Levolor Manufacturing Facility Remodel – Engineering & Surveying Solutions
Introduction
The Levolor Manufacturing Facility in Ogden, Utah, required significant structural renovations, including a structural retrofit, to meet modern operational and safety standards. Anderson Engineering partnered with Brahma Construction to provide critical structural engineering and as-built surveying services. The project included a groundbreaking LIDAR-based as-built survey, roof retrofit engineering, demolition planning, and a custom steel truss design to resolve supply chain issues. These innovative structural retrofit solutions, a testament to our commitment to excellence, ensured the project remained on schedule while improving structural integrity and safety compliance.
The Challenge
Existing Structural Issues & Renovation Needs
Conducting a structural retrofit not only enhances safety but also prolongs the lifespan of the facility, making it a wise investment for industrial operations.
In the context of this project, a structural retrofit was essential to address the challenges posed by the aging infrastructure.
The Levolor facility, an aging industrial building, presented unique structural challenges that required updates to meet modern engineering standards. However, these challenges were not typical:
- Unclear existing conditions. The building lacked up-to-date as-built records, making it challenging to plan renovations without a detailed survey.
- Roof retrofit challenges. The existing structure required reinforcement to comply with updated safety and engineering regulations.
- Steel truss shortages. Due to supply chain disruptions, pre-manufactured open web steel trusses had lead times extending up to a year, threatening project timelines.
Without the immediate implementation of innovative solutions, the project was at risk of significant delays, cost overruns, and potential regulatory compliance issues.
By solving the steel truss shortage with a custom fabrication plan, Anderson Engineering helped Brahma Construction avoid a year-long delay in the structural retrofit process. The LIDAR survey and detailed engineering also reduced unforeseen issues, showcasing our project management skills and keeping the project timeline on track.
LIDAR-Based As-Built Surveying
To address the lack of accurate building documentation, Anderson Engineering conducted a high-precision LIDAR scan of the facility. This advanced scanning technology generated a 3D model of the existing structure, allowing engineers to accurately assess conditions and plan modifications
Key benefits of LIDAR scanning:
- Reduced errors by eliminating guesswork in structural modifications
- Improved planning with a digital blueprint for design teams
- Faster project execution through quicker approvals and construction planning
Roof Retrofit Engineering
The building’s roof structure needed reinforcement to accommodate new design loads and comply with modern safety codes. Anderson Engineering designed structural modifications that:
- Strengthened key load-bearing components
- Ensured compliance with ASCE 7-16 safety standards
- Integrated seamlessly with the existing framework to reduce demolition needs
This retrofit improved structural stability and extended the building’s lifespan while minimizing renovation costs.
Custom Steel Truss Design – Solving Supply Chain Delays
One of the most critical challenges was the shortage of open-web steel trusses. With standard manufacturing lead times of up to 12 months, Anderson Engineering devised a custom truss design solution to bypass these delays.
How this solution worked:
- In-house truss design with detailed shop drawings
- Local fabrication through a partnership with Blue Star Steel, reducing wait times
- Stamped engineering approvals to ensure all components met safety and load-bearing requirements
This approach cut lead times by over 75 percent, allowing construction to stay on schedule.
Project Benefits
Faster Project Completion
By solving the steel truss shortage with a custom fabrication plan, Anderson Engineering helped Brahma Construction avoid a year-long delay. The LIDAR survey and detailed engineering also reduced unforeseen issues, showcasing our project management skills and keeping the project timeline on track.
Improved Safety & Compliance
- Roof retrofit designs met modern safety codes (ASCE 7-16, IBC-2018)
- Accurate 3D modeling reduced structural risks
- Demolition planning ensured the safe removal of outdated structures
Cost-Effective Engineering Solutions
- Minimized material costs by using locally fabricated trusses
- Reduced labor costs with precise LIDAR-based planning
- Avoided rework expenses by ensuring compliance upfront
Conclusion
By leveraging advanced surveying, engineering expertise, and innovative structural design, Anderson Engineering successfully guided the completion of the Levolor Manufacturing Facility Remodel. The project stayed on schedule, met safety standards, and avoided costly supply chain delays, demonstrating Anderson Engineering’s ability to deliver high-quality structural solutions for industrial renovations.
Need Engineering Support for Your Renovation?
Contact Anderson Engineering today for expert structural solutions in Utah.
Our team specializes in various aspects of structural retrofit, ensuring each project meets the highest safety and performance standards.
Overall, the structural retrofit was a clear example of how innovative engineering can solve complex problems in industrial renovations.
For any facility requiring upgrades, a structural retrofit can significantly improve operational efficiency and safety.
Let us help you navigate your own structural retrofit needs and enhance your industrial space.
