A chemical manufacturing facility experienced a contained explosion that destroyed a production building and its associated process systems. While no personnel were injured, the incident halted critical production operations. The manufacturer required complete facility reconstruction—including building structure, process equipment, utilities infrastructure, and automation systems—within six months to minimize production losses and restore operational capacity.
The Details
Industry
Robotics & Industrial Automation
CAPABILITIES APPLIED
The project presented multiple urgent and complex technical challenges requiring coordinated engineering and construction expertise:
Accelerated Timeline: Complete facility reconstruction from assessment through commissioning needed to occur within six months, demanding parallel workflows across design, procurement, fabrication, and installation phases.
Hazardous Area Classification: Multiple building zones required Class I, Division 1 (C1D1) electrical classification, necessitating explosion-proof components and specialized engineering to meet stringent safety codes for volatile chemical atmospheres.
Equipment Procurement Constraints: Long lead times for explosion-rated electrical components, motor control centers, and specialized process equipment threatened project schedule under already compressed timelines.
Legacy Equipment Replacement: Original equipment required replication where possible, but obsolescence and technological advances necessitated redesign of select systems while maintaining process compatibility and performance specifications.
Structural Safety Requirements: Building reconstruction required code-compliant reinforcement of block walls, installation of structural steel roof support systems, and implementation of safeguards to prevent future incidents.
Multi-Disciplinary Coordination: The project required seamless integration between building construction, mechanical systems, electrical infrastructure, process equipment installation, and utility connections across multiple contractors and stakeholders.
Re:Build delivered a fully reconstructed chemical production facility within the six-month timeframe, progressing from site assessment to active commissioning.
The solution integrated building design consultation with a construction firm while maintaining full responsibility for mechanical and electrical scope. This included complete utilities infrastructure (switchgear, motor control centers, process piping), explosion-proof electrical systems compliant with C1D1 classification, and all process equipment procurement and installation.
Modular skid-based process systems were designed and fabricated off-site to expedite field installation and reduce commissioning time. A prefabricated pipe rack system was constructed in sections at Re:Build’s facility, painted, transported to site, hoisted onto the building roof, and field-welded in place—significantly reducing installation duration compared to conventional stick-built methods.
The building structure incorporated reinforced block walls meeting updated code requirements and engineered steel roof support systems designed to prevent structural failure modes identified in the incident investigation.
All process equipment was designed for like-for-like replacement where feasible, with selective system upgrades implemented where original components were obsolete or modern alternatives provided enhanced safety or performance. Custom control panels and automation systems were designed, fabricated, and integrated to restore full process control capability.
The client successfully progressed to commissioning activities within the six-month window, enabling resumption of production operations. Structural and process safety enhancements implemented during reconstruction mitigate risks of similar future incidents while maintaining operational efficiency equivalent to the pre-incident facility.
