Project Scope:

After 40+ years in service, the existing material base machine at Johns Manville (JM) Plant 7 had reached the end of its useful life and required replacement. The new, upgraded mat line forming section being introduced to the facility as a replacement was substantially larger in size than the original machine. To accommodate the new line, the Wet End roof was raised on the East End of the facility.  IPS was the Prime Contractor responsible for all Structural, Architectural, and Mechanical work associated with the project.

Modifications to the existing roof height occurred with construction of the new roof structure over the existing roof to allow the mat line to continue operations.  Work during this portion of the project involved the demolition of existing roof fans, setting the bridge crane rails and the overhead crane, installation of new vent fans, gutters, downspouts, roofing insulation, and siding.

Challenges:

The existing roof penetration flashing contained asbestos, and lead based paint was found in the existing roof and building steel.  Lead-based paint abatement was required at each tie-in to the existing building steel. IPS had to significantly reinforce the existing steel to accommodate for the new structure due to engineering issues, this was required to be done before the start. IPS still met schedule deadline.

IPS
N/A Total Construction
$2.8mil. Project Cost
760,000SF Facility Size
2016 Completion Date
8 Project Duration
bid 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

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