This processing facility was originally built in 1966 out of cast-in-place concrete columns and beams with a double tee precast roof structure. With numerous additions through the years, and the wear-and-tear of a processing facility, the original precast roof structure was beyond repair and needed to be replaced. Numerous challenges were present working in this active plant, from keeping the plant workers safe to relocating the miles of utility lines on the roof, to preventing any outside contaminants making its way to the interior during active hours. To combat these challenges, the Carroll Daniel team immersed themselves into the production process, understanding the details of the day-to-day operations so we could be certain our process didn’t interfere or put Fieldale employees and plant operations at risk.

The only viable option to replace the roof structure and prevent plant downtime was to replace the precast members on weekends only. Starting at midnight on Friday, the roof would be cleared of all utilities and material, original precast would be replaced, and temporary roofing material would be installed to seal all by Sunday night before Monday’s shift was to begin.