Fort Greely contacted the Wilbert Precast, Inc. plant in Yakima from a PCI list as a possible manufacturer. Wilbert submitted their initial quote predicated on the original DOD drawings. Upon further review, Dwight Hauff of Wilbert reviewed the drawings and concluded that the original DOD drawings were not going to work for multiple reasons. After multiple revisions and countless RFI's, Wilbert, Boeing (the general contractor), and the DOD (end user) agreed to a heavily modified revised set of plans to begin construction.
Fort Greely is an Army base in Alaska which contains anti-ballistic missile silos. The purpose of the project was to build a steel generator station with concrete wall panel cladding made of sandwich panels, 3" colored fascia, 3" rigid foam insulation, and a 6" structural piece, joining to complete a 12" thick wall. The innermost layer of cladding on this project was a HEMP plate (High Altitude Electromagnetic Pulse). Its purpose was to protect the operation of the enclosed generator plant from a nuclear attack. All of the seams on the HEMP plates were welded.
These panels were 10' by 19' and weighed 27,000 pounds apiece. Wilbert would cast them, put them on a trailer to Tacoma where they would be shrink-wrapped, put on a steam ship to barge, then sent to Anchorage and trucked to Fort Greely. The panels would stay on a trailer until erection, 50 trailers containing 135 panels in all.
Prior to this project, Fort Greely sought a local supplier to make a 7-panel addition to a similar structure. In this process the supplier produced 7 panels, 5 of which were rejected. After producing an additional 5 panels, 3 of those panels were also rejected. This job was extremely technical and anything short of perfection would be rejected because of the tight tolerances required for construction.
This project placed tremendous demand on all involved Quality Assurance departments. In compliance with the bid specifications, Wilbert retained a third party Quality Assurance Firm. Boeing hired a third party consultant from CH2M Hill to oversee the manufacturing of the panels. Boeing also retained two consultants from Maryland to oversee the erection of the HEMP plates at the point of final application.
One of the key aspects of this project is that multiple entities came together to take an initial plan and make significant changes as a team. All contributing parties worked well together for the sake of the end product and followed a communication plan so that all were able to accommodate continual modifications and still remain profitable.