想象一个没有砖块的世界——砖块是创造我们每天生活和工作的结构的最重要的基石. Boral North America is the largest manufacturer of bricks in the U.S., 但要跟上不断增长的需求, 公司需要一辆新的295,000平方英尺, highly automated and innovative manufacturing facility. 通过班, 哈斯克尔公司, that’s been in the construction industry for over 100 years, 我们帮助Boral建立了一个世界级的工厂,整合了最先进的制造工艺和系统.
开始这项事业, 我们的设计-建造团队与Boral合作,确定制砖工艺要求,随后协调采购和第三方供应商开发和安装综合体, 先进的工艺系统. The manufacturing facility layout included 55,000 square feet to crush and size 150 tons of raw clay per hour, 还有240,000 square feet to extrude and form bricks. 这一过程的部分创新包括利用机器人将成型的砖块装载到一辆自动移动的“汽车”上,该“汽车”将砖块通过17个通道,500平方英尺的窑炉,然后将成品砖送到自动化包装系统.
在项目执行过程中, 由于客户与其供应商之间的谈判困难,以及一些地方和州监管方面的问题,我们遇到了两次重大延误. These delays threatened to set the project back 10 months, 但是通过修改我们的活动顺序将我们的重点转移到工程和采购活动上, we were able to reduce that delay to just four months. Boral required the project budget to be developed at the conceptual (<5%) phase, which posed a potential risk in forecasting costs so early in the process. 我们通过不断地为客户提供准确的成本完成预测预测来减轻这种情况,使他们能够做出明智的决定,以保持支出在轨道上并满足我们的预算.
从这个项目开始, Boral制定了一个明确的目标,即所有新设施的流程和公用事业系统都必须节能. 结果是, 场地的选择是仔细的,以尽量减少能源和运输成本相关的粘土从其来源到加工. 制造设施的布局也旨在通过限制过渡和行程距离来降低能源和设备成本. 在包装方面, 我们的团队专门寻找了一个可以提供环保包装材料的供应商.
所有这些努力结合起来,为工厂节省了每年100多万美元的运营成本,并获得了LEED金牌认证, 超出了Boral的所有期望. 这是砖行业获得的第一个LEED认证,也是为数不多的授予工业制造设施的认证之一.
一旦完成, the new 特拉豪特,印第安纳州, 该设施为Boral提供了每年额外生产1.2亿块砖的能力, increasing their overall clay manufacturing in the 美国 by 7 percent.
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