Client and Facility Overview
ORBIS, a subsidiary of Menasha Corporation founded in 1849, is a leading provider of material handling and packaging products serving diverse industries. Their Greenville, Texas facility encompasses three major operational zones totaling approximately 400,000 sq. ft. of industrial space. The facility features extensive interior structures, including office spaces within the warehouse, multiple columns, and a specialized shredding room, reflecting the company's comprehensive material handling operations.
Requested Maintenance
The client requested a comprehensive facility refresh program across three distinct zones (A, B, and C), focusing on:
Surface Preparation: Thorough cleaning of approximately 400,000 sq. ft. of ceiling surfaces, walls, and interior structures including tanks through compressed air blow-down procedures
Structural Repairs: Remediation of expansion joints, with up to 30 failing joints identified for caulking across all zones
Paint Application: Complete repainting of:
- All warehouse interior office exterior walls
- Building structure walls within the warehouse
- 24 doors and handrails throughout the facility
- 252 columns across all zones
- Specialized coating system for the 2,884 sq. ft. shredding room, including block filler application
Decision Driver and Timing
The project was driven by several key factors:
Facility Maintenance: The comprehensive scope across all three zones indicates a strategic facility-wide maintenance initiative to maintain ORBIS's operational standards
Operational Efficiency: The sectional approach (Zones A, B, and C) allows for systematic completion while maintaining facility operations
Safety and Compliance: The detailed safety procedures and controlled access zones reflect the client's commitment to maintaining a safe working environment during the renovation
Asset Protection: The specialized treatment of different surfaces and structures demonstrates a proactive approach to protecting valuable facility assets
Scope of Work
The project encompasses three distinct zones with identical core procedures but specialized requirements for each area:
Zone A (Largest Treatment Area):
- Surface preparation of 134,577 sq. ft. of ceiling area
- Treatment of 42,812 sq. ft. of wall surfaces
- Cleaning and painting of 5,505 sq. ft. of interior structures
- Installation of 40 expansion joint repairs
- Painting of 84 columns and 8 door/handrail combinations
Zone B (Medium Treatment Area):
- urface preparation of 121,506 sq. ft. of ceiling area
- Treatment of 20,944 sq. ft. of wall surfaces
- Cleaning and painting of 8,723 sq. ft. of interior structures
- Installation of 40 expansion joint repairs
- Painting of 84 columns and 8 door/handrail combinations
Zone C (Specialized Area):
- Surface preparation of 143,753 sq. ft. of ceiling area
- Treatment of 34,580 sq. ft. of wall surfaces
- Cleaning and painting of 10,454 sq. ft. of interior structures
- Installation of 10,454 expansion joint repairs
- Specialized shredding room treatment (2,884 sq. ft.)
- Painting of 84 columns and 8 door/handrail combinations
Notable Details
Specialized Coating Systems: Project utilizes multiple coating systems tailored to specific areas:
- PPG Speedhide Flat in white for general wall surfaces
- Sherwin Williams Industrial Enamel for doors, jambs, and handrails
- Specialized block filler system for the shredding room requiring additional preparation and coating layers
Project Management Protocols:
- Implementation of zone-specific work schedules requiring 100% area availability upon mobilization
- Established clear communication protocols for unforeseen conditions with a two-day notification requirement
- Comprehensive safety measures including Controlled Access Zones (CAZ) with clear boundary markings
Safety Implementation:
- Full PPE requirements including protective suits, respirators, and steel-toe boots
- Certified lift operators and mandatory safety harness protocols
- Strategic placement of safety cones and caution tape
- RED DO NOT ENTER boundary tape for CAZ areas
Quality Control Measures:
- Written approval requirements for any scope adjustments
- Systematic approach to surface preparation across all zones
- Professional management of different coating applications based on surface requirements
Client Satisfaction
The project demonstrates Painters USA's commitment to meeting ORBIS's facility maintenance needs through:
- Detailed planning and systematic execution across three distinct zones
- Implementation of comprehensive safety protocols aligned with both OSHA and facility requirements
- Professional application of appropriate coating systems for different surface types
- Minimal disruption to ongoing operations through strategic project phasing
- Clear communication protocols and project management procedures
The extensive scope and detailed planning reflect the client's trust in Painters USA's ability to handle large-scale industrial facility maintenance while maintaining strict safety and quality standards.