Live-site plant reconstruction with furnace and warehouses
A complex plant rebuild delivered while production continued– multiple work fronts, phased demolition & reconstruction. Operations stayed uninterrupted throughout.
Factory65,000 m²
Glass manufacturing
On schedule
Production facilities with furnace and warehouses
Sofia Bulgaria
65,000 m²
Glass manufacturing
On schedule
Production facilities with furnace and warehouses
Sofia Bulgaria
Planning
The works were planned around uninterrupted 24/7 production, with multiple work fronts running in parallel across the plant. High groundwater and sandy soil required dewatering during execution, while phasing was structured to protect production and warehouse operations located in different parts of the site.
24/7 live-site phasing
We sequenced the works to keep production running continuously.
Groundwater control
We used a pumping system to lower the water table during works in sandy soil conditions.
Multi-front coordination
We planned several work fronts across production and warehouse areas within one active plant.
Designing
Design began with extensive surveys and expert assessment due to missing as-built documentation and legacy installations. The scope also required coordination with local authorities to realign plant border limits with historical maps, ensuring the redesign matched both the site reality and official documentation. The design preserved stability while adapting the buildings to new operational needs.
Surveys replacing missing documentation
We carried out extensive surveys to close gaps caused by missing as-built documentation.
Authority coordination on plant limits
We worked with local authorities to realign plant border limits with official maps.
Stability-first adaptation
We updated the design to meet new needs without compromising existing structures.
Building
Delivery took place in a live industrial environment with continuous focus on protecting people, production, and maintenance equipment. Works were executed without disturbing raw and recycled material flows, while production continued by disciplined sequencing and clear site control.
Live-site protection measures
We managed zones and routines to protect people and critical equipment.
Uninterrupted material flows
We maintained raw and recycled material movement throughout execution.
Continuous operations maintained
Production stayed live while works progressed 24/7.
Maintaining
Maintenance programmes and training were prepared for the client’s team to support consistent upkeep and reliable operation after delivery.
Maintenance programmes
We prepared a structured post-handover maintenance approach for the facility.
Client team training
We trained the client’s team to support safe, consistent upkeep.
Operational readiness support
We aligned handover inputs to help the team maintain performance over time.
Quotes from Project Manager
“We rebuilt most of the plant while production stayed live– demolishing 35 buildings and keeping operations running 24/7.”
— Project Manager, GFS Engineering
