Project Scope: Fabrication, Mechanical & Electrical Assembly; Integration of Material Handling & System Controls; Leak Testing & System Testing; NFPA 70, UL 508A, ASME NQA-1.

Springs Fab, in partnership with Merrick & Company, provided the fabrication, assembly, and testing services for a custom processing system that would remotely punch, drain, and decontaminate a stockpile of 1,880 bulk containers (Ton containers) filled with mustard agent. There were twelve (12) stations built and assembled, coinciding with the steps in the processing of Ton containers. The assembly involved integration of the stations, a punch to penetrate the ½” steel plate wall of a Ton container with a 6” square hole, a pipe cutter to section the drained container, a hot/cold washing station to clean out the cut sections, robotics, conveyors, and all controls (hydraulic, electrical). Springs Fab and Merrick worked together to coordinate programming issues with the various subsystems, and on system testing (functional and controls). The project required close cooperation at the Project Manager level to maintain a schedule while constructing a system of unusual complexity.

Summary of Schedule and Cost Performance 

The project was completed on budget. The fabrication and assembly were completed on time although the shipment was delayed 6 months to address issues involving out-of-round. Since shipping at the end of 2002, the system was installed at a DoD site, decontamination of all Ton containers was successfully completed, and the system has been decommissioned as planned.