Comprehensive Industrial U.S. Facility Decommissioning for Large-Scale Sterilization Company
Overview:
When a large-scale sterilization company vacated a 50,000-square-foot facility located in the U.S. that it had leased for approximately 30 years, it needed a trusted partner to manage a complete decommissioning and facility restoration effort. The goal was to return the building to pre-lease open-warehouse conditions, making it a clean, compliant, and fully functional space ready for its next occupant.
KERAMIDA led the project as the general contractor and construction manager, overseeing every stage from start to finish. With decades of experience in environmental management, construction, and compliance, KERAMIDA provided the full range of services necessary to complete the project safely, efficiently, and in accordance with local and state regulations.
Project Details:
Planning and Permitting
As with any industrial decommissioning, careful planning and permitting were critical first steps. KERAMIDA obtained all required demolition and construction permits, coordinated with municipal authorities, and developed a detailed work plan that prioritized safety, efficiency, and environmental compliance throughout each phase of the project.
Demolition and Equipment Removal
Decommissioning involved the complete removal of all process equipment, piping, and electrical systems associated with the former industrial operations. Interior demolition included the removal of CMU block walls, interior rooms, a glycol tower structure, and a hazardous waste storage area.
KERAMIDA’s team also managed the removal and proper disposal of all remaining items left on site after the tenant’s departure, including office furniture, laboratory equipment, maintenance tools, spare parts, chemicals, and documents—ensuring the facility was fully cleared and ready for restoration.
Structural and Mechanical Reconstruction
Following demolition, significant reconstruction work was required to restore the facility’s structure and systems for warehouse use. Key activities included:
Roof Reconstruction: Pressure relief panels were removed and replaced with new structural steel framing, roof trusses, and TPO roofing to match existing materials.
Electrical and Lighting Systems: The team rebuilt lighting fixtures, exit signs, and electrical receptacles throughout the building.
Fire Systems: The fire suppression and alarm systems were reconfigured to comply with current codes applicable to warehouse operations.
Mechanical Utilities: Process equipment located on the roof was safely removed, and natural gas lines were properly disconnected and capped.
This comprehensive approach ensured that the building met all modern safety and operational standards before turnover.
Environmental Due Diligence
KERAMIDA’s in-house environmental team performed a subsurface investigation, collecting soil and groundwater samples to confirm the absence of contamination and verify compliance with applicable environmental standards. The assessment provided assurance to the property owner that the site conditions were suitable for reuse and future occupancy.
Interior and Exterior Restoration
With structural and environmental work completed, attention turned to restoring the building’s appearance and functionality. Activities included:
Patching and Repairs: Exterior wall openings where process lines and louvers had been removed were sealed and repaired.
Flooring and Drainage: Process trench drains were removed, and asbestos abatement of floor mastic was conducted in accordance with the federal, state, and local regulations and all safety protocols.
Office Upgrades: To satisfy the lease agreement, two new ADA-compliant restrooms were constructed within the office area to meet accessibility standards.
Cleaning and Painting: The warehouse and office areas were thoroughly cleaned and painted throughout, giving the interior a refreshed, move-in-ready finish.
Facility and Site Repairs: Hydraulic loading docks, overhead doors, and the brick façade were repaired to restore full building functionality and curb appeal.
Site Restoration: New asphalt was installed in the parking lot where the glycol tower and generator foundation had been removed, and reseeded areas restored the landscape to pre-construction conditions.
Delivering a Turnkey Solution
From permitting and demolition to environmental investigation and reconstruction, KERAMIDA managed every aspect of the decommissioning project through a single integrated team.
This turnkey approach minimized project complexity, reduced downtime, and ensured all activities met regulatory, structural, and environmental standards. The result was a clean, compliant, and fully restored warehouse facility delivered safely, on time, and within scope.
Related Services:
Companies considering plant closures can rely on KERAMIDA to undertake all services throughout the deactivation, decommissioning, demolition, and redevelopment process, using our innovative and cost-effective phased approach that saves both time and money, and ensures a successful Facility Decommissioning project.
