Small Scale Plants are built in a controlled work environment free from on-site revamps, unforeseen waste, large staging areas, material theft, interruption and delays due to extreme weather conditions and seasons. While (at the same time) the building is being fabricated in plant, on-site foundations, etc. are being made ready for the arrival of the pre-manufactured building. Photos below: Local preparations at site are straightforward and simplified for the foundation and installation of site services and are undertaken by site contractor as the building is being manufactured in parallel back at the Haz-Safe Buildings' plant.

Start-up, testing, small batch and pilot facilities lend themselves to multiple, modular, small-scale process plants, which in turn have an inherent higher safety in redundancy when encompassing hazardous materials in the processes that include drugs, chemicals and foods. Second and third separate small scale plants will ensure continuity of supply in the event of a natural or man-made accident or terrorist attack and shifts in the economy and markets. They offer greater production flexibility for downtime for cleaning, maintenance and trial modifications for process improvements. Haz-Safe clients appreciate greater flexibility with batch size, segregation and refilling new technologies. Photos below: Inside Haz-Safe Buildings' plant in Sarver, PA, the upper module is being placed onto the lower module of a small scale Multiple Module Manufacturing Plant. Individual module fabrication is done on one level for maximum access and ensures optimum safety. Rigorous testing and checks are made before modules leave factory. Prior to shipment, the modules are disassembled, the 'hook-up' components are code marked, and each module is sealed in shrink wrap. This is being done in parallel while the site is being prepared at the same time.

Haz-Safe Buildings meet the needs of industries like pharmaceutical, food and cosmetic and petro-chemical companies for: A. multiple, modular customized manufacturing or process system plants that are, B. engineered, fabricated and tested before shipment, and C. providing a "speed to market" advantage. The faster the decision is made to build (the plant being on site and in production), the quicker to greater market share for our clients. Photos below: After shipment to the client's site, the unloading and installation is executed in accordance to a detailed task list. Left photo shows crane placing lower module on the new foundation. Middle photo is a view down through roofless lower module exposing overhead roll-up door hood and explosion relief panels tied down for shipping. On right, the crane is placing clients' fuel storage tank (typically could have been a mixing, heating/cooling, harvest, decontamination, etc. type vessel or a media prep, storage, neutralization, etc. type tank).

The flexibility of a modern modular Haz-Safe small plant system can be adapted to changing market needs. It expands step by step, in pace with changing requirements and can grow into a large factory. In very large client conventionally constructed facilities, there may be a small scale supporting chemical process involving flammable combustible materials that would be either inside or best be placed outside the main facility, yet connected with plumbing and material handling equipments. Click to look at typical Haz-Safe's Multiple Module and Three-Story Processing Plants. In addition, Haz-Safe Buildings are not set in concrete and are forced to stay at the location where originally installed. At any convenient time, it can easily be moved to the other side of the site, across the road, to another city, state, etc. Try to do that with a brick and mortar building! Photos below: Upper level module is being placed for a perfect fit by crane. Photo on right shows how 1" diameter threaded steel rod (component of patented bolt-up system) is being lowered into vertical tubular member of the wall.

Haz-Safe knows costs better because of more controlled shop conditions and supplies more accurate cost estimates earlier on to give greater confidence to decision-makers during project formulation and funding stages. In-shop workers achieve greater productivity and enjoy increased safety and improved stock control. Factory controlled procedures and elements of production line mentality result in more economical operations. Inside fabrication is inherently cleaner than on-site construction (greater dust generation, density of personnel, noise and vibration and accidental damage), which enhances end product clean-up. On-site construction attempts to achieve a wind and water tight envelope as quickly as possible to reduce sensitivity to adverse weather and a clean build. At the start, Haz-Safe factory achieves a wind and water tight environment. Each module, before leaving the factory, is shrink wrapped to maintain cleanliness. All of these factors, and more, make modular construction very cost competitive.

Photos below: Man on roof, assisted by man in cherry picker, removes crane's connection from threaded rod in photo on left. Middle photo has the lower 8' wide x 4' high explosion relief panel lifted into place. Photo on right shows blast shaft being lowered by crane between client's main facility and the Haz-Safe Building so shaft can be installed over the explosion relief panels.

Where new product introduction requires a "quick built" purpose-built, small multiple module Haz-Safe plant, true for pharmaceutical, chemical, plastics, and food industries because they have need to maximize their drugs' patent protection period, it has been shown modular buildings can reduce construction time by 30-50% through parallel function programming. The construction time, in most cases being reduced, will result in up to 40% increase in the rate of return of up-front investment. Photos below: Assembled 12' wide x 31' long x 21' high small scale, two-module Haz-Safe process building with platforms and stairs attached was engineered by Bill Ory Engineering, 208 Norwood Cove, Georgetown, TX. Mr. Ory's client manufactures fuel dispensers (to be placed underground at roadside gas stations) that his client shall: 1. place through the overhead roll-up door, 2. connect to the fuel storage tank, and 3. turn on for leak and life cycle testing. For details, call Mr. Ory at 512-635-5773. Photo on right exposes the open top of two blast shafts between the roof and the main facility and the Haz-Safe Building.