THE ULTIMATE GUIDE FOR BLAST-RESISTANT BUILDINGS

What You Should Know Before You Buy

TESTED FOR LIFE

 YOU'VE GOT QUESTIONS

Maybe you've been through a facility siting study, or maybe you know you need to add occupied space at your
refinery. Or, it could be time for a planned shutdown, and you're going to be bringing in a lot more contractors.
For those reasons or many more, you need to invest in a blast-resistant structure. But, before you pick up the
phone to start making calls or send that email, let's look at all of the considerations you'll need to make.

WE’VE GOT ANSWERS

As the industry leader in blast-resistant modular buildings, RedGuard takes pride in sharing the wealth of
information we've gained since becoming one of the industry's first manufacturers of blast-resistant buildings.
This is the download of The Ultimate Buyer's Guide for Blast Resistant Buildings that you requested. It’s
divided into chapters, but you can also check out individual topics in our Learning Center.

1 WHAT IS A BLAST-RESISTANT BUILDING?

2 DANGERS DURING A BLAST EVENT…
TO PEOPLE AND FINANCIALLY.

3 WHAT IS RESPONSE LEVEL: IS HIGH

RESPONSE ACCEPTABLE? 4 WHAT IS BLAST-PROOF?

5 A BREAKDOWN OF THE BENEFITS OF

BLAST RESISTANT BUILDINGS 6 HOW MUCH DOES A BLAST RESISTANT
BUILDING COST?

7 WHAT ARE THE PROBLEMS WITH

BLAST RESISTANT BUILDINGS? 8 FOUR REASONS FOR SERVICE CALLS ON
BLAST-RESISTANT BUILDINGS

9 MAKING CHOICES ON A CAPITAL PROJECT

10 WHEN SHOULD YOU LEASE A BLAST-
RESISTANT BUILDING?

11 FIVE QUESTIONS TO ASK BEFORE

CHOOSING A BLAST-RESISTANT BUILDING 12 WHAT HAPPENS AFTER THE SALE?
ALL ABOUT PROJECT MANAGEMENT.

redguard.com 1
 - CHAPTER 1 - They ensure that occupied buildings protect against
WHAT IS A BLAST-RESISTANT BUILDING? potential hazards by recommending specific blast
response ratings to protect occupants from potential
THE BASICS hazards in hazard zones.
A blast-resistant building is a structure that has been
designed to withstand significant blast events. These As a safety authority in blast resistance, RedGuard
buildings are often constructed with thick steel walls recommends using only blast-resistant buildings with
and interior features and fixtures designed to with- a low or medium response rating (meaning low- to
stand the heightened psi levels associated with medium- damage after a blast event). While still
small to large blast events. Sometimes they are considered “blast resistant,” a building with a high
referred to as blast-resistant modules, blast-resistant response rating could sustain structural damage
units, or simply as a BRB or BRM. They are often found during a blast event and may even collapse due to
on oil refineries, chemical processing plants, or environmental conditions. We’ll talk more about what
similar operations. “high response” means in Chapter 3.

A blast-resistant modular building is typically - CHAPTER 2 -

constructed with thick steel walls that can sustain a DANGERS DURING A BLAST EVENT… TO
high level of blast pressure. Inside the building, the PEOPLE AND FINANCIALLY
nonstructural components of blast-resistant buildings,
such as cabinetry, light fixtures, electrical and plumb- Those who work for oil and gas companies take on a
ing, as well as internal fixtures are all designed with certain amount of risk. Because of this, companies
these same assurances. should take the steps needed to protect them from as
much risk as possible. This chapter will examine how a
WHAT ARE THE REGULATIONS COVERING BLAST refinery explosion affects the human body and how a
RESISTANT BUILDINGS? blast-resistant building can prevent injuries and
There are no official regulations that cover blast- mitigate the risk.
resistant modular buildings. There are some
recommended practices laid out by the American HOW DOES A BLAST AFFECT THE HUMAN BODY?
Petroleum Institute that cover permanent and The effects of a blast event on the human body will
portable structures that are located within blast depend on several factors, a person’s proximity to the
zones. These are known as API RP 752 and 753. center of the explosion, the terrain and surroundings
redguard.com 2
 within the area of the blast, the cause of the explosion CAN YOU AFFORD NOT TO HAVE A BLAST RESISTANT
(i.e., the type of gas or other material that caused the BUILDING?
event), and the intensity and frequency of displace- Because there are so many people involved in oil and
ment waves. gas processing, the financial risk of NOT protecting
them as they do their work is huge. Understanding the
With these factors in mind, it is important to note that financial impact of a blast with real-world examples is
the human body can typically survive high blast essential. To do this, let’s take a look at the trick-
overpressure. For example, a 5 psi blast overpressure le-down continuous financial costs of a blast event.
can rupture eardrums, while lung damage can occur at
an approximately 15 psi blast. Understanding the Financial Impact of a Blast Event
One of the easiest ways to understand the long-term
One significant factor that must be considered when financial impact of a blast event within the oil and gas
taking precautions to protect personnel during a blast industries is to explore historical incidents.
event is the impact of blunt force trauma to the human
body. Injuries like these can occur with overpressure as 1. On May 5, 1988, in Norco, Louisiana, a refinery
low at 1-2 psi, when windows may shatter, and debris is experienced a blast event that caused 42 injuries
thrown. Crush and seven fatalities. The major blast event hurled
injuries may occur debris as far as five miles away. The incident itself
DAMAGE OCCURS
at slightly higher was heard nearly 25 miles away in New Orleans.
response levels The total estimated cost of the event was $706

5PSI
when the building’s
structural integrity
begins to fail.
million. The latter funds were used to pay for
property damages, injuries, rebuilding, an investi-
gation, and other components directly related to
the event.
In a blast event, or
explosion, the 2. On March 23, 2005, in Texas City, Texas, one of
human body might the world’s largest refineries experienced a blast
be thrown, large event that caused 180 injuries and 15 fatalities.
objects might be The cost of this blast event included an Occupa-
propelled at a tional Health And Safety Association (OHSA)
person, and light imposed $87 million fine (due to 700 safety
objects can quickly violations found during the investigation into the
become speeding incident) and an estimated $2 billion for repairs

15
PSI
projectiles. Fortu-
nately, a blast-resis-
tant building is
and compensation.

THE REAL IMPACT OF BLAST EVENTS

designed to protect As seen in the proceeding two events, the far-reaching
people from the impact of oil and gas blast events extends beyond
aforementioned structural costs. In fact, the effects of a blast event on
injuries. the human body can result in expensive medical bills,
workers compensation, paid time off, and (if warranted
A blast resistant legal compensation. Additionally, as seen in the Texas
building that has the right psi ratings for its intended City refinery blast event, a failure to meet specific
use and location within your facility can not only safety standards can result in hefty fines. In this vein,
protect personnel during blast events; it can also save oil and gas companies should take the necessary safety
lives and reduce the risk of nonstructural items causing precautions to a) protect against blast events and b)
bodily harm in the aftermath of a blast event. protect their structures and workers from the negative
physical and financial impacts of blast events.

redguard.com 3
 RESPONSE? LOW MEDIUM HIGH
RESPONSE RESPONSE RESPONSE

LOW MEDIUM HIGH

DAMAGE DAMAGE DAMAGE

One way companies and facilities can protect their Substitute the term "damage level" for "response level,"
structures and personnel is to use blast-resistant and you have an instant picture of what these ratings
buildings. This will protect personnel from bodily harm, mean. Given the options of low damage, medium
save lives, reduce the risk of nonstructural items damage, and high damage, you obviously don't want to
causing physical injury or property damage, and reduce be working in an area that is highly damaged during a
the financial impact of a blast event. blast event.

- CHAPTER 3 - WHAT TO LOOK FOR IN A BLAST-RESISTANT BUILDING

WHAT IS RESPONSE LEVEL: IS HIGH Anything worse than medium response is virtually
RESPONSE ACCEPTABLE? synonymous with injuries and fatalities. And suppose
you plan on using the building to house critical control
When it comes to blast-resistant buildings, the indus- systems in a petrochemical facility. In that case,
try’s manufacturers will often use the term response casualties are only one of many problems you'll face in a
level to predict the extent of repair needed on a build- high response situation.
ing after an explosion. This chapter defines what each
response level is, and what to look for in a blast-resis- WHAT ABOUT BLAST TESTING?
tant building. The final proof is in the testing of the blast-resistant
design. RedGuard was one of the first companies to do a
WHAT IS RESPONSE LEVEL? field test of our design. In our original blast test, we
Blast response levels are ratings established by the detonated 1,250 pounds of high explosive ammonium
American Society of Civil Engineers (ASCE) to predict nitrate/fuel oil charge at a standoff distance of 110 feet
the extent of repair resources that would need to be from our building. This explosive amount created a blast
devoted to a building after an explosion. Their descrip- strength far above the ratings required to meet ASCE
tions include: low to medium response standards.

Low response — Localized building and component The building suffered no structural damage, and neither
damage; the building can be used, however, repairs are did the furnishings, office equipment, or the crash test
required to restore the integrity of the structural dummy we placed inside. The building is still in use
envelope; and the total cost of repairs is moderate. today at the RedGuard headquarters.
Medium response — Widespread building/component
damage; building cannot be used until repaired; and This outlines the importance of taking a closer look at
the total cost of repairs is significant. both response level ratings and test results before
High response — Building/component has lost structur- buying a blast-resistant building. In response to the
al integrity; building may collapse due to the environ- question, "Is high response acceptable?" - the answer at
mental conditions; and the total cost of repairs RedGuard will always be a resounding no.
approaches replacement cost of the building. redguard.com 4
 - CHAPTER 4 - Structure Of The Building
WHAT IS BLAST-PROOF? We’ll start with structure because the structural
engineering of a blast-resistant building is probably
At RedGuard, we use the term “blast-resistant” rather the most critical factor in protection. This goes back to
than “blast-proof,” and this chapter delves into why. those response levels, mentioned earlier in Chapter 3.
We’ll define those terms and talk about the factors at
play in blast-resistance, such as the structure of the Remember High, Medium or Low Response? All of
building, the building’s material, proximity to the blast them are considered blast-resistant, though not all are
wave, and duration of the blast. equal. And none of them would be regarded as
“blast-proof.”
WHAT DOES BLAST-PROOF MEAN?
The word “proof” implies that something is Manufacturers of blast-resistant buildings will have
impervious. However, there really is no such thing as a different explanations for their design methodology, or
blast-proof building. If you exceed the load that a why they design to a specific blast response level. Still,
building is designed to resist, there's a strong it’s important to look at whether they regard structural
possibility that it could fail. integrity as a priority, or if they simply meet the
minimum requirements to get their building rated.
The word “resistant” means that the object can resist
some type of hazardous penetration. In our case, the Building Material
hazard is blasts or explosions, but you may also think Hand-in-hand with the structural engineering of a
of objects that are water-resistant, slip-resistant, building is the building material itself. Today’s manu-
heat-resistant or puncture-resistant. facturers of blast-resistant buildings are wise to take
lessons from the past. In some of the early blast
Blast-resistance has a lot of nuance to its meaning events that shaped the industry, onsite offices in
because there are many factors at play that determine temporary trailers were completely destroyed, while
the amount of damage during an explosion. Let’s look metal shipping containers inside the blast zone were
at the factors in play when it comes to how blast- still standing, their contents intact. Though today’s
resistant a building is.
redguard.com 5
designs are far more complex and protective, shipping blast-resistant. A low response building in the same
containers became the basis for an idea to create area may sustain little to no damage.
blast-resistant buildings. Extensive engineering helped
create a final design that has led the industry in blast Both buildings may be resistant to damage in an
resistance. explosion, but are either really blast-proof? Not really.
The most we can do is prepare for the dangers that we
Blast-resistant builders employ many different struc- know are present.
tural designs and materials. There are blast-resistant
structures that are permanent brick and mortar Duration Of The Blast
buildings; there are temporary blast structures, there If how close a building is to a hazard and the rugged-
are even tents, sometimes called air shields; and there ness of the building’s structure are vital components to
are modular buildings made of hardened metals that blast resistance, it makes sense that the blast’s dura-
are either portable for temporary use or anchored for tion, or how long it lasts, is also a significant factor.
permanent use. There are some details you can consider when planning
for safety.
Though many materials can be used in the design,
none of them are blast-proof, and their levels of Manufacturers of blast-resistant buildings usually
blast-resistance vary. employ a combination of pounds per square inch (psi)
and a duration of time, expressed in milliseconds
Proximity to the Blast Wave (msec) that the pressure of a blast is applied. Unfortu-
The further you are from an explosion, the less of an nately, the terminology is often inconsistent from one
impact you will feel. Like structure, proximity to the manufacturer to the next.
blast also makes a difference in the damage a building As an example:
will sustain after a blast. The closer to the blast wave, • A blast resistant building can be engineered to
the stronger the building’s blast resistance should be. withstand an explosion of 5 psi for 200 msec.
• That same building could also be advertised to
A high response blast-resistant building placed in a withstand a blast of 5 psi at 500 psi-msec, which
hazardous process area would be very dangerous in the would also be a correct calculation.
event of an explosion, even though it is technically

redguard.com 6
 One description communicates the duration and the The level of damage is all dependent on the blast rating
other the impulse, or measure of the energy of the and the building’s proximity to the hazard. If you work in
blast event (psi-msec). Unfortunately, that difference a classified area, in a building with a low to medium
is lost on many seasoned professionals in the oil and response (which, as mentioned earlier, means it would
gas industry. The 500 psi-msec impulse appears to sustain low to medium damage), your chances of surviv-
signify a more substantial building than the 200 msec al are much higher than in a soft-sided trailer, which are
duration rating, even though both ratings apply to the still used on some worksites.
same building, with the only difference being what is
calculated. 2. REDUCE LIABILITY, INCREASE PEACE OF MIND
When the risks to human life are decreased, the amount
This simple nuance can lead to confusion and possibly of liability is also reduced. For every significant blast
cause someone to accept an inferior level of blast event that has occurred, when there were numerous
protection. It’s essential to understand these calcula- fatalities or injuries, the investigation to determine
tions and to ask whether the description you see cause and fault begins almost immediately.
communicates a duration or a measure of energy.
Understanding the level of threat that a building can Including blast-resistant buildings as safe havens or
withstand, within a set time, is critical. Be cautious of shelters-in-place can give those who work in hazardous
manufacturers that fail to give you clear information areas peace of mind. Should a catastrophic event
when you ask about the duration of time a building can happen, it can reduce the company’s liability since it
withstand its psi rating. It’s possible that they don’t took measures to keep its workforce safe.
understand this nuance themselves.
3. REDUCE TIME LOST TO RETRIEVE TOOLS OR OTHER
THE VERDICT ON THE TERM “BLAST-PROOF” EQUIPMENT
Put this all together, and you can see why the terms One benefit of blast-resistant buildings that's often
blast-resistant or explosion-resistant are the preferred overlooked is the amount of time, and therefore money,
terminologies. Simply put, we don’t say blast-proof, or that you will save by storing equipment and tools in
explosion-proof, because we know that explosions are blast-resistant tool cribs inside the hazardous area.
powerful forces. If you exceed the load that a building Some refinery sites are huge. Often, the time required to
is designed to resist, it might fail. get into and out of the classified area involves checking
in and out, and even arranged transportation.
- CHAPTER 5 -
A BREAKDOWN OF THE BENEFITS OF BLAST
RESISTANT BUILDINGS

In previous sections, we’ve talked about the lifesaving

benefits to people and the financial
Blast resistant structures keep
benefit to the bottom line. workers safe and near the project.

Now, let’s delve into seven benefits

of blast-resistant build-ings that will
help you make an informed decision
mitigation options for your facility.

1. STAFF, EQUIPMENT, AND

ASSETS ARE PROTECTED
IN A CATASTROPHIC EVENT
Blast-resistant modules, or BRMs, Based on the size of your project lost
are built to withstand the devastating damage wrench time can cost you millions.
resulting from an explosion. The people, equipment,
and assets inside of the buildings will be protected.

redguard.com 7
When you store tools and equipment outside of the 6. MOBILITY
blast zone in order to keep them safe, employees must Traditional buildings are permanent structures. Modu-
make a trip each time a specific piece of equipment lar buildings, on the other hand, and specifically
must be used or checked out. When you begin to blast-resistant modular buildings, are built with the
calculate the amount of time spent going back and knowledge that the ability to move it after it’s been
forth to retrieve tools, you realize the benefit of just placed on a worksite is of great benefit.
keeping those tools closer. Depending on the size of the
workforce, the lost time savings could be huge. The A building may need to be moved to accommodate a
amount of time saved over time might even pay for the facility’s turnaround schedule. A blast-resistant module
cost of the blast-resistant building. can be placed on a site to provide shelter for more
people during a turnaround, and then removed once the
4. REDUCE THE AMOUNT OF TIME EXPOSED TO turnaround is complete and the plant returns to its
HAZARDS regular operating schedule.
It goes hand-in-hand with reducing time and money, that
each time a worker must travel across a worksite to get a Most oil and gas facilities go through turnarounds every
tool, they are spending time exposed to hazards. three to five years. Having a permanent structure that
is only at peak usage during a turnaround is not
Reducing the amount of travel time reduces the time economically feasible. Blast-resistant modules can be
that the workforce is exposed to risks. moved to a different part of a plant to be used
elsewhere, or to a completely different location
altogether, perhaps for a different turnaround.

The relocation of buildings is also desirable when an

area becomes more densely populated. A population
swell makes the environment for oil production less
safe, both due to natural disasters and the possibility of
chemicals in highly populated areas. Many refineries
choose to move when the population grows. The ability
to transfer the buildings during the move can save
millions of dollars in buildings that would otherwise
have to be purchased again.

7. BUILT OFFSITE
When a structure is mobile, in addition to the benefits
listed above, that also means it can be manufactured
off-site and then transferred to the worksite and assem-
5. FLEXIBILITY AND MODIFICATIONS bled.
Modular buildings are easy to modify. If the process
area changes after five years, and your facility siting Compared to an on-site, traditional build, where the
study now shows that the blast zone has changed, you location will be out of commission for weeks at a time,
may need to modify existing buildings in order to there will be fewer restrictions on the area’s use since it
provide protection. won’t be tied up in construction for as long. In a traditional
build, you may go through a multitude of steps, like:
If your building is a multi-section, this might be a
matter of adding additional sections. Alternatively, you Site preparation/grading
may choose to use the existing building and add more Foundation
buildings to accommodate your need. Modular build- Framing
ings can even be stacked to save space. Construction, including windows, doors, masonry, etc.

redguard.com 8
 Roughing the electrical, plumbing, and HVAC building is nearly impossible to find. Let’s examine the
Insulation factors that affect a blast-resistant buildings’ cost.
Finishing the interior walls
Trimming/painting the exterior FACTORS THAT AFFECT THE COST
Installation of interior elements like cabinets or
workspaces How Long the Building Will Be In Use:
Installation of flooring The length of time the building will be in use deter-
Finishing electrical, plumbing, and HVAC mines if the building is purchased or leased, which
Connection to water, sewer, or other services probably affects the cost most of all.

In comparison, the vast majority of the work on a The Location of the Building In Proximity To Hazards:
blast-resistant modular building is done before the A building’s location on the work-site makes a differ-
building leaves the production center. When it arrives ence because, even on one site, areas have varying
on site, the "to-do" list will look more like this: levels of psi during a blast event.
Site prep (done before the building arrives)
The duration of exposure is also considered, typically
Foundation (done before the building arrives)
expressed in milliseconds. You will find that BRBs
External finish of the structure (including welds, if
come in several “response levels,” as mentioned in
the building is multi-section)
chapter 3, or are rated for a specific PSI and duration of
Finishing electrical, plumbing, and HVAC
exposure.
Connection to water, sewer, or other services.
In addition, the process itself is safer, since the skilled The Type and Size of the Building and the Number of
labor constructing the building will need to be in a Units Needed:
hazardous area for only the amount of time it takes to Many people think that all blast-resistant buildings
install it. are the same, but in actuality, a blast-resistant build-
ing can be made to look like and function as almost
- CHAPTER 6 - any type of building. (Labs, control rooms, lockers,
HOW MUCH DOES A BLAST RESISTANT restrooms, tool cribs, break rooms, and more.) Compo-
BUILDING COST? nents of structure will affect the cost.

If you’ve done your research online, you know that Since buildings come in different sizes, the building’s
information about the real cost of a blast-resistant size affects the raw materials and again, the cost.
redguard.com 9
When it comes to size, another factor to consider is The Type of Interior Components Required and the
how much the building’s width and height drive the Level of Interior Finish:
cost of transportation. All interior components must be rugged enough so
that they don’t become projectiles in a catastrophic
If a lot of space is required, you can consider using one event. (Projectiles are the primary source of injury and
or more buildings, or creating a multi-section building, death during blast events.) This means that all interior
where several components are placed together to components, like electrical connections, plumbing
create a larger area. fixtures, cabinetry, furniture, etc. could affect the cost,
when compared to those used in buildings where
The Number of External Doors and if the Building blast-resistance is not a factor.
Requires Windows:
Every component of a blast-resistant building must be Electrical finish is also a factor in the cost of a build-
properly vetted. The most vulnerable elements of a ing. Some blast resistant buildings use surface mount-
blast-resistant structure are the windows and doors. ed electrical, so all of the conduit is visible on the
(These elements are not dangerous. They just require finished walls. While the look is more industrial, this
careful engineering.) allows easier access and is less expensive.

Each component being vetted also means that each On the other hand, if the visual aesthetic of the
component must be blast-tested. It would make no building is essential, a blast-resistant building can
sense to put windows into a blast-resistant building have a more finished look, but it will affect the cost,
without knowing if they could withstand a blast. So the both up front and if repairs are needed at any point.
windows must be blast tested, and when considering
doors, the door itself must be tested, as well as the You must also consider if the interior space of the
latches and hardware. building needs to be ADA compliant. This will mean
wider door frames, ramps, possibly lower counters or
Adding windows to the building means that the studs workspaces and other considerations for those with
must be cut to accommodate the windows. Cutting the disabilities.
studs of a blast-resistant building means that there is
engineering involved to determine that it retains its Special accessibility for ADA compliance is also taken
structural integrity. into consideration when figuring a bid for a blast-resis-
tant building.
When it comes to windows and doors, we must figure
the cost of raw materials, and also the cost of engi- The Type of Foundation that is Planned:
neering required for the placement, to ensure that the A blast-resistant building can be placed just about
building is safe. anywhere. Temporary buildings are often placed on
 gravel or dirt; more permanent buildings are put onto a authority over that location may have its own set of
slab or foundation. It all depends on the requirements unique requirements. The authority having jurisdiction,
that may have been laid out in a facility siting study. or AHJ, could be at the local city or state governmental
levels, or, it could be OSHA.
The properties of the base directly affect the type of
anchors that are used, or if anchors are used at all, At the beginning of the planning process, these
which also affects the cost. There are too many types of requirements will be considered, and there will be
anchors and ways to anchor a building to go into all of costs associated with compliance and with any
the variations, but you can expect it to be an element third-party review that is required.
that will affect the cost of your blast-resistant building.
Some AHJ requirements could be things like the
Ultimately you must ensure the installation will fully addition of fire sprinklers or alarms, specific kinds of
utilize the safety capabilities of the building. For plumbing fixtures or electrical finish, equipment to
example, temporary dunnage should not be used to improve air quality or control emissions, to name a few.
“prop up” BRBs over uneven surfaces.
Master Service Agreements:
If Pressurization or Gas Detection are Required: If you have negotiated a Master Service Agreement, or
If the hazardous elements present require the use MSA, that could affect the cost of the building in a
of pressurization and gas detection, “time is money” sort of way. An
that is yet another element that MSA ensures that terms and
affects the cost of the building. conditions have been negotiated
Consider that every element of up front, so that time is saved in
a blast-resistant building the decision-making process. This
is interconnected. is particularly true when leasing
blast-resistant buildings.
When you add gas detection, other
elements of the building could be You can also make sure there is
affected as well, because now you consistency among facilities and
must consider, for example, how all that all parties are on the same
the doors are sealed since each door page when it comes to needs and
could be an access point for toxins. requirements.

Adding pressurization means adding When you’ve experienced excel-

fresh air stacks and possibly other lent service, an MSA is a good
components, which could add some way to ensure that the level of
complexity to the project and this, in service is reached when addition-
turn, affects the cost of the building. al projects are starting. This will
help you build a relationship of reliable service with a
For Stacked Buildings, the Addition of Stairs trusted vendor.
or Scaffolding:
If you have a limited amount of space on your site, you The Addition of Change Orders During the Build: It’s
might choose to use multiple buildings, stacked to important to make sure that when considering the cost
accommodate the space. When this is the case, while of a blast-resistant building, you are sure about the
you are saving valuable space, there will be additional final plan and have considered all needs. Once a
cost for stairs or scaffolding, and you may have to find company gives you the estimate for the amount of
those from another vendor. time it will take to engineer and design your building,
particular effort has been given to ensure that it meets
State-specific Requirements or Third-party Reviews all requirements and can be delivered on time and
Depending on where your building is being placed, the within budget.

redguard.com 11
Some companies won’t mention during the estimating The following are four levels of blast-resistant
process that changes during the build will lead not buildings. All of these prices would be considered
only to a change in raw materials, but additional costs custom-designed and would be 8psi/200ms, medium
for engineering. It must be determined that proposed response, and include electrical, HVAC and lighting
changes won’t affect the building’s structural integrity. systems.

Getting a quote quickly, with a proposed timeline that Note: These prices are general estimations only to
seems too good to be true, probably IS too good to give you an idea of the range of costs involved, but
be true. do not represent a quote on a specific project.

If you end up changing plans during the build, you will 1. 12’ x 40’ x 11’ - Standard open floor plan,
most likely see changes that will add additional time non-classified internal and external electrical:
and also unexpected costs. $290 per square foot
2. 12’ x 40’ x 11’ - Custom floor plan, highly
SO, WHAT IS THE COST OF A BLAST-RESISTANT custom features, pressurized with classified
BUILDING? external electrical: $455 per square foot
Once you’ve gone through the consultation process, a 3. 36’ x 40’ x 11’ - Custom floor plan, non-classi-
group of estimators, engineers, draftsmen, and project fied internal and external electrical: $335 per
managers all work together and begin putting together square foot
a comprehensive proposal for the cost of your blast-re- 4. 72’ x 45’ x 13’ - Custom floor plan, highly
sistant building. customized HVAC, classified external electrical,
custom interior finishes: $365 per square foot
The process depends on the number of buildings being
quoted, the complexity of the project, and the sourcing It’s important to note that the examples listed above
of custom components. Once they’ve completed this shouldn’t be considered base prices for a building.
process, they’ll get back in touch with you to submit These are merely ranges of some of the most common
their official bid for the project. projects that we see. Your job will be affected by the
type of use for the building, hazard level, size, length of
Now that you have an understanding of many of the the lease, and even environment. Additional building
different considerations and factors involved in or structural considerations can affect the cost of a
determining the cost of blast-resistant buildings, blast-resistant building.
here’s what you can expect to pay, on average.

redguard.com 12
 - CHAPTER 7 - 2. WINDOWS MUST CONFORM TO NECESSARY BLAST
WHAT ARE THE PROBLEMS WITH BRBS? RATING
The presence of windows in a blast-resistant building
As a rule, many companies will avoid talking about design has a direct correlation to its blast-rating. This is
problems with their products. At RedGuard, we referred to as a single degree of freedom. Since a blast-
acknowledge that there are potential problems on ALL resistant building is no stronger than its “weakest”
products, and it’s been our experience that transparen- component, the area the building is located will some-
cy serves the customer well as they research a decision times determine the presence and size of windows.
of this size and magnitude.
In general, blast-resistant buildings that are designed
In this chapter, you’ll find out about some of the for placement in areas that may experience a higher
challenges with blast-resistant buildings and their psi blast will need to have smaller windows. These
solutions. In no particular order, here’s what we’ve areas are places like a factory’s alkylation unit or other
found: areas that have toxic gases or high-pressure pipelines.

1. BLAST-RESISTANT DOORS ARE HEAVY! Windows in these areas typically serve a utilitarian
Yes, blast-resistant doors are heavy, some weigh in at purpose, like monitoring an area, viewing a control, or
450 pounds or more. It makes sense, because they’re interacting with personnel. Buildings that are the
blast-resistant and made of heavy steel. The weight closest to dangerous processes may not be able to
means that they have hydraulic mechanisms to have windows at all.
make opening and closing them easier, and
to prevent slamming. If you are leasing your blast-resistant
building, this might mean that you
Because of these factors, blast are at the mercy of the available
resistant doors require regular inventory. For this reason, it’s best
maintenance to avoid sagging and to begin planning well in advance
out-of-alignment hinges or to ensure the availability when
latches. Without proper care, the windows are required. If a window
doors may not close properly, is a desired amenity but is not
which could affect the building’s required, you would then follow
efficacy in a blast event. And, the best practice of using a
while it’s not common, a large, building with a higher psi rating.
heavy door could cause injury if it’s not
properly maintained and slams on a hand or
foot. - CHAPTER 8 -
FOUR REASONS FOR SER-VICE CALLS ON
WHAT CAN YOU DO? BLAST-RESISTANT BUILDINGS
To avoid problems with these doors, it’s important to
note that they should never be left open to allow the Along with problems, when researching a major
free flow of traffic. Leaving the door open will allow the purchase, it’s a good idea to look at what kind of
blast wave to enter the building in the event of an maintenance will be required and what the most
explosion. common reasons for service on a blast-resistant
building are. It’s a great way to know about some of the
Regular maintenance will also help prevent problems costs that may be required down the road.
with blast-resistant doors, and could include some-
thing as easy as a visual inspection to ensure that all In this section, we break down four types of service
fasteners are tight and that hinges and latches are calls for blast-resistant buildings that are important to
functioning. We’ll talk about maintenance of blast know about before you buy. These are listed in no
resistant doors in more detail in the next chapter. particular order, and don’t necessarily denote that all
buildings will have these issues.
redguard.com 13
1. Service For Poor HVAC/AC Performance • Do the door handles need to be tightened or replaced?
Typically, when an HVAC/AC needs service, there is a How is the viscosity of the fluids in the door’s hydraulic
filter that needs to be changed, and/or the coils need to mechanisms? In areas where temperatures are subject
be cleaned. Occasionally, the technician will also reload to change, the viscosity of fluids could be affected,
coolant or replace a sensor if it’s not functioning. causing doors to slam or have difficulty latching.

At RedGuard, our blast-resistant buildings are designed • If you’ve decided to take on this maintenance your-
with specialized HVAC units to provide proper and self, you’ll need to know what to look for and how often.
sufficient heating and air conditioning for that building An effective service team will be ready to either guide
or unit size. We recommend that they run in an ambi- you through the process or come out to make regular
ent setting of no lower than 73 degrees for cooling and inspections during building maintenance.
no higher than 78 degrees for heat.

These units are often placed in locations with extreme • And, while the doors are heavy, it’s important to
temperatures that require the units to run more remember that they are a factor in saving lives. Doors
frequently than other commercial installations. Higher on blast-resistant buildings should never be propped
traffic in and out of the building will also cause it to open. The amount of wear and tear on the doors when
run more frequently and need service more often. they weigh 450 to 800 pounds, and the amount of
traffic going through the doors in one day are signifi-
Due to the environment, usually places with more dust cant factors in these repairs.
and particulate in the air, the filters should be changed
regularly, preferably every thirty days. In hot, dusty 3. Issues With Floors Or Ceiling Tiles
climates or where debris is more common, they may Issues with floors and ceiling tiles that need to be
need to be replaced even more often. replaced are another cause for service, though these
problems are seen less frequently than the previous
2. Maintenance On Blast-resistant Doors issues mentioned.
• A visual inspection of blast-resistant doors should be
done every 60 days, or more often in high traffic areas. The nature of the work in and around blast-resistant
The visual inspection will include checking these details: buildings calls for heavy footwear. Heavy boots will
track dirt, mud, or other particulates into the buildings.
• Does the door seal correctly or have issues with That can loosen or displace tiles.
slamming? Those are signs it needs to be serviced.
Are the hinges still aligned properly? Because of its Extreme temperature variances can be another issue
weight, the door may need to be realigned on its for floors. Excessive heat may cause flooring to warp or
hinges or replaced. buckle, and cold temperatures may loosen adhesive.

redguard.com 14
 These issues are important to repair, so that you can is a made-to-order blast-resistant building that
avoid the risk of someone tripping and falling on a follows exact specifications for a capital project. It
loose floor tile. could be a complex building that combines uses, like
a control room, conference rooms, offices, and
Some blast-resistant buildings may use a painted floor restrooms - all in one building, made up of several
surface with a texture added in to make them non-slip. blast-resistant modules.
While this flooring won’t have the issues above, they
may require resurfacing at some point to maintain It may incorporate a specialized HVAC system,
their non-slip texture. positive air pressure (to keep clean air in, and contam-
inants out), or any number of special needs. As a
Ceiling tiles will also occasionally need to be replaced if blast-resistant building, all internal elements will be
they become soiled from poor air quality, or due to water vetted for safety, and the building itself will have a
damage. (See next issue!) hazard rating that matches the needs of the project.

4. Water Leaks In Multi-section Buildings As a modular building, the majority of the work is
Water leaks in blast-resistant buildings do happen completed offsite and there may be several rounds of
occasionally. This isn't an issue that is seen frequently, changes, and engineering to be considered. A project
it's not even among the top reasons for service calls, but manager will keep track of all the necessary commu-
it's worth mentioning, so that there are no surprises. nications back and forth on your custom project. Once
the work is finished, it will be shipped to your
The silicon and joiner material used when attaching or location, carefully placed, assembled, and finished.
bringing two buildings together is also sensitive to Typically, in a modular build, you can get the same
ambient temperature, and there can occasionally be amenities that you would find in a stick-built (tradi-
issues with adherence to the surfaces of the two tionally built) building.
buildings being joined.
WHAT IS A PRE-ENGINEERED BLAST-RESISTANT
Sometimes these joints can experience leakage during BUILDING?
heavy storms. When this happens, you should call a As mentioned, a recent entry into the blast-resistant
technician to inspect the surfaces and repair the water building market is that of “pre-engineered” modules.
leak, and any resulting damage to the interior. These are similar to custom blast-resistant modules in
that they are “suite-quality” buildings, with construction
- CHAPTER 9 - completed off-site, and then delivered and finished.
MAKING CHOICES ON A CAPITAL PROJECT
Suite-quality refers to the level of finish in things like
Custom or Pre-Engineered? A comparison. walls, electrical systems, plumbing (if present), and
Often, the purchase of a blast-resistant building is part even some of the other internal elements of the
of a specialized capital project. That doesn’t have to building. You can expect that “suite-quality” will be of
mean a complicated custom project. Recently, the higher quality than that from a rental fleet.
addition of “pre-engineered” buildings added some
flexibility to capital project decisions.
With pre-engineered, the customer looks over avail-
This chapter goes into the differences between a able floor plans and matches them to their needs. The
custom blast-resistant building and a pre-engineered elements that make the building blast-resistant, like
blast-resistant building, as well as scoping out how to the “rib-cage” structure of the external walls and
decide which choice works best for you. steel-reinforced doors are still present in a pre-engi-
neered building and there are several standard config-
WHAT IS A CUSTOM BLAST-RESISTANT MODULAR urations available, all with completed plans and
BUILDING? engineering. The build starts once the layout is chosen
As it sounds, a custom blast-resistant modular building and needs are discussed.

redguard.com 15
ADVANTAGES OF A CUSTOM BLAST-RESISTANT DISADVANTAGES OF A CUSTOM BLAST-RESISTANT
BUILDING BUILDING
Now that you have a short description of each, let’s When someone is trying to sell you something, they’re
weigh the advantages of opting for a custom blast-re- going to shy away from talk of “disadvantages.” But we
sistant building for your capital project. look at disadvantages differently. We realize that each
one of these options (custom or pre-engineered) will
1. Your Options Are Completely Open be a better choice for different people. We’d like to
The main advantage of a custom blast-resistant help you sort that out. Here are some of the reasons
building is that you get exactly what you want. that a custom build might not be for you.

If your project is complex, that means you won’t have 1. Custom Buildings May Cost More
to compromise a thing. If you need a very tall building, Unlike some custom products, when it comes to a
to accommodate lowering the ceiling for duct-work, RedGuard blast resistant building, there is no auto-
that is easily done. If your control room’s specifications matic mark-up just because the project is custom. We
require a platform floor to hide wires or other comput- know that for capital projects, time IS money and
er/communications elements, no problem! If you need that’s the major differentiator. So, a custom building
exactly six offices that are of a specific non-standard may cost you more in time resources.
size - you can get it!
Some capital projects managers are turned off by the
2. Get The Exact Hazard Rating That You Need Another lead time on custom projects. It’s understandable when
advantage to a custom blast-resistant building is that they’re in a situation of having a budget, but needing to
the hazard rating can be exactly to the number called for spend it quickly before things change! Once a company
in your facility siting study. So, if you only need a 1, 2, or is acquired or sold, all bets are off when it comes to a
3-psi building, you can get exactly that! project that was in the making. For many in our indus-
try, spending that budget quickly is paramount.
You also may be able to incorporate shelter-in-place
elements that you might not be able to get in something 2. More Decisions To Make / More Communications /
that has a predetermined layout. This might be elements More Approvals
like gas detection, fire protection, or air filtration. If you’re creating something custom, that means there
are more options and more decisions to make.

redguard.com 16
 And, depending on your approval process and the 2. Pre-engineered Saves Time
number of people involved, that might mean more We’ve used the word “time” in this piece enough to
communications that need to happen and a waiting emphasize that we get how important it is. Our
period for each one. Going back to the concept of "time buildings are designed using a proven blast-tested
is money," this may again be a detractor. design. When you choose pre-engineered, you will
shave weeks off of the process by simply choosing your
Our Project Managers are skilled in communicating preferred layout from a variety of standard options and
with customers for custom projects, but we know that then outfitting it for your capital project.
the more people involved when approvals are needed,
the more likely to add time to the project. We are The standard options are created by evaluating the
always respectful of the time it takes to fulfill a custom standard options that customers in the industry
project, but we acknowledge that they take more time. selected most often and making floor plans to fill
those needs. Our pre-engineered modular buildings
ADVANTAGES OF A PRE-ENGINEERED BUILDING Now have proven to be very popular among midstream
that you know some of the advantages (and the facilities, but have also found homes on downstream
challenges of a custom building, let’s take a look at refineries as well.
the advantages for pre-engineered buildings.
DISADVANTAGES OF A PRE-ENGINEERED BLAST-RE-
1. Hazard Ratings With A Higher Psi SISTANT BUILDING
When a building is a standard design, that means it There’s that word again - disadvantages. We’ve strug-
has to accommodate a greater number of users and gled in this article with the term disadvantages
circumstances. That means with a pre-engineered because both of these building types are top of the
building, it may already be designed to withstand a line and will be valid for specific use cases.
greater blast load. That is true of our RediSuite line, for
example, which has a hazard rating of 8 psi/200 msec. But, of course, there could be elements that mean it’s
That means you are getting more protection for your not the right choice for you. The following “disadvan-

B
R
10 200 LOW/MED.
MSEC

ASCE

B
PSI

RESPONSE

money. This may seem like an irrational thing to think tages” are some of the reasons that you might decide
of as an advantage if you only need 2 psi, for example, to take pre-engineered off your list.
but when you look at the long term, it could work out
in your favor. 1. Height of a Pre-engineered Blast-resistant Building
With a standard configuration, you may need to look at
Things change all the time on worksites, including the your needs and decide if you can fit them into the
boundaries of a hazardous zone. When you get a facility layouts that are available. One thing that can’t change
siting study done in the future, that area could require is height. A standard pre-engineered building starts
more protection. It could be that processes have with a greater height than most fleet buildings, but at
changed and that control room that once only required 11 feet may still not reach the height that you require, if
a building rated for a 3 psi blast, now requires more. It’s you need dropped ceilings or computer platform floors.
always good to have more protection than you need.

redguard.com 17
2. Standard Configurations A custom blast-resistant building is your starting
We’re able to accommodate many requests to make a point if:
pre-engineered building fit your specifications, but • If you have a highly specific layout in mind and
there are some projects that are much more complicat- many specialized needs that can’t budge
ed than pre-engineered will allow. In those cases, a • You need a building that has a hazard rating of a
custom blast-resistant building is the way to go. very specific rating
• You have the time to work within the time frame
Pre-engineered layouts won’t work for every project, nor that a custom project will require
should they. But it’s always worth talking to your vendor
to see what elements can change and what can not. Start by considering your pre-engineered options if:
• You have a little bit of room for flexibility in your
layout
• You can work with a hazard rating of 8 psi (even
if you require less)
• Your time is of the essence and you’d like to get
this project rolling as quickly as possible.

- CHAPTER 10 -
WHEN SHOULD YOU LEASE A BLAST-
RESISTANT BUILDING?

If buying a blast-resistant building is not the solution

you’re looking for, but you still need the protection that
comes along with it, many companies offer a range of
blast-resistant buildings that can be leased temporarily.

This chapter is all about “what you need to know” about

leasing a blast resistant building that can help you get
an accurate quote and plan around potential obstacles.

3. Hazard Rating Could Be Too Low While the use of blast-resistant buildings is wide-
If the requirements for your project require a higher spread, there are still many in the industry who have
hazard rating than the pre-engineered buildings that not utilized modular buildings during outages and
you are considering, that’s an element that cannot projects. Instead, they stage operations outside the
change and will automatically take pre-engineered off facility and transport labor in and out.
the table for you.
Over the past ten years, the use of modular blast-
In other words, if your project requires a 10 psi build- resistant buildings in refineries and chemical plants
ing, and the pre-engineered line has a hazard rating of has dramatically increased due to their wide range of
8 psi, that means it will not work for your use and you benefits. Both permanent and non-permanent use of
should consider a custom blast-resistant building. blast-resistant buildings has proven to be cost-
effective, efficient, and reliable throughout many
WHICH IS BETTER FOR ME? spaces in the oil and gas industry.
Weighing all of these differences, we hope that you are
now more informed about two excellent options for LEASING BLAST-RESISTANT BUILDINGS: WHAT YOU
your capital project. One of them may already be a NEED TO KNOW
standout for you. If you have not leveraged the advantages of blast-
resistant buildings on-site yet, the following list is what

redguard.com 18
 you need to know to get started. Providing this infor- leading to a facility. Then, identifying any overhead or
mation to your supplier will set up an excellent width clearances inside the facility is critical.
opportunity to generate an accurate quote and help
you identify and plan around potential obstacles. Layout: If space is limited in the work zone, proper
sequencing and layout of units optimize the space.
Understand your needs: Blast-resistant buildings are There are seemingly unlimited configurations for a
excellent structures for cafeterias, break rooms, tool blast-resistant building’s long, rectangular shapes.
sheds, equipment storage, and spaces for offices, Ensuring the buildings arrive on-site in the correct
permitting, or security. Identifying specific operations order is a critical element. In the staging portion of a
and trades that drive improved cost-efficiencies while project, there is typically not much lay-up space
being located in the hazard areas is a starting point available to leave large buildings sitting temporarily.
for understanding their importance.
Utilities: Many blast-resistant buildings require an
Capacity: Headcount drives the quantity of blast-re- electrical supply, and communication connections for
sistant buildings needed. The dimensions of blast-re- LAN or WAN networks. Additionally, units with working
sistant buildings are wide-ranging. There are small plumbing require a potable water supply and waste
8-foot units suitable for one to two occupants and connection. On short-term projects, power can come
“multi-section” complexes that can be merged into from generators or site supply. Networking into a
single buildings hundreds of feet wide. Knowing your facility’s communication network is generally straight-
headcount tells you what size building is required. forward. Identifying utility sources and their locations
is a critical piece of the planning process.
Hazards: Recognizing the hazards and specifying
correctly rated blast-resistant buildings are critical for Timing: Establishing start and end dates will provide
creating safe and compliant spaces. When it comes to cost-certainty and allow the blast-resistant building
blast-resistant buildings, there is significant data and supplier to adequately plan for availability, delivery, and
engineering that ensure the correct units meet or pickup. High utilization during certain times of the year
exceed the site’s hazards. can limit availability. Sharing your project’s anticipated
start and stop dates early in the planning process will
Access: Standard blast-resistant buildings are large. offer you greater selection and availability.
Access for truck delivery and crane offloading should
be planned. That starts with your vendor understand- Demobilization: Like all projects, having a vision for a
ing curfews, limits, and clearances on public roads strong finish ensures a clean, organized completion.
redguard.com 19
Efficiently disconnecting utilities and cleaning the 2. ARE BLAST TEST REPORTS SPECIFIC
units allow for an organized, staggered schedule of AND CONCLUSIVE?
trucks arriving to remove units from the site as quickly There are many interpretations of the term blast-test-
as the crane and rigging crew can safely lift, place and ed, but a successfully blast-tested building has the
secure each unit. proven ability to actually save lives. Pay special
attention to duration and psi ratings when you review
- CHAPTER 11 - blast test reports because different applications call
FIVE QUESTIONS TO ASK BEFORE CHOOSING for different specifications. A laboratory blast-resis-
A BLAST-RESISTANT BUILDING tant building placed next to a blowdown stack should
carry a higher rating, such as 8 psi, while a guard
Before pulling the trigger on purchasing or leasing a shack placed at the perimeter of your facility may only
blast resistant building, this chapter gives you a need a 3- to 5-psi rating.
guideline of the important questions to ask your
vendor that can save you from headaches. 3. WAS IT BLAST-TESTED FOR NONSTRUCTURAL/
STRUCTURAL COMPONENTS?
1. WAS THE MODULE DESIGNED AND TESTED BY A If a structure survives a blast but its interior walls,
BLAST EXPERT? lights or other fixtures create shrapnel, the risk of
The science of blast-resistant building design is no casualties is still high. Always ask blast-resistant

?
? ? ?
?
longer a new science, but it is still true that not all blast building vendors to provide data and rationale for
resistant building makers have tested their designs. nonstructural items including wall and ceiling finishes,
light fixtures, plumbing fixtures, cabinets, placement
Make sure your blast-resistant building design has of open shelving and placement of any intake points.
been taken off the drawing board and successfully
blast-tested under the supervision of a well creden- 4. CAN THE FOLLOWING INFORMATION BE PROVIDED?
tialed engineer. There's no shame in asking about your The following items are too technical to cover in the
vendor's "experts" - who they are and about their context of an online article but should be on your list
training and background. Do they have years of of discussions to initiate with any blast-resistant
experience in the science of blast-resistant design, or building vendor.
did they take a three day course to qualify them? 1. Was the blast-resistant module tested dynami-
cally rather than statically?
2. Was it tested in a free field environment?

redguard.com 20
 3. Was a P-I (pressure-impulse) curve generated to MOVING INTO PROJECT MANAGEMENT
show the blast-resistant building's response over a Once a purchase order (PO is received, the project is
wide range of blast loading? handed over to the project management group. At that
time, a purchase order review begins to make sure that
5. DOES THE BUILDING'S RESPONSE LEVEL DEMON- the company can/will accept the purchase order.
STRATE ITS CAPABILITY TO SAVE LIVES?
If close examination of a manufacturer’s data demon- Not all POs are accepted immediately. Sometimes the
strates a high-response result, this is not the structure blast-resistant building manufacturer requires changes
you want protecting your personnel. Response level in the contract language, or there could be details to
ratings have been established to predict the extent of be clarified before the PO is formally accepted.
repair resources needed after an explosion. Here's the
key, as we’ve mentioned: high response equals high Occasionally, some new specs may show up in this
damage. It's crucial to study the response level table, stage. For example, the purchasing agent may not have
then take a very close look at any blast-resistant clarified the type of HVAC system required or whether
module's response rating for a given duration and psi the system should be redundant. Before the PO is
(as proven through actual blast testing). accepted, the building vendor will send it back with
language defining these types of details, and the
customer will need to approve the additional details.
- CHAPTER 12 -
WHAT HAPPENS AFTER THE SALE? Depending on the complexity of the changes, and the
ALL ABOUT PROJECT MANAGEMENT responsiveness of those involved, getting the PO
approved could take between a few days and a few
Another thing to consider just before making your weeks. The project manager will do what they can to
purchase is what happens after the sale. Is it just a ensure the process keeps moving until both parties
matter of waiting? Will you get updates? Will the sign-off on the PO.
timeline change? Is my sales rep still the main contact?
THE KICK-OFF AND DESIGN STAGE MEETINGS
The next step is project management and experienced Once the purchase order is formally accepted, the floor
vendors and manufacturers of blast resistant buildings plan is emailed to the customer for review and an
should be able to paint a picture of what that process initial kick-off meeting is scheduled.
will look like.

redguard.com 21
The kick-off meeting gives the salesperson the oppor- Project sizes can vary from simple single unit build-
tunity to introduce the customer to the project manag- ings, which may be ready in a matter of weeks, to large
er, and for the project manager to begin talking about multi-section complexes which could take months, or
expectations for the project. During the kick-off meet- the better part of a year. The best way to find out the
ing, the customer has reviewed the floor plan in timeline is to ask about the specific details for
advance, allowing for more design conversations to your project.
begin. In this meeting, there will also be a detailed
review of the architectural, mechanical, electrical, As a general rule, ask questions. How will the project
plumbing, structural, and blast components of the be managed? What happens if we have change orders?
building. Additional meetings may be required for each Will this change affect my projected delivery date?
of these components of the blast-resistant building.
In most cases, project management begins when the
Once the project is under the care of the project order is accepted and ends when it leaves the vendor’s
manager, the original salesperson will be relatively production facility. Once the blast-resistant building is
hands-off unless their assistance is needed. For installed, regular maintenance and any issues that
example, their assistance may be required to discuss come up are handled by a qualified service department.
change orders or commercial changes, which occur
when there are customer-driven changes that result in CUSTOMER APPROVAL AND FINALIZING DESIGNS
an increase or decrease to the contract price. Once the kick-off meeting has occurred, initial intro-
ductions have been made, and the customer signs off
Depending on the customer’s preferences, calls will be on the floor plan, then things begin to move forward.
set up weekly, or updates can be given periodically by It’s important to have an approval process in mind on
email. The important part is to keep an open channel your end when approval is required at other stages. This
for communication flowing. will help the process run in a timely manner.

BLAST-RESISTANT BUILDING TIMELINES Other meetings that will need to occur and places
There’s no real way to narrow down how long a blast-re- where other approvals may come into play will be when
sistant building project will take since the timeline will discussing the architectural, mechanical, electrical,
vary based on factors like building size, design plumbing, structural, and blast components of the
complexity, material availability, state-specific approv- building. Each of these components will need to be
al processes, and project backlog. reviewed and approved using detailed pdf files.

redguard.com 22
 These drawings will call out the placement and around the mess of a construction site. There’s no
specifications for each of these elements, which were re-routing of trucks.
not detailed on the floor plan.
During the construction phase, the customer will get
THIRD-PARTY APPROVAL FOR BLAST-RESISTANT updates as needed, including progress photos. There’s
BUILDINGS no way to nail down how long the construction of a
Each build-site is different as far as requirements for blast-resistant building will take because each project
blast-resistant buildings. Some states have strict is different. It’s all dependent on the construction
environmental guidelines (California comes to mind), queue of the vendor, the size of the building, and the
some follow another set of standards, like OSHA or complexity of design and elements.
other federal, local, or regional guidelines.
A typical build, for example, a simple three-plex or
Your blast-resistant building manufacturer will be smaller, may take 16-20 weeks from the time drawings
responsible for ensuring that the building meets all are approved. Other complex projects will take more
requirements of the local authority having jurisdiction time. Your vendor should be able to talk in more detail
(LAHJ) and will set up any third-party reviews that about this, based on the specs of your individual
need to happen. project. There are occasionally ways to expedite builds,
but it’s not a good practice to rely on that to happen.
These requirements could add things like fire sprin-
klers, devices to improve air quality or emissions, or The last thing to happen while the building is still at
any number of details meant to protect the occupants the vendor site is the factory acceptance test. The
of the building. It is the responsibility of the vendor to building is put together at the facility, just like it would
know and expect these requirements. be on the customer’s site. Some customers may choose
to do a final onsite walk-through; others may give
CONSTRUCTION OF THE BLAST-RESISTANT BUILDING approval based on photos of the finalized building.
Because they are modular in nature, the construction This can typically be done in a day.
of blast-resistant buildings happens before they ever
get to your site. This is one of the greatest benefits of TRANSPORTATION AND INSTALLATION
modular construction. Once the final walk-through has happened, there will
be no time wasted before the build is on the road. If
In short, this means there’s much less of an impact on the building is a multi-plex, it could take several trucks
your site operations. There’s no period of downtime for to get it to its final destination.
the space the building will occupy. There’s no working

redguard.com 23
Some companies have their own transportation fleet, worst-case scenario when they come up, but avoiding
while others rely on outside sources. And some will use them will always save you time and money. Following
a combination of their own trucks and third-party the advice here, as well as keeping the lines of communi-
transportation sources. cation open, and the team informed, will serve you well.

PROJECT MANAGEMENT CHALLENGES WRAPPING IT ALL UP

According to the project managers at RedGuard,
working through the design process without delays is At RedGuard, we design and build blast-resistant
the biggest challenge in managing blast-resistant buildings and have been doing it since 2005. All the
building projects. related details are on our minds every day, for at least
40 hours a week, but we know that our customers have
Designing a building requires a lot of information and more to think about. That’s why our team of experts, in
input from the customer. Sometimes there is informa- Sales, Estimating, Engineering, and Project Manage-
tion that is not available during the bid phase. ment, are ready and willing to answer your questions
and consult on your project.
AWAITING DETAILS
Examples of some information that may not be avail- No matter how much experience you have with capital
able before the PO is issued are things like the actual projects or turnarounds, let’s start talking about your
electrical load requirements for equipment that is goals and see if it makes sense to put a RedGuard
supplied by the customer, the expected use for each blast-resistant modular building on your worksite.
room in the building, and final details like color or
finish selections. Waiting on these things can slow No two hazardous worksites are alike, so no two
down the initial design process. blast-resistant projects are alike. Our expert team can
help you start planning your project to save you time,
GETTING EVERYONE INVOLVED money, and, most importantly, lives.
Another hold-up is that sometimes the person who’s
been involved on the customer side, the purchasing
agent, isn’t the end-user of the blast-resistant building.
Once the end-users become involved, they may have
valuable information or knowledge of the project that
will require changes during the initial review. For this
reason, it’s helpful when decision-makers and the
building’s users are both involved during the bid process,
so all details are resolved prior to project award.

CHANGE ORDERS
Change orders are a fact of life in the management of
blast-resistant building projects, so it’s not the

At RedGuard, we focus on five key disciplines: concept, design, build, installation and operation. We have already earned the respect of oil and gas industry
professionals throughout the world. As the leading authority in the area of modular safe space, we are proud to serve the world’s largest corporations and look
forward to earning your business and your trust.

CONTACT US ONLINE | REDGUARD.COM TOLL-FREE | 855.REDGUARD EMAIL | [email protected]

OUR GLOBAL FOOTPRINT

Central U.S.A Gulf Coast U.S.A Asia Europe
Wichita, KS New Iberia, LA Singapore 508988 Aberdeen, United Kingdom ®

Southern U.S.A Canada Middle East Rotterdam, The Netherlands

Baytown, TX Calgary, Alberta Dubai, United Arab Emirates
redguard.com