Tour of Knauf Insulation Plant 1 Expansion
Shelbyville, IN
Dinner meeting, TUESDAY, May 12th, 2009
Place: Knauf Insulation
One Knauf Drive, Shelbyville, IN 46176
PLEASE NOTE driving time from downtown Indianapolis is only 35 minutes.
Time: 5:30 p.m. Tech Session
6:15 p.m. Dinner
7:00 p.m. to 8:00 p.m. Plant Tour*
Theme: LEED, “Green” Fiberglass and Sustainability
Cost: $20/person
Meeting Program:
If you want to see first-hand how glass and then fiberglass is produced and packaged, then this is the tour for you!*
The Knauf Plant 1 Expansion Project began as a modernization and expansion project with the objectives of replacing outdated process and utility equipment while increasing plant capacity by greater than 100%. The project scope included the construction of a 375,000 square foot product warehouse, a new utility and chemical compounding plant, a 42 MW substation, a furnace charge batching silo, upgraded rail yard, two electric-fired cold top glass furnaces, four production lines with fiberization, forming and drying ovens, two wet electrostatic precipitators, regenerative thermal oxidizers, wash water recycle systems and new packaging lines, including robotics.
The Shelbyville site presented numerous challenges for the project. The property is bounded by residential use to the south and east and converging rivers to the north and west. The only land available for improvement was abandoned residential property and aged process buildings that required demolition prior to construction. In order to make use of the abandoned residential property, underground public utilities and an existing substation serving the City of Shelbyville had to be relocated. The new warehouse was constructed over a key storm sewer main serving nearby subdivisions. The project had to be integrated with and constructed around the existing Plant 1 operation without impacting fiberglass production. Lastly, noise from the production processes required abatement measures to minimize impact on the surrounding community. In order to meet the above constraints, the project was executed in seven overlapping phases during a three-year period.
The tour will be orchestrated by knowledgeable staff from Knauf Insulation. Frank St. John, P.E., LEED AP, President of Applied Engineering will present an overview of the Plant 1 Expansion and talk briefly about the recently completed Corporate Office Building project prior to the tour.
*Please note that each tour participant will be required to sign a non-disclosure agreement prior to the tour. Additionally, for the safety of everyone, all tour participants must wear long pants and closed toe leather shoes. Also please note that photos within the plant are not allowed.
Role of Applied Engineering
Applied was chosen by Knauf Insulation as the prime consultant leading the Plant 1 engineering effort. Applied’s role as engineer of record included process mechanical and piping, HVAC, plumbing, electrical, and instrumentation and controls design. Applied was responsible for coordination of sub-consultant design work and integration engineering of numerous OEM systems purchased directly by Knauf. Applied subcontracted civil and structural design to Fink Roberts & Petrie, Inc. Architectural design was sub-contracted to Browning Day Mullins Dierdorf, Inc. This project received the ACEC Grand Project Award in 2008.
Tech Session:
Scott Miller, Director of Knauf Sustainability and Product Affairs, will present an overview of the role that insulation plays in sustainable buildings, including a discussion of Knauf’s new environmentally friendly binder (the compound that holds the fiberglass fibers together) that is being introduced in Knauf’s manufacturing process. The presentation will take place in the “Academy,” an auditorium that is part of the new Corporate Office Building addition. This project incorporated a number of green and sustainable features including an enhanced building envelope, a VAV HVAC system, waterless and low flow plumbing fixtures, active lighting controls, daylight harvesting and is seeking LEED Gold Certification. The design team for this project also consisted of Applied, Browning Day Mullins Dierdorf and Fink Roberts & Petrie.
Scott is a graduate of Franklin University and holds a degree in Mechanical Engineering. Scott joined Knauf Insulation in 2000 after more than twenty-five years with Owens Corning.
Reservations:
For reservations please E-mail Karen Hedback by Friday, May 8th at Hydronic & Steam. Her e-mail is: khedback@hydstm.com. The second option is to call her at: 317-577-8326. If you receive Karen’s voice mail, please leave a message stating your name, company, the number of reservations required, and your phone number.
Directions:
From Indianapolis take I-74 east to Indiana State Road 9. Turn south on State Road 9. Travel approximately one mile and turn left onto Knauf Drive. Travel on Knauf Drive just until you pass the corporate office building, then turn left and park in the parking lot behind the building. Enter the building using the entrance on the north side.