Renovating Leading Poultry Plants

Koch Foods, a U.S.-based leading food company among the country’s largest integrated poultry processors, selected Carroll Daniel to renovate their facility in Morristown, Tennessee. The renovation in Morristown consists of removing the existing roof, insulation, steel support channels and deteriorated precast concrete roof planks. Our project team will then install new precast concrete roof planks, new insulation and a new roofing system.

Koch Foods re-roof aerial

Overcoming Obstacles in an Operational Plant

Safety is a number one priority at Carroll Daniel Construction, and our safety team develops a site-specific safety plan for each and every project we work on. Working on an occupied and operational plant, our safety team strategically planned the removal of the concrete roof planks to limit any disruptions. The project team at Koch Foods, Tennessee monitors plant operations along with weather on a daily basis – determining if working during the upcoming weekend will be possible. Weekly meetings with the Owner allow client weigh in on operational decisions, and the Carroll Daniel project team communicates the decisions to all subcontractors. If operations and weather permit, work continues on the weekend; if not, work proceeds the following week.

Going Above and Beyond

With the level of deterioration evident in many of the concrete roof planks, it was pertinent to develop a plan to protect the operational facility below from any falling debris during the removal and subsequent replacement of the new roofing system. In order to protect Koch Foods employees and equipment, the Carroll Daniel team designed and built one major, critical piece of equipment: a special lifting device to capture falling debris from the planks during their removal.

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