain across the doors with a 5’ horizontal slope to the drain and a center 8” floor drain with a 3’ horizontal slope work well when the excess water is squeegeed to the drains. The drain needs to flow to a sand and oil separator in most jurisdictions. Each bay needs access to the chosen fluids through either overhead reels or portable containers. Compressed air, data, and power also need to be accessible to each bay. Tailpipe exhaust needs to match the location of source with the equipment. Overhead reels prevent tripping hazards. Bus lifts vary in type and configuration. On small garages a single multifunctional lift should be selected for 2 to 3 bays. On larger facilities more than one type of bay is recommended with one lift per every three bays. Parallelogram lifts provide the best use of the space when not deployed; at least one parallelogram lift should be a part of all facilities. Additional lifts can be either 4 post lifts, in-ground lifts or portable lifts. The portable lifts offer the most flexibility to be used in any bay and are the preferred choice for the remaining lifts. Pits are preferred by some mechanics but are discouraged for multi-functioning bays. Affixed cranes or hoists are generally not required for bus facilities. If engine repair is anticipated portable lifts are more cost effective. The floor and walls need to reflect light. Concrete admixtures and floor sealers can address this issue. The type of building insulation will depend on the chosen building materials. If vinyl faced batts are used, they should be protected with metal liner panels or other hard surfaces. Mechanical systems are specific to the large volume spaces with large doors. Gas fired or hydronic radiant heat works best either in overhead locations at the doors or in the floor for the most consistent heat. Supplemental air movement and evaporative cooling via ducted equipment as well as overhead fans complete the system. Due to the huge loss of
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energy required via the International Mechanical Code mandated air exchanges, a heat recovery exhaust unit is recommended. Plumbing includes emergency showers and eye wash station as well as hose bibs and a hand wash station. All trench drains need to be wide enough to allow easy cleanout with a shovel. Lighting should be based on the utilization of the space. Continuous usage of the bays can employ high bay Metal Halide lighting but energy efficient fluorescent lighting is best used for both continuous and infrequent operation with sensors to turn lights off. Standby power is critical to maintain some function in the building when the power is interrupted. The generator can use diesel or natural gas fuel to be compatible with the fueling system. This condition occurs more frequently in some areas of Wyoming than others. Standby power should be provided to a minimum of one office to include outlets and minimal conditioning. One overhead bay door and one fuel dispenser should also be on standby power. In the harsher climates remote engine block heater outlets should be on emergency power. This can be costly so each case should be reviewed individually. Natural gas vehicles are anticipated to become more common in the future. All new facilities should be designed to easily accommodate those vehicles in the future. The roof of the bays must be designed to not create any gas pockets. No solid beams or joists can be used. Sloping roofs must not trap gasses. In addition, explosion relief hatches may be necessary depending on the design. These may be as simple as sheet metal covers attached to chains on roof curbs. The ventilation and alarm system should be designed to accommodate future modifications to operate a natural gas facility. Equipment should be placed away from hazardous areas found in natural gas facilities typically located at the roof. 3. Work Area A general work area for tasks outside the bays for welding, cleaning, and repairing is required. The area contains a work bench, welding table, vise, drill press, welding unit, soldering unit, brake lathe, bench grinder, bench polisher, and other small equipment. The work area should be adjacent to the repair bays and could be placed in a bay and converted into a bay space in a future expansion. The work area should be well equipped with ventilation, compressed air, electrical supply to equipment and outlets on the walls, good general & task lighting, and a welding hood. 4. Tool Crib Secured common tools storage is required for tools not owned by the individual mechanics. These consist of specialized tools or larger more expensive tools and power tools. Tool Cribs consist of chainlink fence or other open walls off the main work area and bays that can be locked. This secures the tools when not in use.
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5. Parts Storage A well-organized parts storage area makes for an efficient operation. The area required depends on many factors; work performed, purchasing cycles, parts availability, variance in rolling stock, quantity discounts, etc. Past experience has required a minimum of 320 SF storage area. An 8’ wide module was used to layout the space with the capability to contain a 2’ deep shelf on either side of a 4’ aisle. Shallow or deeper shelving can be accommodated within that module. In larger facilities a door to the work areas and a counter in the parts area was provided along with a double or overhead door to receive shipments. The shelves should be well lighted with fluorescent fixtures in the aisles. The space should be heated and cooled to office standards with a Heat Recovery Unit with an evaporative cooler. A sealed concrete floor and open ceiling are preferred. Any hazardous materials should be stored in Safety Cabinets in limited quantities so that the area will not become a Hazardous Occupancy per the building code. 6. Tire Storage and Repair Rooms Tire maintenance is one of the major functions of school bus garages. As with the parts storage several variables determine the size of the storage area. Tire racks fit into a 12 foot wide module with a rack on either side of a 5 foot aisle. Each tire requires about a foot of width. Tire racks can be stacked, but lifting aids such as a portable jib crane/hoist or monorail should be used to prevent injuries to staff. Direct access to the exterior is best for receiving new product. Tires take up the most storage space in a facility. Consideration should be given to storing 60 or more tires, or if space is limited in a remote shed. This can be a simple metal, wood or plastic structure to protect the tires from the elements. The tire repair area requires specialized equipment to detach the tire from the rim, repair or replace the tire, remount the tire, and balance the tire. The equipment list includes a tire changer and wheel balancer. Exact equipment sizes will determine the room requirements. A 5 foot deep equipment area with a 7’ to 10’ deep work area is shown on the plans. The Mechanical system can be part of the repair bay system. Fluorescent light fixtures are recommended. Electrical power needs to match the equipment as well as additional general purpose outlets.
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Batteries will be stored in a closet or enclosed storage cabinet. It is assumed the number of batteries stored will be 12 or less. The battery storage area should have the same ventilation requirements as the repair bays and may be served by the same Heat Recovery Unit. 7. Fluids Storage Fluids may be handled in different ways. For larger facilities, double walled storage tanks, called lube cubes, are grouped together to provide the various types of lubricants. In addition, 55 gallon drums can be used but will require containment which generally is a concrete depression with a steel grate under the drums. These commonly are tied into an overhead piping system that is monitored and delivered to the bays. In addition, smaller facilities may use portable storage in the form of wheeled tanks that are also available with double walls. The lube cubes are about 3’ square x 4’ tall. A containment pit for drums is generally 3’ wide. The room has special fire separation and ventilation requirements. All surfaces should be easy to clean and durable using concrete masonry or similar materials. Waste oil needs to be readily accessible for off-site pickup. The compressor and air dryer can be placed in the fluids room to muffle the noise from the work areas. Each garage may have a specific list of the fluids used. Possible fluids include: Motor Oil
Anti- freeze (several types)
Gear lubricant
Chassis grease
Automatic transmission fluid
Windshield washer fluid
Brake fluid
Power steering fluid
Waste oil
Waste coolant/anti-freeze
The room can be conditioned off the main garage system. Standard fluorescent light fixtures are adequate. 8. Wash Bay Wash bays are required to extend the life of the busses, provide a good appearance, and remove road grime and mud to better service the bus. There are several types of wash equipment to meet these needs including drive through bays, hand operated portable power washers, and undercarriage sprays. All types of washing can be done in a general purpose wash bay either a drive through or hand operated system or with a general wash bay and a specialized undercarriage chassis wash. The chassis wash should be used in the larger facilities when the general bus wash may be in use for extended periods of time limiting the time available for preparing the buses for maintenance. Maintenance of the equipment is generally contracted to a local vendor so equipment should be selected that has servicing nearby.
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A drive through wash can require up to 80’ of length and 20’ of width. A power washer will require 20’ x 55’ or the size of a repair bay. Minimal heat is required in the bay and where the wash equipment is located. In addition to a Heat Recover Unit supplemental floor hung gas fired radiant heat panels may be added for winter time bus washing, controlled with wall mounted thermostat and timer. Electrical power is sized for the equipment. Most manufacturers can provide water recycling. 9. Locker Rooms Well-designed locker rooms are an important part of employee morale. Facilities can have combined toilet and locker rooms. Separate toilet rooms for the public should be considered if there is a large office component with visitors. If combined, the locker/shower area should be separated from the toilet and lavatory area. Minimum 18” x 18” x 72” lockers provide adequate storage if additional uniforms are stored separately. The number of lockers is directly related to the number of mechanics and drivers using the facility. Downsizing the women’s locker area due to current employment ratios is not recommended. Uniform storage can be in a separate room or locker depending on the storage requirements. The locker room should be adjacent to the work areas. Locker rooms require complete accessibility. They should be of waterproof, low maintenance materials. If using ceramic tile, walls or floor grout joints should be minimized through the use of large tiles. Hard or gypsum ceilings are recommended. Fluorescent lighting and typical office conditioning with added exhaust based upon plumbing fixture count is standard. Occupancy sensors or wall switch timers may be desired to modulate and control the exhaust. 10. Break Room/Assembly Each facility needs a space to hold all staff meetings. A large assembly area can also function as a break area, especially if it can be divided by moveable walls. The break room should be a refuge and a place to be with people without a need to discuss work. The break room may contain a sink, dishwasher, microwave oven, and a refrigerator along with countertops and storage space. Direct access to an outside area is desirable. Small break rooms require a minimum of 12’ of width with side areas for usable counters along the end walls of at least 9’ in length. Larger areas should be kept open with the food areas off to the side or in an alcove. Office type ventilation with typical return/exhaust and lighting along with an exhaust vent over the microwave is desirable. Air conditioning is typical in this area.
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Area Requirements: 1. Estimating Building Size Based on Mileage and Number of Mechanics a. Mechanics per Mile and Per Bus Each bus requires preventative maintenance (PM) at the 3,000, 6,000, 9,000, and 12,000 mile mark. Over the past 3 years the average mileage per bus per year for Wyoming was 11,200, varying from 5,300 to 16,500. Therefore, the average bus goes through a full 12,000 mile cycle every year. The 3,000 and 9,000 mile PM, takes about 4 hours, the 6,000 mile mark takes about 6 hours and the 12,000 mile mark encompasses about 8 hours. That adds up to 22 hours every 12,000 miles. The time, 22 hours, is doubled for non-scheduled maintenance for a total of 44 hours per 12,000 miles. A mechanic working 2040 hours a year should be able to spend about 75% of that time in the repair bay or 1,500 hours per year. That equates to 34 buses per mechanic per year. The average bus ratio to mechanic for Wyoming is about 20.7 varying greatly from 7 to 56. In looking at the districts with more than 50 buses, the ratio of buses per mechanic goes up to 27. Those larger districts also increase the miles driven per bus to 13,500, a 12.5% increase, requiring 50 hours of maintenance per year. At 50 hours per bus per year the ratio of buses per mechanic goes from 34 to 30 buses per mechanic. This is slightly off the 27 mechanics calculated above. What this says is the smaller districts do not fit a formula for the number of mechanics based on miles driven or number of buses. A ratio of 20 buses per mechanic is appropriate for the smaller districts. b. Mechanics Per Bay In a small facility one mechanic needs 2 to 3 bays depending on availability of parts and supplies. In a medium facility, two to three mechanics need 3 to 5 bays, also depending on parts and supplies. In a large facility with more than three mechanics, it is assumed they have ready access to parts and supplies and are assigned 1.5 bays per mechanic. c. Bay Size to Overall Building Size The bays are estimated at an average of 22.5 x 55’ or 1237 SF. The bay support spaces are estimated at 50% the bay size or 620 SF/bay. The front office, lockers, mechanical areas, etc. are also estimated at 50% of the bay size for a total building size of 2500 SF per bay. A 3 bay garage with a wash bay is then about 10,000 SF. A six bay garage with a wash bay and chassis wash is 20,000 SF and a 9 bay garage with a wash bay and chassis wash requires 27,500 SF.
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The facilities naturally coalesced into three size groups, a small 25 bus facility, a medium 25 to 90 bus facility, and a large 90 plus bus facility. The medium size facility has the widest range and may require adjustments in the number of repair bays and assembly areas as the number of buses vary from the low to high end of the group. 25 Bus Facility Width (ft) 3 Bay Garage Repair bays Wash Bay Wash Equipment in bay Chassis Wash Fluids /Compressor Room Battery Closet Tire Storage Tire Shop Tool Crib Parts Storage Work Area Parts Counter Misc Storage Maintenance Office Subtotal Common Area Factor Garage TOTAL Office Supervisor Assistant Work Area Library/Office Assembly/Break Room Mechanical/Electrical IT Closet Women’s Locker Men’s Locker Uniform Storage
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Depth (ft)
SF
30 25 0
55 55 0
12 3 10 12 8 16 12
15 8 20 25 10 20 20
7,669 1,150 8,819
15%
10 10 10 10 15 15 6 8 8
4,950 1,375 0 0 180 4 lube cubes 24 200 40 to 80 tires 300 80 320 2 aisles of shelving 240 0 0 0
15 12 8 12 15 12 9 14 17
150 120 80 120 225 30 people meeting 180 54 112 136 0
13
Janitor Closet Conference/Muster Subtotal Common Area Factor Office TOTAL
6
6
36 0 1,213 364 1,577
30%
Building Total Guideline SF
10,396 10,400
25 to 90 Bus Facility width (ft) 5 to 7 Bay Garage Repair Bays Wash Bay Wash Equipment Chassis Wash Fluids /Compressor Room Battery Closet Tire Storage Tire Shop Tool Crib Parts Storage Parts Counter Work Area Misc Storage Maintenance Office Subtotal Common Area Factor Garage TOTAL Office Supervisor Secretary/Reception Work Area Library Dispatch Clerk Driver Training Assembly/Break Room
Updated 6/2013
25 22 10 20 15 3 24 15 10 24 8 15 10 10
depth (ft)
SF 55 60 15 55 15 8 20 25 20 30 12 25 25 12
13,685 2,053 15,738
15%
12 10 10 10 10 8 12 24
8,250 1,320 150 1,100 225 5 lube cubes 24 480 80 to 160 tires 375 200 720 3 aisles shelving 96 375 250 120
15 25 8 15 15 8 15 30
180 250 80 150 150 64 180 720 100 people
14
Mechanical/Electrical IT Closet Men’s Locker Women’s Locker Uniform Storage Janitor Closet Mail/Driver Work Area Subtotal Common Area Factor Office TOTAL
20 9 9 9 6 6 5
20 9 30 27 10 8 20
400 81 270 243 60 48 100 2,976 893 3,869
30%
Building Total Guideline SF
19,607 20,000
90+ Bus Facility width (ft) 9 Bay Garage Repair Bays Wash Bay Wash Equipment Chassis Wash Fluids /Compressor Room Battery Closet Tire Storage Tire Shop Tool Crib Parts Storage Parts Counter Work Area Misc Storage Paint Booth Maintenance Office Subtotal Common Area Factor Garage TOTAL Office Supervisor Assistant
Updated 6/2013
depth (ft) 25 22 10 20 15 3 24 15 12 24 16 25 10 15 15
SF
55 110 15 55 15 8 20 25 20 30 8 25 25 15 15
19,562 2,934 22,496
15%
12 10
12,375 2,420 150 1,100 225 5 lube cubes 24 480 80 to 160 tires 375 240 720 3 aisles shelving 128 625 250 225 225
15 15
180 150
15
Secretary/Reception Sub Managers (2) Work Area Library Dispatch Driver Training Sup. Scheduler Mechanic Break Room
10 10 10 10 12 10 10 0
25 12 12 15 16 18 12 0
Assembly/Break Room Mechanical/Electrical IT Closet Men’s Locker Women’s Locker Uniform Storage Janitor Closet Driver Area Mail/Driver Work Area
30 20 9 16 16 6 6 0 5
50 20 9 24 20 10 8 0 30
Subtotal Common Area Factor Office TOTAL Building Total Guideline SF
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30%
250 240 120 150 192 2 work spaces 180 120 0 1,500 200 people assembly 400 81 384 320 60 48 0 150 4,525 1,358 5,883 28,379 28,000
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Equipment 1. Suggested Quantity of Equipment
Equipment Items Bench Grinder Bench Buffer Steel Work Benches Welding Table Hydraulic Lift Tire Changer Brake Lathe Press – Floor Mounted Vacuum Cleaner Battery Charger Safety Stands Tachometer Headlight Adjuster Portable Power Tools Polisher/Drill/Sander Machinist Vise Air Compressor Lube Unit Scope Analyzer Soldering Unit Welding Unit Portable Crane Steam Cleaner Motor Repair Stand Parts Cabinet Washer Parts Wheel Balancer Impact Wrenches Puller Sets Transmission/Differential LiftPort Hand Tool Sets
Updated 6/2013
Number of Maintenance Bays 2 4 6 1-2 1-3 1-3 1 1 1-2 2-4 4-6 6-8 1 1 1-2 1 1 1 1 1 1-2 0 0 0 0 0 0-1 1 1 1 1 1-2 1-3 1-2 2-4 2-4 1 1-2 1-2 0-1 0-1 1-2 1-2 1-2 1 1 0-1 1 0-1 0-1 0-1 1 1-2 0-1 0-1 1 1-2 1
1-3 1-3 1 1 0-1 1-2 0-1 0-1 0-1 1-2 1-4 0-1 0-1 1-2 2-3 1
1-3 1-3 1 1 0-1 1-2 0-1 0-1 0-1 1-3 1-4 0-1 1-2 1-2 3-4 1-2
8 1-3 1-2 8-10 2-3 1-2 1-3 0-1 0-1 1 1-3 4-6 1-3 1-3
10 2-4 1-3 10-12 2-3 1-3 1-3 1 1 1-2 2-4 4-6 1-3 1-3
1-4 2-4 1 1-2 0-2 1-3 0-1 1-2 0-1 2-4 1-6 0-1 1-3 1-3 4-6 1-2
1-4 3-6 1 1-3 1-2 1-3 1-2 1-2 0-2 2-4 1-6 1-2 1-3 1-4 4-8 1-3
Various Various Various Various Various
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Alternative Fuels The State of Wyoming recently completed a Feasibility Study that looked at the conversion of public school district busses to natural gas (“A Feasibility Study of Natural Gas Vehicle Conversion in Wyoming Public School Districts”, The Department of Administration and Information Economic Analysis Division, November 2012). The findings of this study show that there are a number of favorable attributes to natural gas vehicles and that for large school districts, or districts whose vehicles travel a high number of miles per year, the payback for the increased cost of purchasing a natural gas bus could be as low as 9 years (at current diesel and natural gas rates). Appendix D includes a rough comparison of the cost of fuel for a diesel versus a natural gas bus, but for a complete understanding of the issues the study above should be consulted. Interest in natural gas as a local fuel source in Wyoming, along with increasing diesel fuel prices, leads to the likelihood of some future bus fleets converting to natural gas and new maintenance and storage facilities should consider the implications of designing for this fuel source. Compressed Natural Gas and other explosive gasses require special attention when designing a Maintenance Facility. Safety requires removal of potential hazards via gas detection, exhaust ventilation and make-up air, electrical precautions, and architectural designs to avoid trapping gas at the underside of the roof. Below is a brief outline of potential ways to mitigate the hazards. Any design for buildings with explosive gasses should be thoroughly engineered and reviewed by all appropriate authorities. 1. Fill Systems Both slow and fast fill systems currently exist. A fast fill system uses huge compressors and tanks to fuel the vehicles in about the same time as standard diesel fueling. A slow fill can take from 6 to 12 hours but does not require the capital for the special compressors and tanks Most buses are parked overnight and can be accommodated by a slow fill system which is much less expensive than a fast fill. 2010 costs for a fast fill system run in excess of $1,000,000 up to $1,700,000 while slow fill systems are estimated at $400,000 - about 1/3 to ¼ of the cost per the US Department of Energy. The slow fill system is best done in an open environment which may conflict with the need to enclose the buses at night. As the cost of the systems and the fuel will evolve over time, the facility designers should evaluate the payback periods of all the possible fueling systems for each new design. If alternative fuel vehicles are to be maintained in a facility then the following precautions need to be considered. All new facilities should be designed to accommodate these items in the future so that the facility will not need major revisions to provide service to CNG vehicles. 2. Gas Detection • System needs to be fail safe or operates in any and all conditions. • System needs to be monitored and well maintained.
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•
Fire Alarms need to be explosion proof. Fire pull stations are necessary in the event of a gas relief. Alarms need to be seen and heard from every location in the Facility. The alarm system needs to be tied to emergency exhaust and optimally the overhead doors. Power needs to be shut off to non-emergency devices in alarm conditions.
3. • • • •
Exhaust and Makeup Air: The Facility should be continuously ventilated. There should be a slight negative pressure in the facility. Both work and ceiling level need to be exhausted. Heating devices need to have temperatures compatible with safety of handing gasses.
4. • • • •
Electrical All electrical above the bus rooflines need to be mitigated to reduce sparking risk. All lighting needs to be sealed. Electrical Codes for hazardous locations should be studied and may be required. Use hydronic heating where practical.
• • • •
5. Architectural All new facilities should be designed so that ceiling and structural surfaces will not trap or pool gasses. Relief vents at the ceiling should be tied to the alarm system. When CNG vehicles are maintained in a facility then adequate signage needs to be posted with instructions for emergencies.
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Site 1. General Considerations Site design should evolve around access, security, safety, durability, and efficiency. Facilities should be located to minimize driving time and distance with good highway or street access and on generally flat land with adequate slope for runoff and water quality. a. Access Follow local and state requirements for access including size, visibility, and distance from other access points or intersections. Provide traffic studies where local jurisdiction requires. Site layout should minimize the mixing of private and district vehicles. b. Security Provide adequate security appropriate for the location of the facility. This includes fencing the area with materials and heights approved by jurisdiction. Exterior lighting should be provided with cut-off fixtures to reduce off site lighting. There should be monitoring of the exterior area with adequate camera coverage and landscape should be designed and maintained to avoid possible hiding areas. c. Safety In addition to security concerns, the site should be designed to provide safety for the occupants during all hours of operation. This includes surveying the area for utilities, property lines, easements and other features. Provide clearly marked areas for drive lanes, pedestrian movement, and parking areas. Drive lanes on the north sides of buildings should be avoided along with creating areas where snow drifts can form. A snow melt system should be considered at the main entrance walk way if a radiant floor heat system is in the building. Keep fueling and wash islands away from other traffic. There needs to be a separation between quick fueling Natural gas away and all other spaces. d. Durability Provide as much protection of the staff and vehicles from the elements as possible. Provide adequate drainage via swales, piping and natural slopes. Follow Geotechnical reports for paving & foundation recommendations. Use concrete paving where possible at drive areas, bus parking, and garage aprons. Shelter busses when possible. Use low maintenance, low water vegetation where required by local authorities.
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2. Design Parameters a. Parking Three types of parking accommodate most needs: uncovered, covered and enclosed. Enclosed spaces are desirable for severe weather conditions which vary by the geographic site. Covered and enclosed parking for all buses at large facilities becomes impractical due to the size of the facility. It is recommended that at medium size facilities a maximum of 75% of the buses be covered and 50% at the large facilities. i. Standard Uncovered Stalls Uncovered bus stalls should be a minimum of 12’-0 to 13’-0 wide and 35’0 to 50’-0
deep depending on the busses used. Aisle widths for 90 degree parking require a minimum of 130’. In laying out the parking the designer should consider 85 degree parking and one way drive lanes on larger facilities as angled parking allows better mirror overlap. A 10’ wide side walk between bus rows is desirable. Block heater power is required at each bus and can be shared by two to four buses. ii. Standard Covered Stalls Covered bus stalls can be a 13’-0 to 15’-0 wide x 45’-0 to 50’-0 deep x 13’ to the bottom of the structure. Dual access, and or two deep storage is economically desirable. The drive through openings shall be a minimum of 11’ wide and 12’ high, with 22’ wide openings desirable. Bollards should be provided at all openings along with a 40’ concrete pan for durability. Lighting needs to be designed for cold weather. A minimum 55’ wide access aisle should be adjacent to the stall entry and block heater power is required at each bus and can be shared by two to four buses. iii. Standard Enclosed Stalls Stalls can be a 14’-0 to 15’-0 wide x 45’-0 to 50’-0 deep x 13’ to the bottom of the structure with 22’ wide openings or doors if the structure clear spans the space. Dual access and/or two deep storage is economically desirable. Doors should be 12’-0 high and a minimum of 11’ wide for each bus. Bollards should be provided at all openings along with a 40’ concrete pan for durability. Lighting needs to be designed for cold weather. Basic heat should be designed for the space to provide 40+ degree conditioning. As with the design of the Maintenance Facility, the design of the enclosed storage buildings should incorporate safety Updated 6/2013
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features that may be necessary for natural gas vehicles including the removal of potential hazards via gas detection, exhaust ventilation and make-up air, electrical precautions, and architectural designs to avoid trapping gas at the underside of the roof.
30 bus enclosed storage area typ bay, 2 Bus deep
width (ft)
depth (ft)
14' to 15'
#bays
90' to 100'
15
side aisles (2)
8
90' to 100'
Total
Min SF Max SF 1260 18,900
1500 22,500
720
800
19,620
23,300
40 bus enclosed storage area typ bay, 2 Bus deep
width (ft)
depth (ft)
14' to 15'
#bays
20
side aisles (3)
12
90' to 100' 90' to 100'
Total
Min SF Max SF 1260 25,200
1500 30,000
1080
1200
26,280
31,200
50 bus enclosed storage area typ bay, 2 Bus deep
width (ft)
depth (ft)
14' to 15'
#bays
25
side aisles (4)
16
Total
90' to 100' 90' to 100'
Min SF Max SF 1260 31,500
1500 37,500
1440
1600
32,940
39,100
Note bus storage size dependent on specific bus stock and driver skills. Min Size may be further reduced with staggered layouts depending on site configuration
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b. Block Heaters As noted previously, buses exposed to low temperatures should have access to power for block heaters. Cords should be provided from the outlets to reach the buses. Cord Reels or organizers are recommended to minimize the tangling of cords and to extend their life. Block heater power can be shared by 2 to 4 buses. c. Fueling Fuel islands should be sized according to the logistics of how many busses and for what period of time they have to refuel. Fuel storage tanks should be sized by how much fuel is needed for what period of time. Tanks should be placed above ground and well protected from traffic. A simple canopy and fuel island should be placed on an easily accessible part of the site away from the main traffic flows. The island should include air and other fluids such as windshield washer fluid where frequent refills are necessary. A direct connection between the bus wash and fueling is preferred. Fuel monitoring should be incorporated. CNG fueling requires more detailed examination and capital to be deemed a viable fuel source. An area can be planned for future CNG fueling that is separated from the main campus. d. Fueling Dispenser Requirements Small facility, up to 25 buses hoses unleaded
1 island with 1 dispenser 2 hoses diesel 2
Medium facility, 25 to 90 buses
1 island with 2 dispensers 4 hoses diesel 4 hoses unleaded
Large facility, 90 + buses
2 islands with 3 dispensers 6 hoses diesel 6 hoses unleaded
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Codes and Design Standards The following list of code references must be followed in the design and construction of a maintenance facility. Keep in mind that codes and standards change over time and the current adopted code must be followed at all times. In addition to those codes listed below, local modifications to the building codes may need to be incorporated and should be confirmed during the design process. You will note that in some instances codes and standards will conflict. The most stringent will need to be followed. Code Type
Code Model
Building/Dwelling Code
IBC 2012
Structural Code
IBC 2012
Mechanical Code
IMC 2006
Plumbing Code
IPC 2006
Electrical Code
NEC 2011
Fire/Life Safety Code
IFC 2012
Gas Code
IFGC 2006
1. Regulatory Requirements Building permits must be obtained through the local and State authorities. Check each jurisdiction for exact requirements. Separate permits need to be obtained for fuel tanks. Agencies and documents that need to be consulted during design include: • • • • •
Wyoming State Fire Marshal Local Building Department Local Fire Department Local Zoning Department Wyoming School Facilities Department
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Sustainability Sustainability is a natural by-product of a school bus facility whose mission is to provide and maintain an efficient transportation system. 1. Site strategies • Building orientation o North/ south orientation with minimal east/west exposure for best solar control. o South, east, and west orientation at vehicle doors for snow & ice melting. • Water quality & detention o Large paved areas need substantial detention areas but also need snow storage. o BMP for water quality. o Sand & oil interceptor. o Low maintenance landscape. o Impervious paving. • Alternative transportation fuels • Infrastructure availability. o Generally sites are not in dense areas and may require new utilities. o Sites may need emergency power. 2. Building strategies • Envelope o Well insulated buildings with R-32 roof and R-19 walls. o High performance glazing. o Insulated overhead doors. o Low albedo roofing. •
•
Mechanical Electrical & Plumbing o Heat recovery system o Natural ventilation o Geothermal, wind farm, or photovoltaic collectors o Energy efficient lighting o Occupancy sensors o Day lighting o Low flow automatic plumbing fixtures o Recycled bus wash water Materials o Local manufacturers whenever practical o Low VOC o Recycled carpet, steel, concrete, o Rapidly renewable wood
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Sample Layouts The following plans are intended to supplement and clarify written descriptions and are not intended to be a final design for a specific project.
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Appendix A Bus Data Bus Type Type A Type B Type C Type D
Seating Capacity 16 - 36 30 - 36 36 - 78 54 – 90
Overall Length 19’-0” – 21’-2” 21’-4” – 23’-7” 25’-9” – 41’-7” 29’-6” – 40’-7”
Turning Radius Max. 42’-6” 42’-6” – 55’-6” Max. 55’-6” Max. 55’-6”
All buses: Maximum width = 8’-0” (10’-6” max, tip-to-tip of mirrors) Bus width with door open = 11’-0” Tallest Bus: 11’-6” high
Appendix B Questionnaire Basic Functions: a. What type vehicles are you maintaining? (see appendix A) i. What is the largest & the smallest vehicle you service? b. What services do you perform? (Circle all that apply) i.
Diagnostics, Lubricants, Brakes, Tires, Exhaust systems, Drivetrains, Engines, Shocks, Tune-ups, Wipers, Lights other?
c. Describe what happens in the maintenance area? d. How many people will be using the space at a time and in total? e. Is there an attached meeting or classroom? f. Do you use a locker room? g. What type of library do you have? h. Do you do body work, upholstery, painting, etc.? (circle all that apply) i. Do you or will you repair hydrogen fueled vehicles? j. Do you have several ongoing services requiring multiple bays? k. Do you share space with anyone? What spaces? Break areas, Lockers, meeting/muster areas, reception, office spaces? (circle all that apply) l. Does any equipment, doors, computers, hot lines, lifts, fuel dispensers, etc. need emergency power? (Circle all that apply) m. Other Information
Staffing & Visitors n. What is your organizational structure? o. Who is at the site full time? p. Who is at the site part time? q. How many people observe the procedures at a time? r. Do you have visitors or sales calls? s. Do you have an area for the drivers and or general meetings? Equipment: t. What tools and equipment do you use? (See appendix B) u. Are you anticipated buying any new equipment? v. Do you need an overhead or jib crane? w. What type of vehicle lifts do you prefer? In ground, portable, parallelogram, two post pits x. Do you use a welder? y. Do users bring their own tools? z. How many benches or work areas do you envision? aa. Do you need to clean the equipment before you work on it? bb. Do you use hazardous materials? cc. What fluids need to be accessed at the bays?
dd. Do you need compressed air at the bays? ee. What computer access do you need? Storage: ff. How do you store your tools? gg. What do you store on site, Batteries, tires, other stock? hh. How do you store your materials? ii. Do you store hazardous materials? jj. How do you receive large deliveries? kk. Does some storage need to be secured and or manned? ll. How do you manage waste products, exhaust air, mm. How much product do you use weekly? nn. How do you maintain your facilities? oo. Do you store vehicles outside? pp. Do you store vehicle under and open canopy? qq. Do you need to store fuels, coolants, lubricants etc.? ADDITIONAL NOTES:
SHOP EQUIPMENT Quantity
Qty
Equipment Bins, Parts Cabinets Safety Cabinets Std Tire Rack Tire Monorail Battery Charger Reels, Hose Reels, Electrical Reels, Exhaust
Length Equipment Shelving 12” deep Shelving 18” deep Shelving 24” deep Shelving Other Emergency Shower /eyewash Vise Workbench Compressor Compressed Air Drops Bush Washer Bus Wash Water Reclaim Compressor Air Dryer Fuel Pumps Fuel Tanks Fuel Control System Container, Oil Container Heavy Oil Container ATF Container WWF Parts Washer High pressure washer Ignition tester, electronic Impact wrenches ½” and ¾” or 1” Jack safety stands, heavy duty Jacks, hydraulic or air (minimum 10 ton) Key machine Knurl machine (valve guide repair) Masking paper dispenser Metal cutting shears Metal lathe (engine lathe) Micrometers and calipers, inside and outside, complete set Milliampere meter (0-150)
Paint gun (5 gallon pot with agitator) Paint respirators (OSHA approved) Pin hole grinder Power hacksaw Press, 40 ton Pressure gauges, 1 air and 1 hydraulic Pressurized brake bleeder Radiator temperature gauge Radio system, two way (1 base station, 1 radio station, 1 radio on each service vehicle) Rear axle nut sockets, complete set Ridge reamer Rivet gun, air operated Sander, disc type, heavy duty Sander, orbital Socket set, heavy duty metric and standard Steering wheel puller Tap and die set Timing light, electronic Tire balancer Tire changers, 1 truck and 1 car Tire inflation cage Tire matching gauge Torque wrenches, 3/8” drive, ½” drive and ¾” or 1” drive Transmission gear lube gun Transmission jack Transmission stand Tune up equipment, complete set (volt/amp tester, ohm meter, timing light, compression tester, rpm gauge, vacuum gauge, combustion analyzer) Engine analyzer Pro-link 9,000 or equal (electronic test unit) Brake drum and rotor gauge
Appendix C - Transportation Report
Appendix D Comparison of Compressed Natural Gas to Diesel Cost American School Bus Council (ASBC) Average miles traveled per year per bus
12,000
The number of students transported by each school bus
54
Average fuel consumption (mpg) for school buses (ASBC estimate, assuming large capacity buses, diesel engines) Average fuel use per school bus per year (gallons)
7 1,714
Cost of diesel fuel per gallon (Source: Energy Information Administration, September 5, 2011)
$3.870
Cost of diesel fuel per bus per year
$6,634
Average distance from home to school for bus riders (ASBC estimate, miles) Length of average school year (days)
5 180
Assumptions: 1 gallon of Diesel = 1 GGE (of natural gas) 1 Gallon of Diesel = $3.87 1 GGE = $1.31 A GGE is 33.9% of the cost of a gallon of diesel ($1.31 = $3.87 x .339). A CNG bus is less efficient than a diesel bus, getting a 14.3% lower fuel economy according to the 2012 Wyoming “A Feasibility Study of Natural Gas Vehicle Conversion”. Thus a year’s worth of natural gas for a bus is $6,634 x .339 = $2,248 x 1.143 = $2,570 saving $4,065 per year per bus. Currently CNG busses cost $30,000 more than diesel busses for a break even point of 7.3 years. Once past this break even cost, a facility with 100 busses would save $438,600 a year. A slow fill station costs +/- $400,000 and a fast fill station costs +/- $1.5 million. So for a facility with 100 busses the break even cost of a fast fill station is 3.4 years beyond the break even point for the cost of the bus. While the current price per gasoline gallon equivalent of CNG is $1.31 at Cheyenne Light Fuel & Power’s public station in Cheyenne, natural gas prices are predicted to increase beginning in 2015 and continue rising steadily until 2040, according to the U.S. Energy Information Administration (EIA). – “The Republic Free Choice”
Appendix E - Wyoming Transportation Building Needs List
Appendix F Acknowledgements The State of Wyoming School Facilities Department gratefully acknowledges the contributions of the following people: Lanny Applegate, Wyoming State Fire Marshall Ian Catellier, Director, State of Wyoming School Facilities Department Keith Chrans, Transportation Director, Campbell County SD #1 David Horner, Business Manager, Carbon County SD#1 David Koskelowski, Traffic Safety/Pupil Transportation, Wyoming Department of Education - Support Systems and Resources Division Joe Levi, OZ Architecture Vern McAdams, Business Manager, Sublette County SD #1 Ralph Schmitt, Engineering Economics, Inc. Sydney Webb, Transportation Director, Natrona SD #1 Kelly Yamasaki, OZ Architecture “American, Abundant and Affordable” A cost analysis of natural gas vehicle (NGVS) and fueling infrastructure; An Alternative Fuel Fact Brief – Presented by: Auto Gas for America (2011) “A Feasibility Study of Natural Gas Vehicle Conversion in Wyoming Public School Districts”, The Department of Administration and Information Economic Analysis Division, November 2012 “Information Report: Repair or Replacement of Components on School Buses”, National Association of State Directors of Pupil Transportation Services, November 2003 “National School Transportation Specifications and Procedures”, University of Central Missouri, May, 2010 “School Bus Maintenance Facility Planner”, Public Schools of North Carolina, State Board of Education, Department of Public Instruction, Division of School Support / Planning, February, 2011 Transportation Research Board – Maintenance Technician Staffing Levels for Modern Public Transit Fleets, Research in Progress
Wyoming Department of Administration & Information - Economic Analysis Division (A feasibility Study of Natural Gas Vehicle Conversion In Wyoming Public School Districts Presented to Governor Matt Mead and the Wyoming Legislature - November, 2012) Wyoming School Facilities Commission Wyoming Transportation Guidelines, Draft
