Case Study: Shipley 2
PSE Designs, Inc (PSE) was asked by Omega Protein (OP) to assist in the conceptual and detailed redesign of an existing warehouse, deemed Shipley 2, at their Moss Point facility. OP produces and delivers ingredients for food, supplements, and animal feed. These ingredients are derived from menhaden fish. Their process starts with raw fish and ends with a dry fish meal that is then stored in a warehouse called Shipley 1. Omega's goal was to increase their storage capacity to meet new market demands. OP wanted to install new loading stations, storage bins, and a screw conveying system to their existing unused warehouse. The client depended on PSE to use 3D modeling and industry experience to design the best possible system to meet their needs. This project can be broken down into several phases: Field Work, Conceptual Design, Detailed Design, and Construction.
Field Work:
The first phase of the project was to as-built their existing warehouse to determine option feasibility during the conceptual design phase. This involved gathering dimensions of the entire warehouse, spot elevations of surrounding grade, and inspection of structural members. The existing structure was a 20,000 square feet warehouse. After all the field data was gathered, the next step was to model the existing conditions and begin conceptual design. This step in the project was one of the most crucial. PSE spent much time going over photographs, making additional trips to the field, and in discussions with the client to be certain that the existing conditions were as accurate as possible. We found this to be extremely beneficial throughout the conceptual phase of the project.
Conceptual Design Phase:
Once the existing conditions were modeled, PSE began modeling equipment and developing equipment arrangements. One challenge was OP wanted this new warehouse to match their existing warehouse as much as possible. This created obstacles because the two warehouses did not match in size. The Shipley 2 structure was shorter and had less square footage to work with. Because of this, two additional structures had to be designed to house the truck loading and unloading requirements of the project. The truck unloading structure contained a covered truck ramp and an unloading hopper. This hopper was the starting point for all finished products entering storage. The truck loading structure contained a truck scale with a conveyor system to load the trucks, and a bulk bagging system. After the initial design concept was completed, PSE presented the model to the client using Autodesk Navisworks. 3D modeling can be a savvy tool when displaying complex information to a less technical audience. It can also help the engineer review clash detection and other problems that might interfere with design. This was crucial to the project because it ensured the client's needs were being met in a timely manner.
Detailed Design Phase:
Once the conceptual design was approved by the client, the detailed design began. This consisted of putting together orthographics and details that were not present during the previous phase. Since the major portion of the building already existed, the truck loading and unloading structures made up the bulk of the work. The truck unloading ramp and hopper had to be elevated fifteen feet above the existing grade to allow for the conveyor system to flow correctly. The conveyors had to maintain a certain elevation above the warehouse slab. With this project being located on the Gulf Coast, the high wind loads required unique engineering for this tall structure. Both new structures used steel moment frames as lateral support as any x-bracing lateral supports would interfere with production.
Construction Phase:
Because OP is constrained by their fishing season, there was a compressed schedule duration. PSE worked hand in hand with the contractor to solve field issues and ensure the project maintained momentum and stayed on schedule. From a construction standpoint, the only field issues that arose were from assumptions that had been made during the conceptual design phase. As is the case in many projects involving older, existing structures, these assumptions could only be field verified once construction had begun. PSE was involved during construction and made several site visits working with OP and the contractor. This is a commitment that we make on every project. Without our direct involvement, it is our opinion that the schedule could have been put in jeopardy and the project would have been delayed.
Conclusion:
Omega Protein hired PSE Designs, Inc to remediate an existing warehouse to function as storage and distribution facility for their products. There are many aspects that made this project a success for the client. We believe that the success was bolstered by:
The team’s ability to solve problems efficiently and effectively in the field.
The ability to portray complex concepts with 2D drawings or 3D models.
Constantly making certain that the client's needs are being fulfilled.