Pilot, Demonstration, Semi-Works Hazmat

When utilizing hazardous materials, Haz-safe Buildings are blast, fire and sound rated for protecting people, facilities and maintaining safe operating conditions. A Haz-safe pilot plant is generally smaller than a full-scale production plant, built in a range of modular sizes beginning with one modular test facility and easily adds additional modules as successful tests and product sales volume increase.

Another method is to add a second and third separate small scale plant on the same campus so that an accidental event does not affect the whole operation. Modularization allows for more complex facility to be built in a Haz-safe Buildings manufacturing plant’s controlled environment.

Modular construction saves time with tubular steel framed robust modules, complete with insulated steel or reinforced poured concrete floors, allow all finishes, utilities, process piping and equipment to be installed even before units are transported to the final work site.

Haz-safe modules are assembled utilizing patented compression rod technology that maintains blast ratings, earthquake protection and can be expanded, knocked down  and or moved to a new location. Haz-safe Building’s Pilot Plants offer high degree of flexibility as you can see in the following examples:

Pilot Plant’s Modules #2 and #3 placed outside Haz-safe’s plant for aligning purposes. There is a separated middle wall and depending on how the client’s test proceeds the wall may have to be removed. There are both roof top and side wall crane lifting lugs allowing the 17’ tall modules to be laid down for shipping.

One year later successful tests in Modules #1, #2 and #3 (see arrow) took place using trailer on the left as a control room. Trailer on the right will be control room for new module #4 just installed on the concrete pylons with modules #5 and #6 coming on next.

Like all previous modules, Module #5 has been lifted off its shipping trailer, set on the ground and now is being rotated off its side to its upright position so it can be carried over and set next to Module #4.

Module #5 is on its concrete pylons. The open area on the back wall is for explosion relief panels to be installed and the open areas facing the camera are for a shorter and last module #6.

Module #6 is being lowered and moving toward Module #5 and at the same time a 1” diameter threaded rod has been inserted into the patented bolt up tubes under both edges of the base of Modules #3, #4 and #5 to be cranked at the compression rod’s ends where end caps with I” nuts will draw and clamp all the modules together.

Rigger has completed bolting the roof lugs together between Modules #4 and #5 and cover with a cap and will bolt the roof of #5 to #6 and flash seal. Building is 1 hour fire and 215 lbs.sq.ft. blast rated.

The last 8’ high module #7 (see arrow) has been added on top of module #2 (after its roof was cut out) raising its height to 25’ for this Pilot Plant.

Same facility as seen from the back lot allows you to see the 10’ high module #1 (see arrow) on the end on the structure on far right. It was hidden in all previous photos.

After two years of testing, reconfiguration and manufacturing product the demand for the product outpaced the capacity of this facility…

The above Pilot Plant paved the way for the client and Haz-safe Buildings to design and install a new triple story processing plant. In the above upper photo the mid or second level 15’ wide x 24’ long x 9’ high module is being lifted onto module #1. The right photo shows the three modules stacked close to 30’ off the ground hugging concrete pylons.

The lower level module housed chemical tanks, pumps and controls and the next two modules were divided into (2) 14’ wide x 23’ long x 18’ high rooms where the products were manufactured. This structure was beefed up to 4 hour fire rated and a 215 lbs.sq.ft. blast rating with (24) 4’ high x 8’ wide and (12) 4’ square bottom hinged explosion relief panels.

The photo on the right shows side wall fans (one is at the other end of the building) for continuous 6.5 air changes per hour. The emergency event larger fans on the roof provide 60 air changes per hour triggered by a client installed detection system.

This structure was beefed up to 4 hour fire rated and a 215 lbs.sq.ft. blast rating with (24) 4’ high x 8’ wide and (12) 4’ square bottom hinged explosion relief panels. The photo on the right shows side wall fans (one is at the other end of the building) for continuous 6.5 air changes per hour. The emergency event larger fans on the roof provide 60 air changes per hour triggered by a client installed detection system.

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