Patrick Fay, Professional Mechanical Engineer (PE)
Repeated success as a Project, Facilities, Construction, and Engineering Management Professional with an extensive record of achievement in managing multi-million dollar projects requiring expertise in project management, construction industry oversight, and management of numerous internal and external stakeholders. Expert communicator, team leader, and businessperson; able to forge solid relationships with partners and build consensus across multiple organizational levels.
Highlights of Expertise
· Construction & Facility Oversight
· HVAC & Automation System Design, Installation and Operation
· Electrical Systems & Controls
· Full Lifecycle Project Management
· On Job Site Safety Expert
· Utility Cost Savings for Facilities
· Multidisciplinary Team Leadership
· Overseas Professional Environments
· Construction Drawings & Documents
· Profitable Project Outcomes
· Builds Project Esprit de Corps
Career Summary
Contract Engineer, Cost Estimator, Project Manager. 2016 to Present.
Working on a contract basis as a contract engineer and construction cost estimator. Also, provide project management expertise in house construction. Started The Pat Fay Method Home Construction Company LLC as general contractor. If you are in the Seattle area let Mr. Fay help you save money on your home construction project. At this time accepting large home construction projects: new construction, tear down existing and build new, and complete gut and remodel projects as a general contractor. On smaller projects Mr. Fay can be hired as your project manager on a negotiated fee basis. Mr. Fay will be your advisor and/or help you manage the construction of your home construction project.
The Department of State – The Foreign Service, Various Global Locations
Provide comprehensive oversight, maintenance, and repair of U.S. Embassy facilities and their mechanical and electrical systems in locations including Lithuania, Latvia, Belarus, Rwanda, Estonia, DC, Iraq, China, and Liberia.
FACILITY MANAGEMENT – OVERSEAS BUILDING OPERATIONS (March 2010 to 2016)
Responsible for the repair and upkeep of heating, ventilation, and air condition systems, potable water plant, waste water treatment plant, lift stations, electrical generators, and solar cell arrays.
¨ Designed and delivered on-the-job training to 52 skilled technicians and engineers in Kigali, Rwanda focused on enhancing the operational efficiency of HVAC systems through understanding of equipment functions and related engineering principles.
¨ Adjusted HVAC operations in Kigali, which resulted in a 17% reduction in electrical power consumption totaling $178,000 in cost savings within the first year of implementation.
¨ Achieved $40,000 in cost savings through the expeditious and precise resolution of an air conditioning failure in Tallinn while on assignment in Vilnius that was causing critical failure of Embassy communications.
¨ Spearheaded the investigation and remediation of house fires plaguing the Kigali-based staff, which resulted in the elimination of house fires through the repair of faulty wiring.
¨ Provided training to the local staff focused on project management skills, including goal definition, writing a complete work plan, writing schedules, estimating costs, and the best methods to monitor the project process in order to ensure an on time project completion.
The Boeing Company, Seattle, WA
Continually promoted to new leadership positions within The Boeing Company, which resulted in appointment as Senior Facility Cost Estimator and responsibility for estimating and defining budgets for construction projects.
SENIOR FACILITY COST ESTIMATOR (Sep. 2001 to Feb. 2010)
Delivered estimates for facilities and utility support related to commercial airplane and military programs, which included responsibility for producing tentative project budgets for new industrial and office building construction and remodels in support of fast-evolving programs.
¨ Ensured that all estimates reflected the actual project lifecycle based on expertise in estimating risk and contingency.
¨ Created a professional environment centered on team engagement and development through ongoing mentorship of younger planners, construction managers, and engineers related to project and construction management, scheduling skills, and value engineering.
¨ Led the planning, project definition and estimating of the relocation of the 767 assembly line from the south to north side of the factory, which required expertise and understanding in distinct construction disciplines consisting of hydraulics, process piping, structures, tools, and modification of exterior buildings.
¨ Created the 787 manufacturing facility construction budget in 2010 for the new 787 manufacturing facility in Charleston, South Carolina at $1.3 Billion.
¨ Produced an estimate of a small airplane hanger based solely on planning criteria at $7 Million which was within $150,000 of construction costs when numbers were presented by the general contractor from construction documents.
Additional Experience
Mechanical Project Manager – University Mechanical Contractors – January 2001 to August 2001. Responsible for managing and directing all mechanical contractors in the construction of the Museum of Glass in Tacoma, Washington. I successfully managed the following construction contractors: HVAC (heating ventilating and air conditioning), hot shop equipment and utilities, fire protection, compressed air, water, natural gas, sanitary sewer, storm sewer, controls and system startup/comissioning. Led mechanical contractor coordination meetings on site, reviewed and approved shop drawing submittals, and provided engineering and constructability guidance on owner directed changes.
Senior Mechanical and Electrical Systems Engineer – DPR General Construction Company. June 2000 to December 2000. Directed and skillfully managed all mechanical and electrical contractors in the construction of a data center in Bothell, Washington. Responsible for the daily supervision and direction of the construction of all mechanical and electrical systems in the data center and resolution of field construction problems and coordination. I am expert in the reading and interpreting of all construction drawings and documents, as well as, shop drawings. This skill made me invaluable in helping to direct and assist all construction contractors.
Construction Manager, Project Engineer, Project Manager, Facility Lead Mechanical Design Engineer, Principal Engineer, Cost Estimator – The Boeing Company (Seattle) – May 1986 to May 2000. From 1986 to 1994 Boeing Construction Management Group, Seattle & Everett, Washington. I worked as both Project Engineer during the design phase of new facilities and then as the Project/Construction Manager during the bidding, contractor selection, and construction management of large industrial and commercial facilities. As project engineer I was in charge of design criteria development, architectural and engineering design firm selection, managing the building design process with the architectural/engineering company through 30, 60, and 90% design reviews, and managing the permit process. As project/construction manager was responsible for issuing of request for proposals, job bid review and analysis, contractor selection, write and award contracts, and construction management of new and the remodel of existing facilities. During construction, performed on site construction monitoring, reviewed and approved contractor shop drawings, managed change orders, and was responsible for the resolution of construction and contract problems. I was also responsible for scheduling and project finances.
Projects where Patrick Fay was construction/project manager: Low Speed Aeroacoustic Wind Tunnel, $6.5 million. On this project I was the project engineer during the design phase. During construction I was the project/construction manager who acted as the general contractor integrating all subcontractors to a successful, on time, and under budget completion of this highly technical project. Boeing construction management typically hired general contractors to build the projects to be managed by the construction manager. Other projects I managed included: Boeing Telephone System Upgrade, $2.5 million; 18-61 building 3-bay Office Addition, $21 million, Medical Facility, $550,000; Plant 2 Cafeteria remodel, $750,000; 45-04 Paint Hangar at the Boeing Everett site during the 777 expansion project in 1993, $120 million. This would be $250 million in current dollars.
1994 to 2000 Facility Lead Mechanical Design Engineer and Facility Cost Estimator, Plant Engineering/Facilities Maintenance Group, The Boeing Company, Seattle & Everett, Washington. As the mechanical engineering design lead was in charge of engineering staff and led multi-discipline engineering design teams. I was responsible for supervising the design of new and the remodel of existing facilities including HVAC, electrical, architectural, structural, fire protection, as well as, directing the maintenance and repair of existing older facilities. I led engineering feasibility studies, wrote engineering reviews, and critiqued mechanical system designs per design criteria and building codes. Directed the work of plant/facility engineers, maintenance staff, and subcontractors with the result of more efficiently operated facilities. I have extensive experience in the operation and maintenance of heavy industrial manufacturing plants including process piping and controls. Our equipment and utilities were located in below grade utility corridors, in the plant itself and at the 100 foot catwalk level. Also worked in the facility cost estimating group from 1998. Member of the Boeing Safety Committee working to reduce industrial accidents. I was trained in Processed Based Safety where we analyzed all accidents/injuries particularly small accidents/injuries because they are an indicator of worker behaviors that will lead to major accidents and injuries. Our team reduced the number of serious accidents and injuries at the Boeing Company (in Seattle) by analyzing the root cause of small accidents which led to behavior modifications for all employees. This was done by leading classes in awareness training that dangerous personal work behavior is a root cause of accidents. Boeing liability insurance rates were reduced as a result of our work. Also was a member of the facility equipment extended life committee studying and recommending how to ensure long operational life for chillers, boilers, air compressors, and all mechanical/electrical facility equipment common to modern industrial, commercial, and hospital facilities. Our team developed processes and procedures that led to longer equipment life which saved millions of dollars for the Boeing Company.
General Construction and Mechanical/Electrical Superintendent – The Austin Company, Seattle (a design/build general contractor) October 1985 to May 1986. In charge of directing, coordinating, and supervising all construction contractors on a Laser Test Laboratory built for the Boeing Company. Supervised and directed daily work of all building contractors in the construction of this building built for testing of a laser for the US Military. Supervised the installation of the first computer building automation system (BAS) for the HVAC system. Prior to this time all building controls were pneumatic.
Principal Mechanical Engineer – Metcalf & Eddy Engineers, Boston/Saudi Arabia. May 1981 to June 1985. Project: Peace Sun Construction Program for the U.S. Air Force (USAF) and the Royal Saudi Air Force in the construction of four F-15 Fighter Bases in the Kingdom of Saudi Arabia. Project cost: $1.1 billion.
As the in-country principal mechanical engineer (lived in Saudi Arabia for 4 years) on this four site military air base construction program, was responsible for resolution of all mechanical, plumbing, controls, piping, fire protection, and heating, ventilation, and air conditioning (HVAC) design, construction, and startup problems and issues. Based in Riyadh, would travel to the 4 air base construction sites to monitor contractor compliance with contract drawings and specifications, and to resolve mechanical system installation and startup problems. I resolved HVAC startup and controls problems that the mechanical contractors (working for the U.S. Army Corps of Engineers) were unable to solve just prior to building turnover thereby allowing the USAF to meet a contractual completion date. Monitored construction schedule and cost, identified causes of delays and expedited corrective actions. Also worked as Project Engineer coordinating and directing multi-discipline engineering staff for owner directed changes and additions to produce contract documents for construction. Worked productively with US Air Force officers, the U.S. Army Corps of Engineers, senior managers, and contractors from Saudi Arabia, Britain, America, the Philippines and Indonesia.
Mechanical Field Engineer and Mechanical Superintendent – The Austin Company (a design/build general contractor). June 1979 to April 1981 in Everett, Washington and St. Louis, Missouri. Hired as Mechanical Field Engineer and promoted to Mechanical Superintendent on the Boeing 767 Expansion Program. This $100 million 130 foot tall, 700,000 square foot (SF) project is where I became an expert in HVAC installation, startup, and energy efficient operation. Transferred to St. Louis to be the Mechanical Superintendent on the construction of a 280,000 SF manufacturing building for McDonnell Douglas. Supervised dozens of contractors on these two projects. I was responsible for directing construction of all HVAC systems, plumbing, fire protection, high pressure steam piping, 3,000 psi hydraulic piping, and underground utilities in contract compliance, field problem resolution, change order management, and startup of all mechanical systems. Supervised the installation of chillers, boilers, Air Handling Units, miles of piping, and worked collaboratively with the electrical superintendent to ensure correct HVAC system startup and operation.
Site-Office Engineer – Arabian Sundt, Dhahran, Saudi Arabia (Sundt Construction, Tucson, AZ). April 1977 to May 1979. The company built 2,000 houses for ARAMCO and I was a field engineer on the construction of over 800 houses. Responsible for coordination between the field construction superintendents, the engineering office, and material warehouse. Performed material takeoffs of construction drawings, ordered material from the warehouse, and coordinated the delivery to the construction sites. Also, ran concrete, carpenter, plumbing, electrician and labor crews in the building of the houses. Worked in and directed crews in the installation of underground utilities, footings and foundations, electrical and plumbing, framing, roofing, and the installation of all interior house finishes.
Mechanical Engineer – Formost Packaging Machines, Woodinville, WA. March 1976 to December 1976. Responsible for machine design of bread packaging machines. In my first six weeks completed a major design modification to their bread packaging machine allowing for a larger European loaf of bread that expanded the company’s sales market. Supervised engineers and draftsmen. Also, responsible for shop manufacturing coordination and quality control.
Owner/Engineer – Wooden Rocking Horses – April 1975 to March 1976. Started a company making and selling rocking horses. Market was daycare centers. Was responsible for design, purchasing, manufacturing, and sales.
Hydraulic Design Engineer – The Boeing Commercial Airplane Company, Everett, WA. November 1973 to March 1975. Responsible for design of hydraulic piping systems on the 747SP aircraft. Performed hydraulic design calculations, designed and drew hydraulic piping drawings, and supervised draftsmen. Design drawings were all done by hand.
Education & Credentials
Bachelor of Science in Mechanical Engineering
University of Washington 1973
Professional Credentials
§ Licensed Professional Engineering (P.E.)
§ Top Secret Security Clearance during period of employment with the Department of State
§ Class 1 Medical Clearance (available for worldwide assignment)
§ Extensive training in Behavior Based Safety.
§ Founding Member of the Equipment Long Life Committee, which led to the extension of useful life of facility equipment saving millions of dollars at the Boeing Company.
§ Language Skills: Intermediate French and German. Basic Arabic and Spanish. Some Russian.