Projects Flagship Case Study

Multi-Site Firefighting & Dust Control Program

A large-scale safety and compliance program delivering integrated fire protection and dust control solutions across 20 operational industrial facilities.

Scale: 20 Sites Scope: Turnkey Safety Value: ~100M Scale

The Challenge

The client operated a large network of flour mills and industrial facilities facing regulatory pressure and operational risks. The challenge wasn't just installing one system, but standardizing safety across a diverse, aging infrastructure.

  • Varying levels of fire protection maturity across sites.
  • High dust generation in grain reception and processing areas.
  • Urgent need to comply with international and local fire codes.
  • Requirement to execute works without stopping production.
"The challenge was not one system — it was standardizing safety across an entire industrial network."

Program Objectives

To deliver a scalable, auditable safety program that achieved full compliance and reduced risk across all 20 locations.

Full Compliance

Meet all local and international fire/safety codes.

Risk Reduction

Mitigate fire and dust explosion hazards in critical zones.

Standardization

Unified systems and documentation across all sites.

Minimal Disruption

Execute works while maintaining plant operations.

Multi-Discipline Solution

Program Scope

Engineering & Audit

Site-by-site risk analysis.

  • Fire hazard analysis
  • Dust explosion study
  • Unified design standards

Firefighting Systems

Diverse suppression technologies.

  • Sprinkler networks
  • FM-200 / CO2 systems
  • Foam & Water Mist

Fire Alarm

Early detection and warning.

  • Addressable systems
  • Beam & Heat detectors
  • Central monitoring

Dust Control

Extraction and safe disposal.

  • Jet-pulse collectors
  • Cyclone separators
  • Dust conveying lines

Structural Works

Support infrastructure.

  • Equipment frames
  • Collector towers
  • Silo integration

Testing & Logic

System intelligence.

  • Cause & Effect logic
  • Panel integration
  • Site acceptance

Engineering Challenges Solved

Challenge 1

Varied Risk Profiles

Each of the 20 sites had unique layouts, ages, and hazard levels, making a "one size fits all" approach impossible.

Our Solution:

We adopted a risk-based design approach, classifying zones per site and selecting specific suppression/detection technologies to match the local hazard.

Challenge 2

Dust Explosion Risk

Grain handling areas posed severe dust accumulation issues, creating ignition and explosion risks.

Our Solution:

Integrated dust extraction systems with spark detection and explosion venting were installed and interlocked with the main safety logic.

Challenge 3

Live-Plant Execution

Production could not be stopped for installation, requiring work in active industrial zones.

Our Solution:

Phased execution plans, night shifts, and strict permit-to-work systems allowed installation to proceed without disrupting daily operations.

Program Delivery Flow

1. Risk Assessment (Per Site)

Hazard Analysis & Zoning

2. System Selection

Fire vs Dust Solutions

3. Detailed Engineering

Unified Standards

4. Fabrication & Supply

Logistics Coordination

5. Installation (Phased)

Live Plant Execution

6. Testing & Commissioning

Safety Verification

7. Standardized Handover

Auditable Documentation

One safety philosophy applied consistently across all facilities.

Program Outcomes

Safety & Compliance

  • Full regulatory compliance
  • Dust explosion risk reduced
  • Safer working environments

Operational

  • Zero major stoppages
  • Seamless integration
  • Optimized maintenance access

Program Management

  • Consistent standards (20 sites)
  • Simplified future audits
  • Scalable safety model

Why This Is A Flagship Project

This program proves our capability to deliver large-scale, multi-site safety programs. It required managing complex regulatory requirements, integrating fire protection with dust control engineering, and executing in live, high-risk industrial environments—acting as a trusted safety partner, not just a contractor.

Standardize Your Safety

If your organization operates multiple industrial sites and requires standardized, compliant, and auditable safety systems, this project demonstrates our ability to deliver at scale.

Discuss Your Program

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