General Motors Corporation
Bowling Green Assembly (Corvette Plant) Elpo Frame Project

The Elpo frame project consisted of a 10,000SF building addition, Elpo machine and conveyor system. This was a complete turn-key, design and build project with a very aggressive schedule. Gallagher-Kaiser Corporation self performed the installation of the building enclosure and ventilation system. The site / civil work, building utilities and conveyor system was subcontracted-out to approximately 15 separate companies, all managed and coordinated by Gallagher-Kaiser Corporation. The building, process equipment and conveyor systems were all installed simultaneously in order to meet the customers production schedule.

Building Addition: (New 6-Bay Building Addition 40'-0" x 241'-9”)

 
1. Architectural / Engineering Designs
•    Surveying
•    Architectural Floor Plan and Elevations
•    Structural Engineering Design with Calculations
•    Design Drawings for all Structural Steel
•    Kentucky Licensed Structural Engineer
•    Site Grading Layouts
•    Structural Concrete Engineering
•    Fire Alarm Engineering (Simplex)
•    Electrical Load Study (Orion Engineering)
•    Card Access System (Automated System Group)
•    Basement Egress Engineering Study
        
2. Site Demolition and Relocations
•    Saw Cut Asphalt
•    Demo and Replace Security Fence
•    Relocate and Install New Storm Sewer
•    Building Demo (Conveyor Entrance and Exit Openings)
•    Fire Main Relocation
        
3. Site and Civil Work
•    Silt Fencing
•    Site Security Fence
•    Excavation for Foundation
•    Footings, Grade Beams and Pier Foundations
•    Asphalt Paving for Truck Drive Areas
•    (55) "HP" Piles 20'-0"lg
•    Recessed Truck Dock and Leveler Pit
•    Top Soil, Seeding and Ground Cover
        
4. Floor and Enclosure
•    12" Concrete Slab
•    Concrete Trench Drains for Process Equipment
•    4"Thk. House Keeping Pads for Storage Tanks
•    Chemical Resistance Floor Coating
•    Pre-Cast Concrete Side Wall Panels 7'-2"h    
•    Masonry Block Walls at Employee Entrance Vestibule
•    Structural Steel Fabrication and Erection
•    Bollards at Employee Entrance

4. Floor and Enclosure (continued)
•    Double Guardrail 4'-0"h
•    Wood Blocking around Roof Perimeter
•    Coal Tar 4-Ply Built-Up Roof
•    Metal Siding with Insulated Interior Liner
•    Gutters, Downspouts, Caulking and Sealants
•    Man Doors
•    Eight (8) Door Employee Entrance System
•    "Store Front" System at Employee Entrance
•    High Speed Fabric Roll-Up Door
•    Loading Dock Equipment
            
5. Building Electrical    
•    Building Copper Cable Grounding System
•    Temporary Power
•    1600 AMP Power Feeder with 2500 AMP Bus Duct
•    Metering Study (Orion Engineering)
•    High Bay Lighting
•    Exit Lights
•    Emergency Egress Lights
•    Outdoor Lights
•    Lighting Panel
•    Lighting Connection to Building EMS
•    Welding Receptacles
•    GFI Receptacles
•    Card Access Readers
•    Controlling Circuit for Dock Levelers
•    Fire Alarm System,
•    Voice and Data Communication
•    Duct Mounted Smoke Detectors
        
6. Building Mechanical
•    20,000 CFM Air Handling Unit with Chilled Water Coil and PLC Controls
•    Supply Air Ductwork with 1" Foil Wrap Insulation
•    Building Exhaust Fans
•    2.5" Compressed Air Piping Main
•    6" Chilled Water Supply and Return Main
•    Building Fire Protection Sprinkler System
•    Potable Water
•    Process Water
•    Natural Gas
•    Roof Conductors
•    Process Waste Piping
 

Process Equipment:    
    
 
•    New 144'-6" ELPO Machine    
•    Stage #01 Elpo Paint Dip     
•    Stage #02 UF Spray Rinse
•    Stage #03 UF Dip Rinse    
•    Stage #04 Fresh UF Spray Rinse    
•    Stage #05 Recirc. DI Spray    
•    Stage #06 Fresh DI Spray Rinse    
•    Elpo Exit Plastic Enclosure    
•    Inspection Deck    
•    Exhaust Duct to RTO            
•    Spang EMR Rectifier    
•    Ultra Filter System    
•    Anode Cells    
•    Anolyte System    
Process Equipment (continued):

•    DI Water Storage Tank    
•    Elpo Paint Storage Tanks    
•    Horizontal Pumps with Seal Flush System    
•    Exterior Platform    
•    Bag Filter Platforms        
•    Controls and Field Wiring    
•    Mechanical Piping    
•    Fire Protection Sprinklers under Drain Pans    
•    Deep Cleaning (Building and Process)    
•    Painting    
•    Elpo Dip Tank Lining    
 
        
Conveyors:    
 
•    Conveyor 110a Install New Chain Transfer    
•    Conveyor 111 Install New Chain Transfer and Return Drive    
•    Conveyor 112 New Phosphate/Elpo Strip-Out    
•    Conveyor 113 New Elpo Machine    
•    Epoxy Coated Rail in Elpo Machine    
•    Conveyor Support Steel (Outside of Elpo Machine)
•    Screen Guard Basket, Full Width Pan and Drain    
•    Drip Pan under Conveyor Rail    
•    Truss Reinforcements and Lead Paint Abatement (10-Trusses)