Steelcase Inc., Grand Rapids, Michigan

Office furniture manufacturer divides plant space
during production process

Construction of a wall 30' high by 630' long in an existing wood-finishing room.

Plant production had to continue during construction, with a clean installation being essential. Plus, the wall had to be reusable for future applications.

The Situation
Steelcase, Inc. - the world's leading designer and manufacturer of office furniture - solved a tall problem in one of their Grand Rapids plants with a PortaFab modular wall system.

Roger Lamer, a senior facilities engineer for Steelcase, reports that they needed an existing wood finishing room separate from the rest of their plant. This industrial partition was necessary to prevent airborne particles, originating in a sanding station, from contaminating furniture being finished.

To effectively divide the two work areas, the new wall would have to stand 30' high to reach the underside of the roof deck from the plant floor. It would also have to fit around existing piping. Since the new wall might be moved within a very few years, Lamer wanted the flexibility to be able to reuse it.

Steelcase required that its plant production continue during the construction, and they needed a type of wall system that could be built without dispersing airborne particles in the process.

The Evaluation
Alternative construction methods were evaluated. "Block wall construction was eliminated," says Lamer, "because dust and dirt during installation would not allow production to continue - and removal of the wall would be too costly."

While metal studs could be reused, he eliminated drywall construction because plaster dust would force production to halt during installation.

Pre-engineered modular wall systems satisfied both requirements. All cuts would be made outside of the finish room, so very little dust and dirt would be created. Modular panes could be reused at a later date.

Lamer contacted a PortaFab distributor and asked for recommendations that could meet al the Steelcase requirements. Larson, working closely with both PortaFab design engineers and Steelcase, determined that a PortaMax XTRA-TALL modular wall system best met the project's specifications and budget criteria.

The Solution
PortaFab proceeded to draw up plans for the wall, customizing the PortaMax panels to fit the particular specifications indicated by Steelcase. The design was based on the PortaMax 600 wall system with 6" thick steel-faced panels to tie in to the 30' roof line.

"PortaMax modular panels allowed a simple installation," stated Larson. "No special equipment was needed, and we got the job done without interrupting plant production."

By using panels with PortaFab's Fire and Sound control Option, the installation provided a noncombustible wall - essential in this type of plant. And, with 1/2" steel-faced gypsum covering an expanded polystyrene core, the wall effectively reduced noise in the plant area.

Thanks to the timesaving advantages of a pre-engineered wall system, construction was completed in just eight weeks.

"We really didn't have to be sold on the concept of a modular wall," said Roger Lamer. "We were familiar with PortaFab and their high quality. We felt they would be an effective answer to our needs - and we were right."

The results speak for themselves. "Steelcase in very happy with the PortaMax wall reports Larson. In fact, they've already ordered another one."

PortaFab PortaMax wall systems offer a clean, cost-effective solution
In today's world of business, you have to stay flexible to succeed - and that includes your working environment. That's why PortaFab PortaMax wall systems offer a cost-effective alternative to conventional construction, without compromising quality, durability or cleanroom efficiency.

Developed specifically for use in plants with high ceiling or roof lines, PortaMax wall systems are pre-engineered to join with ceiling, floor and mechanical components to provide complete control of critical environmental conditions. In addition, panels have smooth surfaces to minimize particle build-up and feature fire & sound control benefits.