Expanding glass production facilities with furnace
A live-site expansion for a glass plant– delivered without interrupting 24/7 production, while upgrading structure and preserving a consistent vintage look of the facility.
Factory16,000 m²
Manufacturing
6 months
Production facilities with furnace
Bucharest Romania
16,000 m²
Manufacturing
6 months
Production facilities with furnace
Bucharest Romania
Planning
The project was planned around one non-negotiable constraint: keep production running 24/7 while expanding and upgrading the facility. Early planning focused on sequencing works safely around live operations and addressing high groundwater and sandy soil conditions– so structural stability and schedule could stay under control from day one.
Injected piles
Adapted foundation solution for sandy soil and high groundwater conditions.
High-capacity dewatering
Pumping system designed to lower the water table during works (over 135 m³/hour).
Under-foundation construction
Structural elements erected below the level of existing massive foundations– without compromising stability.
Designing
Design started with extensive surveys and expert assessment, due to limited historical documentation and incomplete legacy drawings. The goal was to preserve the stability and character of a 1960s structure while modernizing it cleanly—avoiding visible “patchwork” and delivering a result that feels new, yet keeps the building’s vintage identity.
Expert surveys and diagnostics
Extensive site and structure surveys to replace missing as-built information.
Stability-first adaptation
Design updates introduced new functional needs without compromising the existing structure.
Architectural consistency
Modernisation executed without “patchwork” on the facade—preserving the look in its surrounding context.
Building
Works were delivered in a live industrial environment with continuous focus on protecting people, production, and maintenance equipment. Construction was organised to avoid disturbing raw and recycled material flows, while the plant continued producing at high output—so the facility could evolve without operational disruption.
Live-site protection measures
Work zones and sequencing designed to protect people, operations, and critical equipment.
Continuous production coordination
Construction aligned with production routines to avoid stoppages during 24/7 operations.
Material flow continuity
Raw and recycled material logistics maintained throughout execution.
Maintaining
After delivery, maintenance programmes and training were prepared for the client’s team to support reliable long-term operation and smooth day-to-day upkeep.
Maintenance programmes
Structured maintenance approach prepared for post-handover operation.
Client team training
Training delivered to support safe and consistent facility upkeep.
Operational readiness support
Handover inputs aligned to help the client run and maintain the facility confidently.
Quotes from Project Manager
“For a facility of this scale, the schedule was a real test. Strong control and follow-through made the difference.”
— Project Manager, GFS Engineering
