Generates complete construction documentation packages — BOM, installation sequences, commissioning checklists, and O&M manuals — from verified engineering designs.
Generate the complete paper package that contractors need to build a system — Bill of Materials, installation sequences, commissioning tests, and Operations & Maintenance manuals — from verified engineering designs.
Activation: After the Architect, Calculator, and Safety agents complete a design and the blueprint engine has generated drawings. InfrastructureRequest with outputFormat including 'construction'.
Four output types:
When to use: Design is verified and safety-reviewed, ready for construction. All calculations must pass Safety Warden review before generating construction documents.
Key constraint: All construction documents require review by a licensed Professional Engineer before use in procurement, construction, or installation.
ENGINEERING DISCLAIMER: All construction documents generated by this skill are AI-assisted drafts. They MUST be reviewed, stamped, and signed by a licensed Professional Engineer (PE) before use in procurement, construction, installation, or commissioning. Local building codes, jurisdictional requirements, and site-specific conditions may impose additional requirements not captured here. User assumes all responsibility for PE review and code compliance.
Quick start: Provide a completed BlueprintPackage (from the blueprint engine) and this skill generates all four document types. Templates are available in @references/templates/ for customization.
Input: BlueprintPackage (drawings + calculations + BOM + safetyReview)
Output: BOM spreadsheet, installation sequence, commissioning checklists, O&M manual
Quick routing:
The BOM is derived from verified design calculations and drawings. Each CalculationRecord in the BlueprintPackage identifies materials by their engineering specifications; the BOM skill translates these into procurement-ready line items.
Extraction process:
Every BOM must include these columns:
| Column | Description | Example |
|---|---|---|
| Line Number | Sequential identifier by category | 100, 101, 102... |
| Item Description | Engineering description with specification | "Carbon steel pipe, 3" SCH 40, ASTM A53 Gr B" |
| Part Number | Manufacturer part number (if applicable) | "VIC-77" |
| Quantity | Count or measured amount | 150 |
| Unit | Unit of measure | EA, LF, SF, SET |
| Unit Cost | Estimated cost per unit (if known) | $12.50 |
| Supplier | Preferred vendor or manufacturer | "Ferguson" |
| Notes | Installation notes, alternatives, lead time | "Per ASTM A53 Gr B, 21-day lead" |
Organize BOM by category with line number ranges:
| Category | Line Range | Contents |
|---|---|---|
| Pipe and Fittings | 100-199 | Pipe by size/material, elbows, tees, reducers, flanges, unions, couplings |
| Valves | 200-249 | Gate, globe, ball, check, butterfly, control valves by size and class |
| Equipment | 250-299 | Pumps, CDUs, heat exchangers, chillers, cooling towers |
| Electrical Equipment | 300-349 | Transformers, UPS, PDUs, panelboards, switchgear |
| Cable and Conduit | 350-399 | Conductors by type/gauge, conduit by type/size, cable tray, fittings |
| Supports and Hangers | 400-449 | Pipe hangers, conduit straps, cable tray supports, seismic bracing |
| Insulation | 450-499 | Pipe insulation, duct insulation, firestopping |
| Consumables | 500-549 | Welding rod, solder, joint compound, tape, sealants, fasteners |
For items that come in multiple sizes (e.g., pipe with fittings), create a separate line item for each fitting type and size:
100 Carbon steel pipe, 3" SCH 40 — 150 LF
101 90-deg elbow, 3" SCH 40 BW — 12 EA
102 Straight tee, 3" SCH 40 BW — 4 EA
103 Concentric reducer, 3"x2" SCH 40 BW — 2 EA
104 Gate valve, 3" 150# flanged — 6 EA
105 Flange, 3" 150# RFWN — 12 EA
106 Gasket, 3" 150# spiral wound — 12 EA
107 Bolting, 3" 150# B7/2H set — 12 SET
For a typical 200 kW chilled water cooling system:
Template location: @references/templates/bom-template.md
Installation sequence is not arbitrary — it is driven by building code requirements, trade coordination needs, and inspection hold points.
NEC Article 110 (General Work Requirements):
IPC Chapter 3 (General Regulations):
ASHRAE 90.4 / Data Center Commissioning:
Installation steps use prerequisite notation to enforce ordering:
[PREREQ: item X complete before starting] — hard dependency[HOLD: Inspection Required] — jurisdictional inspection point; work stops until inspector approves[TRADE: E/M/S] — trade assignment (Electrical/Mechanical/Structural)Standard data center MEP installation sequence:
Phase 1: Pre-Construction
[TRADE: S] Structural modifications (floor penetrations, wall openings, equipment pads)[TRADE: S] Seismic bracing installation (if required by IBC zone)[HOLD: Structural Inspection Required]Phase 2: Rough-In
4. [TRADE: E] Conduit and cable tray installation — [PREREQ: structural mods complete]
5. [TRADE: M] Overhead piping rough-in (supply/return headers) — [PREREQ: structural mods complete]
6. [TRADE: M] Below-floor piping rough-in (condensate drains, CDU connections)
7. [HOLD: Rough-In Inspection Required] — before ceiling/floor close-in
Phase 3: Equipment Setting
8. [TRADE: M] Set mechanical equipment (CDUs, pumps, heat exchangers) — [PREREQ: floor/pad complete]
9. [TRADE: E] Set electrical equipment (transformers, UPS, PDUs, panelboards) — [PREREQ: floor/pad complete]
10. [TRADE: E] Set rack power distribution (rack PDUs, whips)
Phase 4: Final Connections
11. [TRADE: M] Piping final connections to equipment — [PREREQ: equipment set and anchored]
12. [TRADE: E] Wire pulling through conduit — [PREREQ: conduit complete and inspected]
13. [TRADE: E] Terminations and connections — [PREREQ: wire pull complete]
14. [TRADE: M] Pipe insulation — [PREREQ: hydrostatic test passed]
Phase 5: Pre-Commissioning Testing
15. [TRADE: M] Hydrostatic pressure test — [PREREQ: piping complete, before insulation]
16. [TRADE: E] Megger (insulation resistance) test — [PREREQ: all terminations complete]
17. [HOLD: Pre-Commissioning Test Review Required]
Phase 6: Commissioning
18. [TRADE: E/M] System energization and startup — [PREREQ: all pre-commissioning tests passed]
19. [TRADE: E/M] Performance verification against design specifications
20. [TRADE: E/M] Punch list walk-down and remediation
21. [HOLD: Final Inspection Required]
Inspection hold points are jurisdictional — they vary by Authority Having Jurisdiction (AHJ). Common hold points:
| Hold Point | Typical Inspections | Trades Affected |
|---|---|---|
| Structural | Foundation, steel connections, seismic bracing | S |
| Rough-in | Conduit placement, pipe routing before concealment | E, M |
| Equipment | Equipment mounting, grounding, seismic anchoring | E, M |
| Pre-commissioning | Pressure test results, insulation resistance results | E, M |
| Final | Complete system operation, code compliance | E, M, S |
Template location: @references/templates/installation-sequence-template.md
The hydrostatic test verifies piping system integrity before insulation and concealment.
Test parameters per IPC 312.5:
| Parameter | Requirement |
|---|---|
| Test pressure | 1.5x maximum working pressure, minimum 100 PSI, maximum 500 PSI |
| Hold time | 15 minutes minimum |
| Acceptance criteria | No pressure loss greater than 5 PSI during hold period |
| Medium | Clean water (potable for domestic systems) |
| Temperature | Ambient (not below 40 deg F to prevent freezing) |
Test equipment requirements:
Procedure:
Common failure causes: Threaded joint not properly sealed, flange gasket improperly seated, valve packing not tightened, temporary cap cross-threaded.
The megger test verifies conductor insulation integrity before energization.
Test parameters per IEEE 43:
| Parameter | Systems up to 1000V | Systems 1001-5000V |
|---|---|---|
| Test voltage | 500 VDC | 1000 VDC |
| Minimum acceptable IR | 1 MOhm (absolute minimum) | 1 MOhm (absolute minimum) |
| Practical minimum (new) | 100 MOhm | 100 MOhm |
| Duration | 1 minute (standard reading) | 1 minute + optional 10-minute PI test |
| Polarization Index (PI) | PI = IR_10min / IR_1min, target > 2.0 | PI > 2.0 required |
Test setup:
Polarization Index interpretation:
| PI Value | Insulation Condition |
|---|---|
| < 1.0 | Dangerous — do not energize |
| 1.0 - 2.0 | Questionable — investigate further |
| 2.0 - 4.0 | Good — acceptable for service |
| > 4.0 | Excellent — clean, dry insulation |
Common issues: Low IR readings caused by moisture in conduit (drain and dry), contaminated terminations (clean with solvent), damaged insulation during wire pull (inspect and repair).
All test instruments must have current calibration certificates:
| Instrument | Calibration Interval | Standard |
|---|---|---|
| Pressure gauge | 12 months | ASME B40.100 |
| Megger/insulation tester | 12 months | NIST-traceable |
| Multimeter | 12 months | NIST-traceable |
| Torque wrench | 12 months | ISO 6789 |
Each test must document:
Template location: @references/templates/commissioning-checklist-template.md
Before any system startup, complete visual and mechanical verification:
Mechanical systems:
Electrical systems:
For data center infrastructure, follow this startup order:
Step 1: Utility Power (Day 1)
Step 2: UPS Systems (Day 1-2) 5. Start UPS in bypass mode first (verify output voltage) 6. Transfer to online (double-conversion) mode 7. Verify UPS output: voltage (+/- 1%), frequency (+/- 0.1 Hz) 8. Perform battery discharge test (verify runtime meets specification)
Step 3: Power Distribution (Day 2) 9. Energize floor-standing PDUs from UPS output 10. Verify PDU output voltage and phase balance (within +/- 10%) 11. Energize rack PDUs 12. Apply test loads (portable load banks) to verify capacity
Step 4: Cooling — Mechanical (Day 3) 13. Start chilled water pumps (verify flow rate with ultrasonic meter) 14. Start CDU secondary pumps 15. Verify flow to each rack manifold 16. Check for leaks at all connections under operating pressure
Step 5: Cooling — Thermal Verification (Day 3-4) 17. Apply thermal load (load banks or actual IT equipment) 18. Verify supply and return temperatures at each CDU 19. Verify design DeltaT is achieved 20. Check approach temperatures at heat exchangers
| System | Parameter | Acceptance |
|---|---|---|
| Power | Voltage (line-to-line) | +/- 2% of nominal |
| Power | Frequency | +/- 0.1 Hz of 60 Hz |
| Power | Phase balance | Within 10% across A, B, C |
| UPS | Transfer time | < 4 ms (online double-conversion) |
| UPS | Battery runtime | Meets or exceeds design specification |
| Cooling | Flow rate | Within 10% of design GPM |
| Cooling | Supply temperature | Within 2 deg F of setpoint |
| Cooling | DeltaT | Within 20% of design DeltaT |
| Cooling | Leak test | Zero visible leaks at operating pressure |
Non-conforming items discovered during commissioning:
Per ASHRAE Guideline 0-2019 (The Commissioning Process), the O&M manual includes these sections:
Section 1: System Description
Section 2: Design Intent
Section 3: Sequence of Operations
Section 4: Operating Procedures
Section 5: Maintenance Schedule
Section 6: Spare Parts List
Section 7: Vendor Contacts and Warranties
Section 8: Training Requirements
Section 9: As-Built Drawing References
Section 10: Commissioning Test Records
Extract maintenance tasks from equipment manufacturer manuals. Organize by frequency:
| Frequency | Typical Tasks |
|---|---|
| Daily | Visual inspection, BMS alarm check, leak detection system check |
| Weekly | Strainer differential pressure check, UPS status check, coolant level check |
| Monthly | Valve exercise (1/4 turn open-close on isolation valves), battery voltage check |
| Quarterly | Water chemistry analysis, filter replacement, belt/coupling inspection |
| Annually | Pump vibration analysis, UPS battery load test, thermographic scan of electrical connections |
| 5-year | Major overhaul (pump rebuild, valve repacking), UPS capacitor replacement, transformer oil analysis |
Filter BOM to maintenance-critical items — components expected to require replacement within the system's operational life:
| Category | Items to Stock | Recommended Qty |
|---|---|---|
| Seals and gaskets | Pump mechanical seals, valve packing, flange gaskets | 2 per installed |
| Filters | Strainer screens, air filters, water filters | 1 year supply |
| Bearings | Pump bearings, motor bearings | 1 per installed |
| Belts and couplings | V-belts, flexible couplings | 1 per installed |
| Fuses and breakers | Branch circuit breakers, control fuses | 10% of installed |
| Lamps and indicators | Pilot lights, panel indicators | 20% of installed |
For each failure mode, document immediate actions and escalation:
| Failure Mode | Immediate Action | Escalation |
|---|---|---|
| Total power loss | Verify UPS operating on battery, check generator start | Notify facility manager, contact utility |
| Cooling pump failure | Verify standby pump started, check flow switch | Notify mechanical contractor, monitor temps |
| CDU leak detected | Automatic shutoff activates, verify containment | Notify mechanical contractor, begin cleanup |
| High rack temperature | Verify cooling flow, reduce IT load if needed | Notify operations, consider controlled shutdown |
| UPS alarm | Check UPS display for specific fault code | Contact UPS vendor, prepare for bypass |
Template location: @references/templates/om-manual-template.md
NEC 110.3(B): All electrical equipment must be installed per the manufacturer's listed and labeled instructions. Deviation requires AHJ approval.
NEC 110.12: Mechanical execution of work. Electrical equipment must be installed in a neat and workmanlike manner. Internal wiring must be neatly bundled, connections properly torqued, and unused openings closed.
NEC 110.26: Working space about electrical equipment. Minimum clearances:
NEC 250 (Grounding and Bonding):
NEC 300.4: Protection of conductors against physical damage. Cables and raceways within 1.5" of framing must be protected by steel plates.
NEC 690.12: Rapid shutdown for PV systems — conductors outside array boundary must de-energize to less than 30V within 30 seconds of shutdown initiation.
IPC 312.5: Hydrostatic pressure test for DWV systems. Test at no less than 10-foot head of water (4.3 PSI) for 15 minutes with no pressure loss.
IPC 312.3: Water supply system pressure test. Test at working pressure plus 50% (minimum 40 PSI) for 15 minutes.
IPC Chapter 3 (General Regulations):
UPC 609.4: Maximum velocity in water distribution piping: 8 ft/s for pipe sizes up to 2", 6 ft/s for pipe sizes above 2". Higher velocities risk erosion and water hammer.
The commissioning process spans the entire project lifecycle:
| Phase | Activities | Owner |
|---|---|---|
| Pre-design | Develop Owner's Project Requirements (OPR) | Owner + CxA |
| Design | Develop Basis of Design (BOD), review design documents | Designer + CxA |
| Construction | Verify installation per design, witness pre-functional tests | Contractor + CxA |
| Acceptance | Functional performance testing, seasonal testing | CxA |
| Post-occupancy | 10-month warranty review, ongoing commissioning plan | Owner + CxA |
CxA = Commissioning Authority (independent third party for LEED projects).
BICSI 002 (Data Center Design and Implementation Best Practices):
TIA-942 (Telecommunications Infrastructure Standard for Data Centers):
| Line | Description | Qty | Unit | Notes |
|---|---|---|---|---|
| 100 | CS pipe 3" SCH 40, ASTM A53 Gr B | 250 | LF | Supply + return headers |
| 101 | CS pipe 2" SCH 40, ASTM A53 Gr B | 120 | LF | Branch lines to CDUs |
| 102 | 90-deg elbow, 3" SCH 40 BW | 16 | EA | Per isometric drawing |
| 103 | 90-deg elbow, 2" SCH 40 BW | 24 | EA | Per isometric drawing |
| 104 | Straight tee, 3"x2" SCH 40 BW | 8 | EA | CDU branch takeoffs |
| 105 | Concentric reducer 3"x2" SCH 40 | 4 | EA | Header to branch transitions |
| 200 | Butterfly valve 3" wafer, EPDM seat | 8 | EA | Header isolation |
| 201 | Butterfly valve 2" wafer, EPDM seat | 16 | EA | CDU isolation (supply + return) |
| 202 | Balancing valve 2" circuit setter | 8 | EA | One per CDU branch |
| 203 | Check valve 2" swing | 2 | EA | Pump discharge |
| 250 | CDU, 30 kW, 20 GPM | 8 | EA | Per thermal calc |
| 251 | Centrifugal pump, 160 GPM @ 45 ft | 2 | EA | Duty + standby |
| 252 | Expansion tank, 20 gallon | 1 | EA | Per system volume calc |
| 253 | Air separator, 3" | 1 | EA | At system high point |
| 300 | VFD, 5 HP, 460V 3-phase | 2 | EA | Pump motor controllers |
| 350 | THWN-2 copper, 10 AWG | 300 | LF | VFD to motor |
| 351 | EMT conduit, 3/4" | 150 | LF | VFD to motor |
| 400 | Pipe hanger, Grinnell FIG 65, 3" | 25 | EA | 10' max spacing per ASME B31.9 |
| 401 | Pipe hanger, Grinnell FIG 65, 2" | 30 | EA | 10' max spacing |
| 450 | Pipe insulation, 1" thick, 3" pipe | 250 | LF | Per ASHRAE 90.1 |
| 451 | Pipe insulation, 1" thick, 2" pipe | 120 | LF | Per ASHRAE 90.1 |
| 500 | Teflon tape, 1/2" x 520" | 12 | RL | Threaded connections |
| 501 | Pipe sealant, Rector-Seal No. 5 | 6 | PT | Threaded connections |
[TRADE: E] De-energize and LOTO existing distribution — [PREREQ: shutdown schedule approved][TRADE: S] Set concrete equipment pads for new transformer and UPS[HOLD: Structural Inspection Required][TRADE: E] Install new conduit runs (EMT/rigid) from utility to transformer to UPS to PDU locations[TRADE: E] Set transformer on pad — [PREREQ: pad cured 7 days minimum][TRADE: E] Set UPS on pad — [PREREQ: pad cured, conduit complete][TRADE: E] Set floor-standing PDUs at rack row locations[HOLD: Equipment Setting Inspection Required][TRADE: E] Pull conductors: utility to transformer (500 kcmil per phase)[TRADE: E] Pull conductors: transformer to UPS (4/0 per phase)[TRADE: E] Pull conductors: UPS to PDU (2 AWG per phase per PDU)[TRADE: E] Terminate all conductors per manufacturer torque specifications[TRADE: E] Megger test all conductors — [PREREQ: all terminations complete][HOLD: Pre-Commissioning Test Review Required][TRADE: E] Energize transformer from utility — verify secondary voltage[TRADE: E] Start UPS in bypass mode — verify output[TRADE: E] Transfer UPS to online mode — verify transfer[TRADE: E] Energize PDUs — verify output voltage and phase balance[TRADE: E] Apply test load (load bank) — verify full-load performance[HOLD: Final Inspection Required]| Reference | When to Read | Coverage |
|---|---|---|
| @references/templates/bom-template.md | Generating a BOM for a new project | Reusable BOM table template |
| @references/templates/installation-sequence-template.md | Planning construction sequence | Numbered checklist with prerequisites |
| @references/templates/commissioning-checklist-template.md | Pre-commissioning testing | Hydrostatic and megger test sheets |
| @references/templates/om-manual-template.md | Writing O&M documentation | ASHRAE 0-2019 compliant manual structure |
Construction Documents Skill v1.0.0 — Physical Infrastructure Engineering Pack Phase 440-01 | References: NEC (NFPA 70), IPC/UPC, ASHRAE Guideline 0-2019, BICSI 002, TIA-942, IEEE 43, ASME B31.9 All outputs require verification by a licensed Professional Engineer.