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Facility Expansion

Market: Nonwovens
Delivery Method: Engineer, Procure, Construction
Location: Simpsonville, SC
Services Provided: Engineering, Procurement, and Construction

O'Neal completed the design, preconstruction, and construction for FitesaFiberwebs nonwovens plant expansion and renovation in Simpsonville, SC. The project was driven by the clients need to add a Reicofil R4 spunbonded/thermobonded nonwoven composite line at their existing plant.

The project included significant demolition and extensive site work. O'Neal extended an existing rail spur to provide rail access to the plant. The rail spur extension required relocation of the existing fire access road and underground fire loop. Five new resin silos and rail car unloaders were built. These required significant foundation work that included pits, trenches, and drains.

The project included a new 50-foot-high bay preengineered metal building to accommodate two production and packaging lines. The design of the building incorporated several energy-efficient ideas and generous use of skylights. The preengineered metal building supports a 25-ton crane over each production line that runs the length of the high bay building. The existing operation located in the France facility was disassembled and relocated to the United States.

The building includes mezzanines and a cast-in-place concrete machinery basement with 18 thick walls. In addition, the project included separate transformer and electrical rooms, a hot oil room, a surfactant room, and a pack room.