Poly B Packaging Warehouse, The Dow Co. Plaquemine, LA

Transcription

1 Poly B Packaging Warehouse, The Dow Co. EXCELLENCE IN CONSTRUCTION

2 Poly B Packaging Warehouse Plaquemine, LA

3 Poly B Packaging Warehouse Plaquemine, LA

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5 Poly B Packaging Warehouse, The Dow Co. EXCELLENCE IN CONSTRUCTION CONTRACTED SCOPE Poly B Packaging Warehouse Plaquemine, LA

6 SCOPE OF WORK: The new Poly B Packaging Warehouse provides critical product storage capacity for Dow s Plaquemine plant, one of the largest petrochemical facilities in Louisiana and home to most of Dow s global businesses. The 3,000-acre integrated manufacturing site produces more than 50 different basic and specialty chemical products. The 86,000-square-foot structure includes a pre-engineered metal warehouse and precast concrete office complex. Despite flooding rains, high river stages and 25 change orders threatening to delay the project, GROUP Contractors completed the project on schedule. TYPE OF CONSTRUCTION: Pre-engineered metal building and precast office project providing vital storage capacity for Dow s Plaquemine location. Included were significant concrete forming and construction, interior buildout, finishing, HVAC, electrical and instrumentation, among other installations. Numerous subcontractors were managed to erect the buildings in overlapping phases, since high river levels and a host of change orders forced a re-sequencing of the project schedule. SIZE OF PROJECT: 86,000-square-foot in building construction at Dow Plaquemine. Buildings comprised of 10,000 cubic yards of concrete; pre-engineered metal panels; poured-in-place footings, some measuring as deep as 6 feet; concrete slabs meeting stringent 1/4-inch levelness specifications; precast panels; structural steel; interior stucco; 25 change orders; numerous days of delays caused by high river levels. CONTRACT VALUE: $8,810,000 LENGTH OF PROJECT: Contract award and notice to proceed July 6, Substantial completion August 1, PERCENTAGE OF LABOR SELF-PERFORMED: 20%; 80% of subcontracted work performed by ABC members, suppliers or associate

7 Poly B Packaging Warehouse, The Dow Co. EXCELLENCE IN CONSTRUCTION PROJECT NARRATIVE

8 GROUP s performance to accomplish this project was outstanding. This project was met with many challenging obstacles ranging from constant inclement weather to a Mississippi river lever that hindered the start of the project causing delays in ground preparations. My hats off to you, David Talbot, and the site supervisor, Dustin Cutrer, for outstanding leadership and guidance to accomplish this project work successfully and overcoming these obstacles. The work was performed safety, and with high quality, which is a direct reflection of the efforts you and your staff displayed in this task. Kerry Cautrelle, Construction Manager, Dow USA When flooding rains, high river stages and 25 change orders threatened to delay completion of the 86,000- square-foot pre-engineered metal warehouse and precast office complex at Dow s Louisiana Operations near Plaquemine, GROUP Contractors was determined to find a way to make it happen. The new Poly B Packaging Warehouse provides critical product storage capacity for Dow s Plaquemine plant, one of the largest petrochemical facilities in Louisiana and home to most of Dow s global businesses. The 3,000-acre integrated manufacturing site produces more than 50 different basic and specialty chemical products. From the beginning, the Mississippi River levels were a problem, with crews having performed only minimal work before the river stages rose to unacceptable levels, hindering work for three weeks in late summer At the time, crews had only performed some of the formwork for the building s grade beams and slabs in the MCC and office areas, and were about to begin digging for footings and walls. Given the resulting loss in time to the schedule, the owner had doubts that GROUP or any contractor for that matter could make deadline.

9 Project manager David Talbot and the GROUP field staff quickly developed a plan of action that involved working weekends, re-arranging schedules and closely collaborating with a host of subcontractors. Facing an immovable deadline, GROUP chose to begin erecting the metal warehouse building concurrently with the concrete form work. While the original schedule called for much of the foundation and formwork to have been completed prior to building erection, GROUP faced an immovable deadline, meaning certain phases had to be performed concurrently. If not, the schedule would have been severely impacted. GROUP also revised its safety plan to incorporate additional precautions since its ground crew had to work in close proximity to the steel erection crew, primarily through the addition of safety barricades and safety tape to ensure crafts didn t venture into other areas. The crane lift plan was also adjusted, as well as lift and crane locations, with all changes communicated to the entire project team. Another challenge numerous change orders were necessary throughout the erection of the building, caused by an abundance of design errors discovered as materials arrived at the site. Imprecise cuts, improper lengths and inaccurate bolt hole locations were widespread throughout the building, forcing GROUP s jobsite superintendent, Dustin Cutrer, to coordinate closely with the Texas-based metal building supplier over every design change. Since GROUP supervisors knew they needed more control over the building s design in order to maintain schedule, Dow provided them with the authority to make all necessary changes. When a design error was

10 discovered, Cutrer would electronically deliver photos and descriptions to the manufacturer for correction. Since the building is designed to be blast resistant, new blast calculations had to be re-run by the manufacturer for every change, then approved by Dow. Concrete Complications The building required an impressive 10,000 cubic yards of concrete and came with some significant footings reaching as deep as 6 feet. The unusually deep footings were used in lieu of pilings, with some of the more substantial footings constructed to support a large conveyor system coming into the building. Throughout the process, GROUP had difficulty finding a concrete supplier who could provide the volume of concrete necessary at the time it was needed. Most of the concrete was poured overnight, beginning at 1 a.m., which is more conducive to the summertime heat. While one of the suppliers had a batch plant in close proximity, its location near a neighborhood prohibited it from operating at night due to sound ordinances. Ultimately, the concrete had to be batched across the Mississippi River and transported to Plaquemine. There were additional issues during the concrete testing phase, when the testing agency came back with a bad break in one of the slabs. Resulting in another 1-week delay, no formwork could be performed as they determined if the concrete had to demolished and re-poured. Ultimately, the test results came back favorably, and the project was allowed to proceed. Another challenge concrete flatness requirements were specified in the MCC area, where a tolerance of 1/8

11 inch in a 10-foot span had to be maintained. To achieve the stringent tolerance, GROUP crews determined the locations for each piece of equipment and laid out 2-foot by 2-foot intervals throughout the area, using chalk lines and shooting each corner. While more typical flatness specifications of a quarter of an inch were specified for the remainder of the site, the equipment within the MCC area had to be precisely level in order to operate properly. Other areas, such as the office building and the packaging area, did not require specific tolerances. The specification for the use of screed guides, while meant to ensure that flatness requirements were maintained, ultimately caused further delays. In fact, ACI suggests not using screed guides, since they can hinder a contractor s ability to accurately measure flatness in some situations. Fortified Precast Panels For the office building, explosion resistance was incorporated throughout the building, primarily through additional reinforcing steel on the east and west sides of the precast panels, which were then filled with grout. The precast was given a textured, beige-colored finished. Manufactured by Tindall Corp., the panels reach as high as 22 feet. The panels were lifted by a 200-ton crane operating from within the building. The tallest column within the building was 45 feet. Additionally, the crew installed nine overhead doors, one providing entry into the building while the others were needed for the loading dock.

12 Poly B Packaging Warehouse, The Dow Co. EXCELLENCE IN CONSTRUCTION PHOTOGRAPHS

13 Concrete work early in the project had to be performed concurrently with other crafts.

14 Stringent levelness specifications were required in some areas.

15 Form work is constructed for building slabs and grade beams.

16 The pre-engineered metal structure required 25 change orders, which significantly impacted the schedule.

17 Precast panels reaching as high as 22 feet were necessary for the office building.

18 The crane lift plan was adjusted when multiple crafts had to work concurrently during building construction.

19 Cable trays weave through the interior of the warehouse.

20 Aesthetic interior finishes were required in areas within the office space.

21 Situating mechanical and electrical components within the warehouse was challenging.

22 The 86,000-square-foot Poly B Packaging Warehouse project is vital to Dow s Louisiana operations.

23 Poly B Packaging Warehouse, The Dow Co. EXCELLENCE IN CONSTRUCTION PROJECT SAFETY

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40 Tool Box Talks and Job Safety Analysis For efficiency, the documentation of the daily Took Box Talks was combined with the Job Safety Analysis Worksheet (see below and the following page).

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42 Specialized Safety Training & Innovative Safety Programs When high river levels and multiple change orders forced a re-ordering of the project schedule, forcing many crafts to work concurrently, GROUP revised its safety plan to incorporate additional precautions since its ground crew had to work in close proximity to the steel erection crew, primarily through the addition of safety barricades and safety tape to ensure crafts didn t venture into other areas. The crane lift schedule was also adjusted, as well as lift and crane locations, with all changes communicated to the entire project team. Throughout the project, GROUP also leaned heavily upon its Ask about Life safety program, incorporating the safety slogan Live Incident Free Every Day. The program provides a way for management to interact with employees at the jobsite level, with the goal of safety improvement. Any employee, whether management, superintendent or crew member, can approach a fellow employee and Ask About Life, and if the employee responds properly with Live Incident Free Every Day they are eligible to receive an incentive. Of course, the true purpose of the program is to open a dialogue about safety. GROUP also uses Safety Observation Cards, which employees can fill out should they notice a safety violation without identifying the employee. By allowing employees to report violations in that manner, GROUP is better able to pinpoint problem areas and track safety trends. In effect, this provides employees with a way to talk to upper management without fear of backlash. They are also encouraged to talk to the employee who is in violation in order to correct the problem. Other safety policies include: Daily Hand Safety Analysis: The analysis forces the employees to think about possible hand safety hazards that exist while working on a specific task. The forms (included in this binder) are completed individually by each crew member prior to the daily tool box meeting. At the site each morning, GROUP superintendents discussed the job responsibilities of every worker, and each worker signed the Job Safety Analysis (JSA) acknowledging that he understood the hazards. GROUP s impressive safety statistics Zero OSHA Recordables, Zero Lost Time Accidents & Zero First Aids provide proof that safety is its No. 1 goal.

43 2016 Poly B Packaging Warehouse Site Specific Safety Training 1) Met w/all subcontractors & Group supervisors before starting work 2) Discuss work activities daily w/subcontractors & Group supervisors 3) Group supervisors & subcontractors to communicate w/employees 4) Installed construction fence & signage to keep non-construction personnel out of danger 5) Follow up on discussed plan of action, if changes were made share w/personnel onsite. 6) Stay in your work area as discussed the day before. 7) Identify hazards before incident/injury occurs 8) Head count of all personnel onsite for each subcontractor & Group daily 9) Hold all personnel accountable for their actions 10) Stressed housekeeping daily ( A clean worksite is a safe worksite) 11) Observed subcontractor & Group personnel working ( Safety Audits) 12) Stopped personnel if not complying to safety policies & explained proper way to be safe while performing task 13) Preplan all activities ( Three Week Work Plan updated weekly & shared w/supervisors) 14) All Group personnel to lead by example ( Subcontractors will follow) 15) Always had full support from Home Office Management

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45 Near Miss Reporting

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47 Near Miss Reporting, Page 3

48 Near Miss Reporting, Page 4

49 Substance Abuse Policy Implementation & Table of Contents, Page 1 At GROUP Industries, our priorities include protecting the safety of our employees, property, the public, as well as an interest in the productivity of our workforce. In an effort to ensure the success of our priorities, GROUP has adopted a Controlled Substance Use & Alcohol Misuse Policy that is applicable to all employees. Our purpose in adopting this policy is to further GROUP s objective of establishing and maintaining a work environment free from the adverse effects of drug use and alcohol misuse. In order to verify compliance with GROUP s Controlled Substance Use and Alcohol Misuse Policy, all candidate employees are required to complete a drug and alcohol screening (provided by a qualified and accredited Occupational Medicine provider) prior to employment. As a condition of continued employment, all employees are required to complete a drug and alcohol screening at least annually, as well as consent to random drug and alcohol screenings. as required. on a monthly basis.

50 Substance Abuse Policy Implementation & Table of Contents, Page 2

51 New Employee Safety Orientation

52 GROUP s Safety Program Overview

53 Weekly Field Observation Report, Pie Chart

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55 Weekly Field Observation Report

56 Poly B Packaging Warehouse, The Dow Co. EXCELLENCE IN CONSTRUCTION REFERENCES

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60 Poly B Packaging Warehouse, The Dow Co. EXCELLENCE IN CONSTRUCTION SUPPLEMENTAL MATERIALS

61 Excerpt from Houston Business Journal, referencing plastics expansion at Plaquemine plant: Poly B Packaging Warehouse Plaquemine, LA

62 Excerpt from IMPACT, Dow Louisiana s Official Magazine: Poly B Packaging Warehouse Plaquemine, LA

63 Excerpt from Dow Louisiana Website:

64 Poly B Packaging Warehouse, The Dow Co. EXCELLENCE IN CONSTRUCTION AQC CONTRACTOR Poly B Packaging Warehouse, The Dow Co., Plaquemine, LA

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66 Project Team Poly B Packaging Warehouse, The Dow Co. James Construction (Civil) Baton Rouge, LA TWA Erectors (Building Erection) Baton Rouge, LA All Service Plumbing (Mechanical) Baton Rouge, LA Union Service and Maintenance (HVAC) Mandeville, LA Lanehart Painting (Painting) Baton Rouge, LA TSC of Louisiana (Drywall and Masonry) Baton Rouge, LA Himmels (Doors) Baton Rouge Cornerstone Flooring (Flooring) Baton Rouge, LA Fisk Electric (Electrical) New Orleans

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