Construction Docs

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:

• BOM generation? See BOM Generation
• Installation ordering? See Installation Sequence
• Test procedures? See Pre-Commissioning Checklists
• System startup? See Commissioning Procedures
• Maintenance docs? See O&M Manual Generation

BOM Generation (CONSTR-01)

Extracting Materials from Design Specifications

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:

1. Parse P&ID drawings for pipe sizes, fittings, valves, and equipment tags
2. Parse SLD drawings for conductors, conduit, panelboards, and protective devices
3. Cross-reference with CalculationRecord outputs for exact sizing (pipe NPS, conductor AWG, equipment ratings)
4. Apply material specifications from design basis (ASTM pipe grades, NEC conductor types, equipment model numbers)
5. Add supports, hangers, and insulation per ASME B31.9 (pipe) and NEC 300 (conduit) spacing requirements
6. Include consumables (welding rod, solder, tape, sealant, fasteners)

Standard BOM Columns

Every BOM must include these columns:

Material Categories

Organize BOM by category with line number ranges:

Multi-Size Item Handling

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

Data Center Cooling BOM Example Elements

For a typical 200 kW chilled water cooling system:

• 3" carbon steel supply/return headers (ASTM A53 Gr B, SCH 40)
• 2" carbon steel branch lines to each CDU
• Butterfly isolation valves at each CDU connection
• Balancing valves for flow adjustment
• Pressure/temperature test ports (Pete's plugs)
• CDU units (sized per thermal-engineering calculations)
• Centrifugal pumps (duty + standby, per pump selection calculations)
• Expansion tank (sized for system volume thermal expansion)
• Air separator (at system high point)
• Chemical treatment pot feeder
• Pipe insulation (per ASHRAE 90.1 minimum thickness)

Template location: @references/templates/bom-template.md

Installation Sequence (CONSTR-02)

Code-Driven Ordering Principles

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):

• All electrical equipment must be installed per manufacturer instructions (110.3(B))
• Working space clearances must be maintained during and after installation (110.26)
• Equipment grounding must be complete before any conductor is energized

IPC Chapter 3 (General Regulations):

• Rough-in inspection required before concealing piping (jurisdictional)
• Pressure testing required before insulation application
• Final inspection required before occupancy

ASHRAE 90.4 / Data Center Commissioning:

• Factory Acceptance Test (FAT) before equipment delivery
• Site Acceptance Test (SAT) on equipment delivery
• Integrated Systems Test (IST) before occupancy

Prerequisite Notation

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)

Trade Sequencing for Data Center Work

Standard data center MEP installation sequence:

Phase 1: Pre-Construction

1. [TRADE: S] Structural modifications (floor penetrations, wall openings, equipment pads)
2. [TRADE: S] Seismic bracing installation (if required by IBC zone)
3. [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

Inspection hold points are jurisdictional — they vary by Authority Having Jurisdiction (AHJ). Common hold points:

Template location: @references/templates/installation-sequence-template.md

Pre-Commissioning Checklists (CONSTR-03)

Hydrostatic Pressure Test (IPC 312.5)

The hydrostatic test verifies piping system integrity before insulation and concealment.

Test parameters per IPC 312.5:

Test equipment requirements:

• Calibrated pressure gauge: 2" face minimum, 1% accuracy class
• Gauge range: test pressure at 50-75% of gauge full scale
• Hand pump or hydrostatic test pump
• Isolation valves (ball or gate, not butterfly)
• Temporary test caps or blind flanges

Procedure:

1. Isolate system from permanent equipment (remove pressure relief valves, install temporary caps)
2. Fill system with clean water, vent all air from high points
3. Pressurize slowly to test pressure
4. Record initial pressure and time
5. Hold for 15 minutes; record pressure at 5-minute intervals
6. Pass: pressure drop less than or equal to 5 PSI over 15 minutes
7. Fail: locate and repair leaks, repeat test from step 2

Common failure causes: Threaded joint not properly sealed, flange gasket improperly seated, valve packing not tightened, temporary cap cross-threaded.

Megger Test — Insulation Resistance (IEEE 43)

The megger test verifies conductor insulation integrity before energization.

Test parameters per IEEE 43:

Test setup:

• All conductors tested phase-to-phase and phase-to-ground
• Far end of each conductor disconnected (open circuit)
• All sensitive electronics (VFDs, UPS control boards) disconnected before testing
• Ambient conditions recorded (temperature and humidity affect IR readings)

Polarization Index interpretation:

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).

Test Equipment Calibration

All test instruments must have current calibration certificates:

Documentation Requirements

Each test must document:

• Project name, system identification, drawing reference
• Test date, ambient conditions (temperature, humidity)
• Technician name and license/certification number
• Test instrument make, model, serial number, calibration date
• Test parameters (pressure, voltage, duration)
• Results with pass/fail determination
• Technician signature and date
• PE review signature, license number, and date

Template location: @references/templates/commissioning-checklist-template.md

Commissioning Procedures (CONSTR-04)

Pre-Start Checklist

Before any system startup, complete visual and mechanical verification:

Mechanical systems:

• All piping connections tight and leak-free (post hydrostatic test)
• All valves in correct position (open/closed per startup sequence)
• Pump alignment verified (laser alignment for coupled pumps)
• Strainers installed and clean
• Expansion tank pre-charge verified
• Chemical treatment system charged and operational
• All temporary test equipment removed
• Insulation complete on all specified piping

Electrical systems:

• All terminations torqued to manufacturer specification
• All megger test results acceptable (IR > 100 MOhm for new installations)
• Breaker settings verified against coordination study
• Ground fault protection tested and operational
• Arc flash labels installed per NEC 110.16
• All temporary jumpers and bypasses removed
• UPS battery string voltage verified
• Emergency power off (EPO) system tested

Sequential Startup Procedure

For data center infrastructure, follow this startup order:

Step 1: Utility Power (Day 1)

1. Energize main switchgear from utility
2. Verify voltage at main bus (all three phases within +/- 2%)
3. Energize step-down transformers
4. Verify secondary voltage at each transformer

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

Acceptance Criteria

Punch List Process

Non-conforming items discovered during commissioning:

1. Document: Describe deficiency, location, responsible trade, severity (A/B/C)
   • A-item: Prevents system operation — must fix before acceptance
   • B-item: Functional but not per specification — fix within 30 days
   • C-item: Cosmetic or minor — fix within 90 days
2. Track: Assign responsibility, target date, status
3. Verify: Responsible party fixes and signs off; commissioning agent verifies
4. Close: PE reviews completed punch list and issues certificate of substantial completion

O&M Manual Generation (CONSTR-05)

Standard O&M Package Sections

Per ASHRAE Guideline 0-2019 (The Commissioning Process), the O&M manual includes these sections:

Section 1: System Description

• Overall system purpose and capacity
• Major equipment list with tag numbers, manufacturers, model numbers
• System flow diagram (reference P&ID drawing number)

Section 2: Design Intent

• Design basis (heat load, redundancy level, safety class)
• Design conditions (flow rates, temperatures, pressures, voltages)
• Performance targets (PUE, availability, efficiency)

Section 3: Sequence of Operations

• Normal operating sequence for each system
• Control logic descriptions (setpoints, deadbands, PID tuning)
• BMS/EPMS integration points and alarm setpoints

Section 4: Operating Procedures

• Normal operations: Startup, shutdown, steady-state monitoring
• Emergency procedures: Power failure, cooling failure, leak detection response, fire alarm response
• Seasonal procedures: Changeover between economizer and mechanical cooling modes

Section 5: Maintenance Schedule

• Derived from equipment manufacturer recommendations
• Organized by frequency: daily, weekly, monthly, quarterly, annual, 5-year

Section 6: Spare Parts List

• Filtered from BOM to maintenance-critical items
• Includes recommended stocking quantities and lead times
• Minimum spare inventory for 90-day self-sufficiency

Section 7: Vendor Contacts and Warranties

• Equipment vendor name, phone, email, contract number
• Warranty start date, duration, terms, exclusions
• Service level agreements (SLA) for critical equipment

Section 8: Training Requirements

• Required certifications for operations staff
• Training topics: system operation, emergency response, LOTO procedures
• Recommended training schedule and refresher intervals

Section 9: As-Built Drawing References

• Drawing number index with revision history
• Mark-up procedure for field changes
• As-built submission requirements to facility owner

Section 10: Commissioning Test Records

• Hydrostatic test results
• Megger test results
• System performance verification data
• Punch list completion records

Maintenance Schedule Derivation

Extract maintenance tasks from equipment manufacturer manuals. Organize by frequency:

Spare Parts List Generation

Filter BOM to maintenance-critical items — components expected to require replacement within the system's operational life:

Emergency Procedure Templates

For each failure mode, document immediate actions and escalation:

Template location: @references/templates/om-manual-template.md

Deep Reference

NEC Code References for Installation Sequence

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:

• 0-150V: 36" front clearance
• 151-600V: 36" front clearance (condition 1), 42" (condition 2), 48" (condition 3)
• 30" minimum width or width of equipment, whichever is greater
• 78" minimum headroom

NEC 250 (Grounding and Bonding):

• Equipment grounding conductor required in all raceways (250.118)
• Grounding electrode system must be complete before first energization (250.50)
• Bonding of building steel and water piping per 250.52 and 250.104

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/UPC Code References for Plumbing

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):

• Rough-in inspection before concealment (jurisdictional, but nearly universal)
• Pipe identification (color coding per ASME A13.1) required for exposed piping
• Access panels required for concealed valves and cleanouts

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.

ASHRAE Guideline 0-2019 Commissioning Process

The commissioning process spans the entire project lifecycle:

CxA = Commissioning Authority (independent third party for LEED projects).

Data Center Documentation Standards

BICSI 002 (Data Center Design and Implementation Best Practices):

• Requires as-built documentation within 90 days of substantial completion
• Hot/cold aisle documentation including airflow diagrams
• Cable management documentation with port mapping
• Power chain documentation from utility to rack outlet

TIA-942 (Telecommunications Infrastructure Standard for Data Centers):

• Tier-level documentation requirements scale with Tier rating
• Tier III/IV require comprehensive commissioning documentation
• Requires ongoing testing schedules post-commissioning

Example: Complete BOM for 200 kW Cooling System

Example: Installation Sequence for Power Distribution Upgrade

1. [TRADE: E] De-energize and LOTO existing distribution — [PREREQ: shutdown schedule approved]
2. [TRADE: S] Set concrete equipment pads for new transformer and UPS
3. [HOLD: Structural Inspection Required]
4. [TRADE: E] Install new conduit runs (EMT/rigid) from utility to transformer to UPS to PDU locations
5. [TRADE: E] Set transformer on pad — [PREREQ: pad cured 7 days minimum]
6. [TRADE: E] Set UPS on pad — [PREREQ: pad cured, conduit complete]
7. [TRADE: E] Set floor-standing PDUs at rack row locations
8. [HOLD: Equipment Setting Inspection Required]
9. [TRADE: E] Pull conductors: utility to transformer (500 kcmil per phase)
10. [TRADE: E] Pull conductors: transformer to UPS (4/0 per phase)
11. [TRADE: E] Pull conductors: UPS to PDU (2 AWG per phase per PDU)
12. [TRADE: E] Terminate all conductors per manufacturer torque specifications
13. [TRADE: E] Megger test all conductors — [PREREQ: all terminations complete]
14. [HOLD: Pre-Commissioning Test Review Required]
15. [TRADE: E] Energize transformer from utility — verify secondary voltage
16. [TRADE: E] Start UPS in bypass mode — verify output
17. [TRADE: E] Transfer UPS to online mode — verify transfer
18. [TRADE: E] Energize PDUs — verify output voltage and phase balance
19. [TRADE: E] Apply test load (load bank) — verify full-load performance
20. [HOLD: Final Inspection Required]

Reference Documents

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.