When Penn Waste, Inc. needed a new truck maintenance facility, they turned to Keystruct Construction, Inc. to renovate a former trash and recycling building. Critical to the success of this project was the strict completion date, because the finished facility required certification from the state before the owner could begin their operations inside. The owner scheduled the state certification for a Friday, with their staff beginning work at the facility the following Monday, so there was no room for construction delays.
The first step for the renovation was a comprehensive cleaning of the building to ready it for the new use. The surfaces were cleaned as quickly as possible, and the catch basins in the floor were emptied with a mini excavator to clear them of compacted trash. The cleaning crews worked additional hours and extra days to ready the building, however an innovative plan was still necessary to ensure the strict completion date was met.
A key feature for the new building was the epoxy floor, which required five weeks for installation and curing. The tight construction schedule did not permit the flooring contractor to have unlimited access to the floor with no other activities for five weeks, so Keystruct developed a patchwork grid and schedule to coordinate the completion of the flooring while other work was prioritized for the renovations to proceed without delays.
The middle portion of the building was completed first to accommodate placing of the mechanical systems and tanks. Next the parts cage location was finished for installation of the fencing and racking systems. The floor was completed in this manner throughout the rest of the building; areas critical to the renovation work were finished so work could progress, on schedule, to that location.
During construction, the owner suggested several improvements, including additional painting, trench drains beneath the service bays, and new cabinetry and counter-tops for an employee break-room. The original design featured 18’ high garage doors, however following a walk-through, the owner requested that the doors be made taller, to better accommodate the trucks that will use the building. Facilitating this request required re-engineering by the pre-engineered building manufacturer, additional steel orders, and extra door panels for seven new doors and four existing doors.
Part of the renovation included removal of conveying systems, and trash and recycling equipment. The conveying systems passed through the wall panels to the exterior of the building. By using materials from the newly created garage door openings, Keystruct was able to patch the openings left by the conveying systems with siding and wall panels that were near perfect matches in color and texture to the existing areas.
Because two shifts work at the facility and some of their work would be taking place during hours of darkness, the owner wanted to be sure that sufficient lighting was provided for the mechanics. Keystruct coordinated with the owner to place several trucks inside the building for several hours so the owner could verify that the lighting levels were adequate throughout the work shifts.
This new facility creates a state-of-the-art truck maintenance shop for an owner dedicated to making his business stand above the rest, and provides a modern and functional space for the Penn Waste employees. Taking a former trash building and transforming it into a clean, bright, work space was a huge transformation. Keystruct was proud to play a pivotal role in creating this wonderful new space.