Integrated Piping & Duct Installation Success

By maintaining high-quality standards, completing thousands of welds with zero rejects, and efficiently managing resources, ParFab successfully met all key milestones. The result was a seamless, problem-free startup, demonstrating ParFab's reliability and expertise in overcoming the client’s challenges while ensuring optimal project performance.
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Massive Installation

Completed 15,210 feet of ductwork, combining horizontal and vertical sections up to 66 inches in diameter, across 3,084 spools.

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Expanded Scope

Due to exceptional quality, the project scope grew to include 17,050 feet of carbon steel piping and 2,208 feet of stainless steel piping, totaling 8,643 welds.

 
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Complex Equipment

Installed 3 tanks, 3 heat exchangers, and over 1,545 devices, including valves and meters.

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Peak Workforce

Grew from 34 to 142 crew members by project peak, including day and night shifts.

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Zero Incidents

Achieved almost 500,000 man-hours with zero OSHA recordables, maintaining excellent safety and environmental standards.

Project Background

In September 2022, we received a call from our client stating that they needed a contractor to install ductwork and within 5 days, ParFab’s leadership team was onsite with client to determine how we could support. We mobilized in October 2022 with a crew of 47, ready to safely install the duct. The installation was completed successfully with 15,210 feet of ductwork.

Due to the success resulting from efficiencies and the quality of supporting the initial ductwork scope, we received a request to further support the project. The subsequent scope awarded to us involved piping installation. This led us to support multiple scopes and extended our presence on the project until the end of 2023.

Our team installed a total of 15,210 feet of ductwork, consisting of 6,820 feet of horizontal duct and 8,390 feet of vertical duct, ranging in size from 10 inches to 66 inches, totaling 3,084 spools of duct. Additionally, 17,050 feet of carbon steel piping was installed, ranging in sizes from ¼ inch to 30 inches, totaling 8,643 welds. Furthermore, 2,208 feet of stainless-steel piping was installed, ranging in sizes from ¾ inch to 6 inches, totaling 394 welds. In addition to the piping, 3 tanks, 3 heat exchangers, and over 1,545 devices, including valves, strainers, pumps, flow devices, temperature and pressure meters were also installed.

Industry

Semiconductor

Project Scope

HVAC & Piping

Project Challenge

Our client was behind schedule on their capital project and was in need of a qualified contractor to install ductwork with a quick turnaround.

How We Helped

Within 15 days of the initial meeting, ParFab was onsite to begin the ductwork installation. We installed 17,050 feet of carbon steel piping and 2,208 feet of stainless steel piping, along with other components, positioning them as a top contractor and securing future opportunities with the client.

Manpower

The workforce and PFS personnel needed to complete the project.

Crew Expansion Timeline

The ParFab team started with 19 boilermakers, 11 pipe fitters, and 4 welders, growing to 85 crew members by mid-December. At its peak, the team reached 142 crew members working on-site across day and night shifts.

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Total # of Boilermakers

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Total # of Pipe Fitters

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Total # of Welders

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Total # of Personnel

Health, Safety, & Environmental

This project peaked at 142 ParFab employees and 4 subcontractors with 88 employees.  ParFab had 1 safety supervisor and 2 safety techs on days and 1 safety supervisor on night with 35 ParFab employees, 2 subcontractors with 24 employees.  The total project completed almost 500,000 manhours with zero OSHA recordables.
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Project Quality and KPI Overview

This project was overseen by 1 quality manager, 3 Certified Welding Inspectors (CWIs), and 4 quality technicians. Key performance indicators (KPIs) included the installation of 1,545 pieces of equipment, 7,350 flange makeups, and 246 hydro tests, all completed at 100% with zero startup leaks. The team installed 17,050 linear feet of carbon steel piping, 2,208 linear feet of stainless steel piping, and 15,210 feet of ductwork. A total of 8,643 welds were made with zero rejects, reflecting the project’s exceptional quality and efficiency.

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