BMM and Core Building
Elyria Foundry consists of three fully-integrated foundries on a 30-acre plant site in Elyria, Ohio. On November 16, 2012 the Core Building north of Foundry 1 erupted into flames and not only damaged the Core Room and Core Storage where molds and patterns are stored but also crippled the smaller foundry BMM (British Molding Machine) area where smaller castings are produced.
Osborn, with its previous history with Elyria Foundry, was called in to provide engineering services to help rebuild the facility so that production could be restored. Osborn worked closely with Elyria Foundry staff and the contractor to rebuild the facility. No existing drawings of the facility were available; thus Osborn had to produce drawings of the fire-damaged remains and also had to measure the existing structures integral to the re-build. Osborn worked closely with the City of Elyria’s Building Department to streamline the submittals for permit so that construction could commence in phases in a timely manner but also so that the City would not be overwhelmed with a large one-time submittal.
The BMM Building required removal of fire damaged columns, roof purlins, girders, and roof deck in the northeast quadrant of the pre-engineered building due to the intensity of the fire. These parts were twisted, bent out-of-plane and damaged beyond repair. New parts were provided by the original building manufacturer with some minor structural modifications from Osborn on the east side of the building.
The Core Room and Core Storage areas required their entire roof systems to be removed. The columns in the Core Room were completely damaged and were replaced in their entirety. The columns in the Core Storage were partially damaged and new steel was spliced onto the remaining columns.
A high-bay building is now incorporated into the Core Room to accommodate new equipment clearance requirements.
The original buildings were built at various times, the oldest in 1911 and the newest building in 1993. The re-built structures not only had to accommodate new equipment but also had to incorporate the present-day codes. Revisions to egress, fire suppression, ventilation and other issues had to be addressed due to code changes from the original designs.
Presently, the BMM area has been restored and production has resumed. The Core Room and Core Storage Areas are under roof and are fully operational.