| Rolyn Disaster Recovery/Restoration |

Case Study: Manufacturing Plant

Location: Providence, RI

Loss: Damage and Corrosive Smoke

In February 2002, a microelectronics plant sustained massive fire damage. The fire started in the chemical plating area of the factory and smoke soon filled the entire 57,000-square-foot manufacturing facility. The damage, extensive due to the release of corrosive chlorides and hazardous chemicals such as cyanide, brought plant operations to a complete shutdown.

It was vital for the facility to continue its business operations since a large portion of their work was U.S. Military related. The facility’s chips were also used in implantable medical devices such as pacemakers. Rolyn began work by securing the building in order to protect the employees during the clean up process. Containment barriers were constructed on site in order to separate the facility’s office areas from the affected plant operations area. Through the use of air filtration systems, Rolyn created a positive / negative air exchange to prevent cross-contamination between the divided areas.

As soon as barriers were erected and the property was stabilized, Rolyn began to decontaminate the affected area. Simultaneously, Rolyn converted the office area into a temporary first class computer chip manufacturing facility with 100 ppm clean rooms, water cooled lasers, chemical fire suppression systems, orbitally welded stainless steel pipes, explosion proof gas bunkers, and haz mat storage containers. As a result the plant was able to continue production.

Since the offices were now being used as a temporary manufacturing area, the office staff had to be relocated to the parking lot. Using portable field trailers, Rolyn set up management offices in the parking areas, allowing the company to reestablish contact with their customers and bring their operations back online. Acreage adjacent to the plant was used as a temporary parking lot.

The reconstruction of the plant was also a challenge. Due to the sensitivity of the company’s functions, extreme cleanliness was critical. All plant operations had to perform to semiconductor Class 100 cleanroom protocol. Rolyn arranged for periodic testing by qualified laboratories to ensure cleanliness standards were met. Once the rebuilding of the plant was completed, all temporary conditions needed to be reversed. Rolyn moved the employees back into their offices, disassembled the trailers, restored the adjacent acreage, and returned the plant to one hundred percent production.