BOC Penrose Acetylene Plant Structural Rectifications and Roof Rectifications
The BOC Penrose Acetylene Plant Structural and Roof Rectifications project demanded exceptional precision in design, meticulous project planning, and flawless execution. Acetylene manufacturing is inherently high-risk due to the gas’s volatile and flammable nature, requiring strict adherence to safety protocols, robust engineering controls, and seamless coordination across all project phases. Every aspect of this project—structural integrity, roof rectification, and operational continuity—was carefully managed to minimize risks, ensure regulatory compliance, and safeguard the health and safety of all personnel on-site.
| 1) Project Name | BOC Penrose Acetylene Plant Structural Rectifications and Roof Rectifications |
| 2) Client Company | BOC |
| 3) Project Type | Capital Project – REIT – Renovation |
| 4) Project Value | $1,213,000 |
| 5) Project Start and Finish | 2017 – 2017 |
| 6) Strategic Objective | To ensure structural integrity and operational resilience of the Penrose Acetylene Plant by addressing critical structural deficiencies and performing roof rectifications, enabling long-term sustainable operations. |
| 7) The Challenge / Need | – The existing structural components of the plant required urgent rectifications to meet compliance and safety standards. – The roofing system exhibited significant wear and tear, posing operational and safety risks. – Ensuring minimal disruption to ongoing plant operations during structural and roofing rectifications. |
| 8) Our Approach | – Conducted a comprehensive structural assessment to identify critical vulnerabilities. – Developed a phased rectification plan to minimize operational downtime. – Engaged specialist contractors and engineers to address structural and roofing challenges. – Implemented real-time safety monitoring protocols during construction. – Delivered staff training on new structural and operational safety measures. |
| 9) Solution & Key Deliverables | – Executed critical structural rectifications across key plant infrastructure. – Completed roof replacement and waterproofing to ensure durability and resilience. – Upgraded safety and operational systems in alignment with compliance requirements. – Delivered detailed operational manuals and training sessions for plant staff. – Provided comprehensive handover documentation to the client. |
| 10) Risks and Challenges | – Balancing operational continuity with extensive structural and roofing work. – Addressing unforeseen structural weaknesses discovered during construction. – Ensuring strict adherence to safety standards in an active industrial environment. – Managing project timelines and costs within the allocated budget. |
| 11) Result / Outcome | – Successfully rectified structural deficiencies and enhanced plant resilience. – Completed roof upgrades with advanced waterproofing solutions. – Achieved zero safety incidents during the project lifecycle. – Delivered the project on time and within budget, ensuring seamless operational handover. |
| 12) Our Value-Added Differentiator | – Engineering Expertise: Effective rectification of complex structural vulnerabilities. – Safety-First Approach: Zero safety incidents across the project lifecycle. – Operational Continuity: Managed the upgrade with minimal disruption to plant processes. – Future-Ready Design: Delivered sustainable solutions for long-term operational efficiency. |
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I led the development and execution of the project as Head Contractor Program Director/delivery team.
Design for the design project the team consisted of:
- 1 x Lead designer
- 2 x Structural Engineers,
- 1 x Safety Engineer
Construction for the Construction project the team will consist of:
- 1 x Project Manager
- 1 x Construction Engineer
- 1 x Contracts Manager
- 1 x Quality Manager
- 1 x Safety Manager
- 1 x Structural Fabrication contractors
- 1 x Mechanical systems Fabrication contractors
- 1 x Erection contractor
- 1 x Electrical contractor
- 1 x Roofing Contractor
Project was completed with 6,000 hrs with ZERO LTI and 1 x FAI
