Knauf Insulation GmbH Renovation
May 2008
Shelby Materials provided the concrete for Runnebohm Construction who completed the Knauf Insulation $220 Million dollar renovation in Shelbyville, IN. Knauf Insulation, one of the worlds leading manufacturer of fiberglass insulation embarked on a monumental 673,000 square foot expansion to advance product quality, double production capacity, and greatly increase energy efficiency.
This project required building a new 373,000 square foot warehouse adjacent to existing production and warehousing facilities. Upon completion of the new warehouse, old warehouse facilities and existing production lines were torn out and replaced with two new production lines and required support facilities. The demolition and construction schedule, which spanned 2 1/2 years, allowed Knauf to maintain their fiberglass production during construction. The job was completed in December of 2007.
In addition to conventional concrete designs, this project utilized pervious concrete, lean concrete, flowable fill, mass concrete, and over 9000 cubic yards of auger cast grout. Delivery and placement schedules included high-volume laser screed pours, mass concrete foundation pours and around the clock slip form pours.
The total amount of concrete used was 54,000 cubic yards. Concrete and aggregate delivery required great coordination and driver safety awareness as deliveries to the small site were routed through factory production areas and multiple construction areas.
In February of 2007 Knauf suffered a large fire to an older building in the middle of the existing site. Knauf officials were interested in utilizing the remaining building slab for outside warehousing, but the remaining slab was flat and would not allow rainwater to drain from the slab. Sections of the old slab were removed and replaced with pervious concrete. The pervious sections provided needed drainage so that the remaining slab could be utilized for outside storage.
