Kalamazoo Pulp & Paper Piping Restoration Project

ParFab stepped in to bring the project back on track, significantly expanding its scope to install over 55,000 feet of both small-bore and large-bore stainless steel piping. Despite the challenging timeline and growing workforce, ParFab achieved 1,095,350 man-hours without any OSHA recordables, maintaining exceptional quality standards with a 0.01% weld reject rate and successfully supporting the client’s requirements to completion and reinforcing ParFab as one of the worldwide leaders in end-to-end fabrication and field services.
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Scope Expansion

Originally tasked with installing 8,000 ft of small-bore piping, ultimately installing over 50,000 ft of small and large-bore stainless steel piping due to exceptional performance.

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Comprehensive Installation

Over 700 devices, including valves, control valves, and flow meters, were successfully installed.

 
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Peak Workforce

The team grew from 30 to 360 members by the end of October, managing 9 subcontractors and 405 additional workers.

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Zero OSHA Recordables

Achieved 1,095,350 project man-hours with no OSHA recordable incidents, showcasing a strong safety record.

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High-Quality Standards

Completed 12,558 small-bore welds and 3,376 large-bore welds with only 6 rejects, maintaining a 0.01% reject rate.

Project Background

In July 2021, Graphic Packaging International (GPI) contacted ParFab for assistance with a project that had fallen behind schedule.

Initially, our team mobilized with a small crew to handle approximately 8,000 feet of small-bore piping installations. However, as other contractors continued to fall behind, ParFab's scope of work significantly expanded.

Ultimately, we installed 33,290 feet of small-bore piping and 22,206 feet of large-bore piping, performed 15,934 welds, and installed over 700 devices. Our systems walkdown team ensured all installations met GPI's specifications, providing thorough reviews and detailed reports.

Industry

Pulp & Paper

Project Scope

Piping

Project Challenge

With other contractors falling behind, ParFab was given additional scope to help bring the project back on track, ultimately requiring significantly more work than initially planned.

How We Helped

ParFab installed 33,290 feet of small-bore piping, 22,206 feet of large-bore piping, and completed 15,934 welds. Our team also installed over 700 devices and verified installations against isometrics and P&IDs, ensuring everything met GPI’s specifications.

Manpower

The workforce and PFS personnel needed to complete the project.

Crew and Subcontractor Expansion

ParFab began the project with a crew of 10 welders, 10 pipefitters, and 10 boilermakers, expanding to 100 crew members per shift within 30 days, and ultimately reaching 360 crew members by the end of October. During this period, the systems walkdown team grew from 1 to 6 members.

After 30 days, ParFab took over as the general contractor, managing 9 subcontractors with a peak manpower of 405 employees. The subcontractors included union teams for crane, scaffolding, carpentry, electrical, sheet metal, and painting, as well as non-union teams for NDT, cleanup, and inspection.

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Welders

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Pipe Fitters

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Boilermakers

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Total # of Personnel

Health, Safety, & Environmental

This project peaked at 765 personnel, consisting of 360 ParFab employees and 405 subcontractor employees across 9 subcontractor companies. ParFab’s safety team included 1 safety manager, 1 safety supervisor, and 4 safety techs during the day, and 1 safety supervisor and 3 safety techs at night, while each of the 5 subcontractors had a dedicated safety representative. After ParFab assumed the role of general contractor, the project was completed with an additional 1,095,350 man-hours, all achieved with zero OSHA recordable incidents aligning with ParFab's commitment to their safety standards.
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Project Quality and KPI Overview

This project featured a dedicated quality team consisting of 2 quality managers, 3 CWIs, and 5 quality technicians. Key performance indicators (KPIs) include the successful installation of 33,290 feet of small-bore stainless steel piping, 22,206 feet of large-bore stainless steel piping, and 15,210 feet of ductwork. Additionally, 5 tanks/vessels were installed, along with 711 pieces of equipment, and a total of 5,350 flange makeups were completed—all with 246 hydro tests and zero startup leaks. The project included 12,558 small bore welds and 3,376 large bore welds, with a reject rate of just 0.01%.

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