ORBIS Industrial Facility Paint & Surface Refresh

in Greenville, TX

Location

Greenville, Texas

Client and Facility Overview

ORBIS, a subsidiary of Menasha Corporation founded in 1849, is a leading provider of material handling and packaging products serving diverse industries. Their Greenville, Texas facility encompasses three major operational zones totaling approximately 400,000 sq. ft. of industrial space. The facility features extensive interior structures, including office spaces within the warehouse, multiple columns, and a specialized shredding room, reflecting the company's comprehensive material handling operations.

Requested Maintenance

The client requested a comprehensive facility refresh program across three distinct zones (A, B, and C), focusing on:

Surface Preparation: Thorough cleaning of approximately 400,000 sq. ft. of ceiling surfaces, walls, and interior structures including tanks through compressed air blow-down procedures
Structural Repairs: Remediation of expansion joints, with up to 30 failing joints identified for caulking across all zones
Paint Application: Complete repainting of:
- All warehouse interior office exterior walls
- Building structure walls within the warehouse
- 24 doors and handrails throughout the facility
- 252 columns across all zones
- Specialized coating system for the 2,884 sq. ft. shredding room, including block filler application

Decision Driver and Timing

The project was driven by several key factors:

Facility Maintenance: The comprehensive scope across all three zones indicates a strategic facility-wide maintenance initiative to maintain ORBIS's operational standards
Operational Efficiency: The sectional approach (Zones A, B, and C) allows for systematic completion while maintaining facility operations
Safety and Compliance: The detailed safety procedures and controlled access zones reflect the client's commitment to maintaining a safe working environment during the renovation
Asset Protection: The specialized treatment of different surfaces and structures demonstrates a proactive approach to protecting valuable facility assets

Scope of Work

The project encompasses three distinct zones with identical core procedures but specialized requirements for each area:

Zone A (Largest Treatment Area):

Surface preparation of 134,577 sq. ft. of ceiling area
Treatment of 42,812 sq. ft. of wall surfaces
Cleaning and painting of 5,505 sq. ft. of interior structures
Installation of 40 expansion joint repairs
Painting of 84 columns and 8 door/handrail combinations

Zone B (Medium Treatment Area):

Surface preparation of 121,506 sq. ft. of ceiling area
Treatment of 20,944 sq. ft. of wall surfaces
Cleaning and painting of 8,723 sq. ft. of interior structures
Installation of 40 expansion joint repairs
Painting of 84 columns and 8 door/handrail combinations

Zone C (Specialized Area):

Surface preparation of 143,753 sq. ft. of ceiling area
Treatment of 34,580 sq. ft. of wall surfaces
Cleaning and painting of 10,454 sq. ft. of interior structures
Installation of 10,454 expansion joint repairs
Specialized shredding room treatment (2,884 sq. ft.)
Painting of 84 columns and 8 door/handrail combinations

Notable Details

Project utilizes multiple coating systems tailored to specific areas:

PPG Speedhide Flat in white for general wall surfaces
Sherwin Williams Industrial Enamel for doors, jambs, and handrails
Specialized block filler system for the shredding room requiring additional preparation and coating layers

Implementation of zone-specific work schedules requiring 100% area availability upon mobilization
Established clear communication protocols for unforeseen conditions with a two-day notification requirement
Comprehensive safety measures including Controlled Access Zones (CAZ) with clear boundary markings

Full PPE requirements including protective suits, respirators, and steel-toe boots
Certified lift operators and mandatory safety harness protocols
Strategic placement of safety cones and caution tape
RED DO NOT ENTER boundary tape for CAZ areas

Written approval requirements for any scope adjustments
Systematic approach to surface preparation across all zones
Professional management of different coating applications based on surface requirements

Client Satisfaction

The project demonstrates Painters USA's commitment to meeting ORBIS's facility maintenance needs through:

Detailed planning and systematic execution across three distinct zones
Implementation of comprehensive safety protocols aligned with both OSHA and facility requirements
Professional application of appropriate coating systems for different surface types
Minimal disruption to ongoing operations through strategic project phasing
Clear communication protocols and project management procedures

The extensive scope and detailed planning reflect the client's trust in Painters USA's ability to handle large-scale industrial facility maintenance while maintaining strict safety and quality standards.