Froedtert South St. Catherine’s Medical Center Central Plant Expansion

Kenosha, Wisconsin

Riley Construction provided Construction Management at Risk service to the Froedtert South’s St. Catherine’s Medical Center Campus project, consisting of more than doubling its total size by expanding and renovating approximately 322,000 SF. This project involved a three-story, vertical expansion on top of an active, full-service hospital facility. The infrastructure upgrade included complete chiller replacements, removal and replacement of a deteriorated chilled water distribution system, and the complete rebuild of the mechanical penthouse piping system to provide an increased pumping capacity. The project also included three phases of remodeling and a physical plant expansion consisting of new chillers, boilers, cooling towers and pumps.
During the two year project, all work activities occurred while the existing hospital remained fully operational.
The central plant expansion and modifications include:

  • 800HP 20,700 lb/hr Boiler
  • 776 Ton Chiller
  • (4) Air Cooled 235 Ton Chillers
  • (3) 2,070gpm Cooling Towers
  • 25,000 Gal below grade Fuel Oil Tank
  • (2) 1,000kW Kohler Generators
  • (2) 25kva service lines
  • 3,000kva Substation
    Modifying the existing 24.9kV Medium Voltage Switchgear to primary selective and new feeder bays. Coordination with We Energies for the new second utility line including the dedicated reserve capacity.
  • New Double-Ended Substation, 3000kVA Transformers serving 4000amp, 480volt Switchboard Lineups
  • Convert the existing 480volt standby Priority Selector System to synchronize with the two new Standby Generators
  • Converting the campus from a secondary utility customer (480volt) to a primary utility customer (24.9kV); The new primary service consisted of metal clad switchgear with two incoming lines and automatic transfer
  • One (1) new 80kVA UPS to be redundant for the existing relocated 80kVA UPS