NAPCO Royal Pipe & Fittings, a Westlake company, is a leading North American polyvinyl chloride (PVC) pipe manufacturer. Continued growth required 2 additional production lines at their existing manufacturing facility.
Compass was awarded the Construction Management mandate and provided value-added pre-construction services for the conversion and renovation of an existing 250,000 sq. ft. warehouse to accommodate the 2 new production lines. The scope of work included extensive demolition of the existing interiors, 2 360-foot-long concrete trenches below grade to house the production line’s mechanical and electrical services, a new 3-level, 30 ft-high mezzanine, new shipping/receiving doors, loading and offloading zone with 2 automatic industrial rolling shutter doors and the various associated structural steel modifications. To accommodate this new use, the building’s mechanical and electrical systems required upgrades. These included 2 50-tonne chillers, which are connected to a new Pump room to circulate the chilled water within the trenches to service the production equipment.
Intricately designed and fitted to the existing structural steel-built production facility, the mezzanine contains two spiral staircases, and one rectangular staircase for access. Compass facilitated these modifications that were required for exits and egresses. Due to site conditions and the structural steel-nature of the facility, Compass rearranged the bracing to accommodate the building’s own design.
Pre-construction meetings with design consultants, multiple international equipment manufactures and NAPCO’s facilities and operational teams ensured an agreed upon approach. This collaboration ensured the new production lines were functional and met NAPCO’s rigorous Health & Safety standards.
COVID-19 delayed shipping of equipment for the second line as well as restricted the ability of the international equipment installation teams to arrive in Canada. To ensure proper equipment assembly and calibration, only authorized installation teams could complete this scope and their travel was restricted.
Construction resumed as soon as travel restrictions were lifted. The production lines are operating at full capacity and NAPCO is very pleased with their new production facility.