(55w) Ignoring Building Codes Can Result in Costly Design Rework | AIChE

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(55w) Ignoring Building Codes Can Result in Costly Design Rework

Authors 

Porter, A. - Presenter


  • We were approach by Client (let's call them Fast-Track Inc) to provide engineering, procurement, and construction management (EPCM) for a chemical manufacturing facility.
  • We sat down with them to discuss their project and schedule. The said we have a design in Asia that we'd like to replicate. All of the drawings are completed, so we just need to copy the design and build it here in the US. We need to be up and running by the end of the year.
  • Our group in Ramboll really excels at delivering these small/medium size complex chemical projects quickly. This was going to be a green field ~$50MM facility.
  • They said don't worry we already have a building selected and a contractor, so we're already started, we just need the engineering so we can get our construction permit.
  • We start requesting documents, look at their chemical SDS and we start to have concerns. They have flammables and unstable reactive above their maximum allowable quantities (MAQs).
  • It does not appear they have considered these chemicals effect on the building occupancy classification and construction type.
    • We propose an FEL-2 Study including a chemical hazard assessment, PSM applicability evaluation, P&ID development, building code evaluation and cost estimation.
    • The feedback we get is that they do not have time to break the project into phases and just need a detailed design proposal, which we provide but has an extended schedule because it included performing these FEL-2 activities and a conservative estimate for detailed design.
    • We were not awarded the work.
  • Provide a quick summary of building codes and why they are important.
  • Fast forward to Q1 of the next year. This Fast Track Inc was already supposed to be up and running. And they we got the call:
    • "We need some help with permitting. Our construction permits were declined by the city, and we need a solution ASAP."
  • We drive up and we visit the facility. Construction had already started; equipment was being set. We sit done with the client and review the letter from the fire marshal saying you're not approved; you haven't properly designed for the hazardous chemicals and flammable materials.
  • We did a code review workshop and provided them with a handful of options looking at how they can divide up the building into control areas and hazardous occupancies. Build 40 ft fire walls, remove roof insulation and spray on fire protection, replace tilt up concrete wall with blow off panels.
    • In hindsight the extra 3 months and $100k for preliminary engineering would have been a value investment now that they have spent 6 months and $5MM retrofitting a new building to meet building code. The final design was far from optimal as they had to separate production, and storage areas which created material handling challenges.
  • Take-aways:
    • It is critical to understand the applicable codes and standards at the beginning of a project.
    • A complete chemical hazard assessment needs to be performed to assure that the design accounts for the hazards appropriately.
    • It is very costly and time consuming to make changes to a project after construction has already started.

Topics 

Design/Green Engineering
Safety & Health

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