Project Scope:

Johns Manville’s TPO facility doubled production with an expansion to its existing plant. Thermoplastic polyolefin plant (TPO) is the fastest-growing segment of the roofing membrane market in North America. As demand for these products continued to increase, Johns Manville, (JM) found it was necessary to boost their overall production at their TPO roofing facility to satisfy their customers. IPS was contracted to build a 40,000 sqft warehouse addition to their existing plant. Scope of work included five separate additions that allowed them to add a second production line of their PVC roofing. This allowed JM to double their capacity by 20 percent. They were limited to 5, 8 and 10 foot wide material and now with this second line they are able to make 12 ft. materials for use in commercial and industrial mechanically attached and fully adhered roofing systems. IPS also improved the fire protection system for the entire site and extended their rail spur to off load raw materials. Additional upgrades included process equipment, extruder, vacuum system for new material, cooling towers for processed cooling water lines, electrical service upgrades to feed new lines and 150,000 sq. feet of additional warehouse space.

Challenges:

IPS worked around John Manville’s demanding production schedule that runs 24/7with minimal interruption. IPS worked 10 hour days 5 days a week to accommodate tight working conditions in small spaces and to ensure time deadlines were met.

IPS
$8mil. Total Construction
N/A Project Cost
1m sf Facility Size
2017 Completion Date
8 Project Duration
design build Delivery Method

Project Scope:

Fenner Dunlop is the world’s leader in the field of conveyor belting, manufacturing the most comprehensive range of conveyor systems for many industries and applications.

IPS was contracted to provide setting, aligning, and installation services for five (5) process equipment lines: calendar line; steel cord press line; fabric belt press line; inspection line; and laminating line. Scope of work include process piping, process electrical, and equipment installation.

The preplanning for the equipment moves began while the building was being erected. Provisions had to be made for the process piping runs to be integrated within the building and the process electrical runs that had to be embedded within the concrete. Additionally, alignment plates were strategically placed in order to ensure that each individual process line was precisely installed to meet the required tolerances.

IPS was also responsible for the installation of all electrical work in the new building to support the expansion. Planning and pre-work was completed prior to the substation retrofit, which took place during a 72-hour shutdown over Thanksgiving. IPS worked around-the-clock to ensure the substation was available to the customer a full day earlier than required.

2/2013 Delivery Method
9 Delivery Method
design build Delivery Method
$38mil. Total Construction
$3mil. Project Cost
2/2013 Completion Date
9 Project Duration
design build Delivery Method

Ready to get started?

Contact Us today