How MelRok onboarded a 35,000-point healthcare building automation system across many buildings, reconciled it against inconsistent documentation, and became the source of truth that surfaced costly gaps the drawings hid.
THE SITUATION
A major healthcare system brought MelRok in to onboard a very large, multi-building automation system for monitoring-based commissioning — tens of thousands of points, dozens of equipment types, spread across many buildings and levels. The plan was simple: get every point reporting and analyzed against the acceptance criteria. The reality was not.
Across many buildings and levels, in dozens of equipment types.
No one held an accurate picture of what was actually installed.
The goal: every point reporting, analyzed against acceptance criteria.
MelRok’s scan found more equipment than the OEM submittals listed — extra units, renamed units, and some that weren’t there at all.
Cryptic, non-descriptive equipment tags confused even the design team, and the documents couldn’t reliably tell one terminal-unit type from another.
35,000 points, over 10,000 per gateway — with some controllers too point-heavy to read the conventional way.
THE APPROACH
When documentation failed, MelRok identified each terminal-unit type from the points that existed — a VAV with no heating-valve point isn’t a VAV with reheat.
Where controllers were too point-heavy to read conventionally, engineers manually registered points, for full coverage instead of blind spots.
The system was organized into 70+ analysis notebooks, split by equipment type and by building group and level.
Two mechanical engineers plus software support — with the analysis functions coded up front, before onboarding began.
Reconciling the scan against the submittals gave the client an accurate equipment inventory — extras, renames, and gaps all accounted for.
MelRok surfaced points required by the acceptance criteria and sequence of operations that were never delivered, plus equipment never integrated to the BMS — gaps tied to a month of schedule delay.
MelRok’s reports revealed that the acceptance-criteria intent differed from the written M&V document — prompting the design team to update the criteria.
points onboarded & registered
analysis notebooks built
points per gateway
to onboard the full system
A massive, inconsistent building automation system became a fully-registered, structured, continuously monitored one — and a reconciled record of what is actually installed that the client, the controls contractor, and the design team can all act on.
On a system this large, submittals, names, and point lists inevitably fall out of sync with what’s actually installed.
Registering the whole system creates one accurate, current picture — and surfaces the spec gaps, integration misses, and criteria mismatches the paperwork hid.
MelRok’s platform and its engineers become the single source of truth a large project can work from — turning a chaotic onboarding into a reconciled, monitored foundation, and catching costly gaps before they compound.
MelRok turned a 35,000-point, poorly-documented healthcare BAS into a structured, continuously monitored system — and, along the way, into the reconciled source of truth the whole project could finally trust.