Quick Mobilization for Pilot Plant Dismantling and Demolition

When a building consolidation commitment required our client to dismantle and demolish a 30,000 square-foot pilot plant immediately, they turned to R. Baker & Son. Having rigged much of the process and mechanical equipment into the building 28 years earlier, we were already familiar with the site and building structure - making us the ideal candidate for this urgent project.

Immediate Response to Tight Deadlines

Our client needed to accelerate the start date significantly, as another tenant required the space. R. Baker responded immediately, meeting with the client to review the project scope and requirements. After touring the facility and thoroughly understanding their needs, we coordinated with the decontamination contractor and the owner who had systematically isolated, cut, and capped all utilities prior to our dismantling crews arrival.

We provided a comprehensive written plan, detailed safety protocols, and an aggressive area-by-area schedule outlining exactly how and when the work would be executed.

Systematic Equipment Dismantling

The building was fed by a large above-ground utility rack. The building's front and rear sides featured a translucent plastic panel system, that could be removed to provide easy access for equipment removals across all three floors. Prior to unbolting the process equipment, our team checked and insured that all connections were air-gapped before rigging any of the following specialized machinery and devices:

*Reactors on their platforms
*Multiple heat transfer fluid skids (HTFs)
*Several large steam-to-hot-water heat exchangers
*Steam PRV stations
*Two scrubbers
*Drying and milling equipment
*Three 100% outside air AHUs from the roof
*Two low-temperature chillers from the third-floor mechanical room
*Large high plume exhaust fans

Simultaneously, two additional R. Baker teams worked alongside a mechanical contractor who cut and center piled all piping in the process support areas and Central Utility Area (CUA) corridors on each floor - for our demolition team to dispose of.

Efficient Material Handling and Removal

Using heavy-duty Lulls, an 80-ton hydraulic crane, and several portable gantries, we successfully extracted equipment through the newly created front and back building openings. All equipment was temporarily stored in a covered storage building next door, while piping and metals were removed and sold for scrap.

An electrical contractor handled disconnections while R. Baker teams removed the first-floor electrical gear, all motor control centers, and power distribution conduit throughout the facility. We installed temporary string LED lighting neatly throughout the building and removed all existing metal halide and fluorescent fixtures.

Overcoming Complex Challenges

The project presented two significant challenges:

Challenge 1: Working above and below the large utility rack while removing equipment and large-diameter piping required careful coordination and precision.

Challenge 2: The small footprint of CUA areas demanded a layered removal approach, as the density of piping and conduit in these tight spaces made everything highly compact.

Complete Building Transformation

The building was eventually safely and successfully dismantled, with all hangers, piping supports, and straps removed down to clean concrete. Only the sprinkler system and two elevators - both passenger and freight - remained operational. The translucent panel system was scheduled for replacement with a new one, and a new roof was planned.

Successful Project Completion

The facility was repurposed as a storage facility, with floors two and three designated for general storage and the first floor converted to secured spare parts storage areas. Our client was extremely pleased that the dismantling and demolition portion of the project was completed on time, within budget, and with zero safety incidents.

R. Baker & Son All Industrial Services, a certified Minority and Women-Owned Business Enterprise (M/WBE) since 1935, is your trusted partner for complex industrial projects. We specialize in expert demolition, dismantling, rigging, and plant relocation across North America and Puerto Rico. With a proven safety record, significant bonding capacity, and direct involvement in ten VPP OSHA Safety Award-winning sites, we execute complex projects with precision. Our comprehensive services include industrial and commercial demolition, machinery moving, environmental remediation, and asset recovery. Discover why leading industrial clients rely on R. Baker & Son for safe and efficient solutions to their most challenging projects. Learn more about our proven expertise in industrial rigging and project management in complex plant relocation.

R. Baker & Son - All Industrial Services 
190 Boundary Road
Marlboro, NJ 07746
732-222-3553
https://www.rbaker.com/dismantling-contractors.php