Aspen Aerogel Insulation Manufacturing

East Providence, RI

  • Contract value:               $2,992,132                                          
  • Total Man-hours:                  26,620                                                              
  • Recordable injuries:                      0      
  • Completion date:                     2006

Project Accolades  

Winner of two construction industry awards from Associated Builders and Contractors.                                                  Excellence Award from the Connecticut Chapter                                                                                   Merit Award from the National organization    

“The result of this team effort was accomplishment of all of our project goals; a showplace plant, on-time, and within budget. I thank you for your company’s significant contribution to this successful endeavor.”                                                               Best regards, Chris M. Director, Manufacturing and Engineering

Project Overview    

The client launched this flagship manufacturing facility incorporating its own advanced technology product into its structure. The 140,000 square foot building was repurposed to meet the unique manufacturing process requirements. Aerogel’s insulation blankets are a nanotechnology based product that provides full insulating properties with significantly less bulk. Aerogel’s product is used in everything, including energy pipelines, shipyard and construction applications, and even in apparel!

Notch’s Scope Summary    

Notch was hired to install over 30,000 feet of pipe for this project. Our portion covered the process and utility piping used in their manufacturing process. This included: chilled water, hot water, cooling tower water, acid, hydraulic oil, nitrogen, compressed air, non‐potable water, liquefied gas (low, medium and high pressure), instrument air, process chemicals, flush lines, and finish product piping. The fill and supply piping connected 6 outdoor storage tanks and the Cooling Tower with the interior process loops. A hot water loop was installed for each of the boilers and connected the tank farm to the process areas via an 800-foot pipe bridge. One unique feature was a cooling tower unit which was purchased to support the rest of the chilled process. The high-accuracy, low-pressure mixing and metering area lies beneath the vessels in a well designed labyrinth of support beams and manifolds. The high-pressure process area required instrumentation tubing at regular intervals throughout the system. The facility also utilizes a liquid/gas separation process area. Prefabrication of indoor and outdoor pipe racks and bridges were done at the Notch shop before the shutdown began. Working with the great diversity of content and structural materials required our crews to be highly conscious of the restrictions and  requirements for each line—non-potable water and hazardous gases demand different standards.

Highlights & Challenges

  • High pressure SS gas piping
  • 30,000 feet of pipe, sizes 1/2” to 14” diameter with associated fittings, valves, and instrumentation
  • 4” sch 160 pipe with 2500# flanges for liquid supply
  • 4” ‐ 14” Victaulic piping for chilled water loop with copper final connections at equipment
  • High pressure process area (2” ‐ 6” pipe, 26 manifolds with 50,000 ft instrumentation tubing)
  • Full integration of prefabrication
  • Pipe Racks installed throughout process area

Project Team

Client: Aspen Aerogel

Engineering Firm: SPEC Process Engineering & Construction

General Contractor:  SPEC Process Engineering & Construction