TOWERING ACHIEVEMENT IN MECHANICAL SYSTEMS
Smart Building Integration and Collaborative Sheet Metal Project
McKenney’s completed a significant sheet metal installation at the new 111 East Carson high-rise development in uptown Charlotte. This 42-story residential tower topped out in March 2025, showcasing McKenney’s expertise in integrating complex, large-scale mechanical systems. As part of a collaborative approach with a Chicago-based mechanical contractor, McKenney’s handled large-scale sheet metal fabrication and installation totaling over 94 tons of fabricated ductwork, risers, and sheet metal components.
The McKenney’s team successfully addressed several unique challenges throughout the 111 East Carson project. This included coordinating with the Chicago-based mechanical contractor, who managed all water-based mechanical systems, while McKenney’s focused on the air-side installation. This complex project management approach required careful integration to ensure uninterrupted construction.
The project showcased McKenney’s regional strength and collaborative capabilities with sheet metal being jointly fabricated between the Atlanta and Charlotte shops. This allowed for optimized production capacity, ensuring timely delivery of the massive 187,000-pound sheet metal requirement while maintaining McKenney’s high-quality standards across both facilities.
The team also implemented innovative methods, such as using flying connexes to install rooftop ductwork with tower cranes. These shipping container-sized units were strategically hoisted to the rooftop, allowing for the efficient installation of complex ductwork systems at significant heights. Additionally, to optimize building performance, the team incorporated a self-regulating ventilation system that significantly reduces the need for manual testing and balancing.
McKenney’s demonstrated expertise in maintaining construction timelines, progressing at approximately one floor per week despite numerous timeline changes and delays that were outside of McKenney’s control. Our project managers and technicians maintained superior quality control throughout the project, with a peak crew of 20 skilled sheet metal workers. This project solidified McKenney’s position as a leader in large-scale mechanical systems and demonstrated their ability to navigate complex building integrations while delivering a high-quality solution for the 111 East Carson development with expected completion by November 2025.
The Challenge
- Coordinating complex mechanical systems with a Chicago-based partner while maintaining schedule integrity
- Installing extensive ductwork systems at extreme heights across 42 floors
- Fabricating and installing approximately 187,000 pounds of sheet metal components
- Navigating frequent timeline changes, delays, and competing priorities with the project team
The Solution
- Implemented innovative flying connexes method for efficient rooftop ductwork installation
- Jointly fabricated sheet metal components between Atlanta and Charlotte shops
- Incorporated a self-regulating ventilation system significantly reducing the need for manual test and balancing
- Maintained construction pace of approximately one floor per week with a team of 20 skilled workers
The Results
- Successfully topped out Charlotte’s newest residential high-rise tower in March 2025
- Completed McKenney’s largest collaborative sheet metal project
- Demonstrated superior project management and flexibility despite GC-imposed scheduling challenges
- On track for successful project completion by November 2025