Pilkington announced their plans to rebuild their 6F1 and 6F3 furnaces in Rossford, Ohio with production to begin production in 2000. The rebuilt furnaces manufacture flat glass to be used in building products such as decorative glass, low-e glass and self-cleaning glass; and in automotive glass such as laminated and tempered glass.

IPS was responsible for the demolition of existing process piping and the installation of all new natural gas piping, oxygen piping and nitrogen piping. In addition, IPS installed cooling water lines, compressed air, combustion air piping and instrumentation of the 6F1 furnace. All installation work had to be performed while the demolition of the existing piping systems furnace was still operational to meet Pilkington’s operational workflow needs.

Once the installation work was complete, IPS moved down to the Cold End of the furnace where the glass is cooled, cut and prepared for shipping to self-perform the demolition and installation of all material handling equipment inclusive of power wiring and control wiring. IPS installed all new conveyors, glass cutters, clean room and robotic equipment.

Highlight:

Pilkington was thoroughly impressed with IPS safety and performance they awarded an identical furnace rebuild to their 6F3 furnace to IPS in 2001.

$3.5MIL. Total Construction
1,000,000 Facility Size
6 Project Duration
Bid Build Delivery Method

Project Scope:

IPS successfully completed design/build construction for a new R&D glass furnace facility to serve O-I in their ongoing development of glass technology. The new building is home to a 20-metric ton oxy-fueled furnace, two production lines, and inspection equipment.

IPS was responsible for the plant and office HVAC and plumbing as well as the furnace exhaust stack, cooling water, cullet cooling water, natural gas, oxygen, compressed air, emergency backup systems, process electrical power and controls. Due to schedule constraints, IPS aided in the process utilities design on-site while the building was being constructed. The entire facility was made operational in a compressed six-month construction schedule.

The Innovation Center will help advance new concepts and test emerging technologies for next generation methods to melt and form glass.

Challenges:

Due to the compressed schedule, the EPA Permitting submittals/approvals became a major hurdle that threatened the project timeline. IPS worked with plant engineers to prepare the necessary documentation and obtain permit approvals in order to stay on schedule.

9 Delivery Method
Design build Delivery Method
$35MIL. Total Construction
$3.5MIL. Project Cost
2/2013 Completion Date
9 Project Duration
Design build Delivery Method

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