Martinez Refinery

1. Schedule Execution

The project’s primary driver was schedule. As a refinery shutdown project with significant daily cost implications to the owner, Worley requested MSI to deliver all assemblies on site within 4–5 weeks from receiving design drawings—many of which were preliminary and not yet issued for construction. Despite this challenge, MSI successfully met all required milestones through strategic planning, extended shifts, and real-time coordination with all stakeholders.

2. Early Material Procurement

Given the compressed schedule, MSI partnered with Worley to forecast material requirements based on early-phase design packages. Our procurement team secured and pre-stocked all necessary materials, enabling immediate fabrication start-up without waiting for final IFC drawings. This proactive approach was essential to keeping the project on schedule.

3. Design Coordination

At the time drawings were released, final design was still ongoing. MSI initiated processing and fabrication based on detailed models derived from preliminary design documents, with full understanding—and Worley’s agreement—that revisions would follow. This required: • Strict AISC compliance for working from non-approved drawings • Close engineering collaboration • Maintaining flexibility for rework, adjustments, and design incorporation • Rapid adaptation to frequent design updates This process allowed the project to advance without delay while still ensuring alignment with the evolving design.

4. Fabrication During Ongoing Design Revisions

Fabricating structural assemblies while design was still progressing presented major QC and documentcontrol challenges. MSI’s QC and Document Control teams maintained: • Detailed revision logs for all assemblies • Weekly (and sometimes daily) change tracking • Verification of modifications against latest Worley revisions • Seamless communication between engineering, fabrication, and QC teams This ensured every assembly matched the latest approved design prior to shipment.

5. Fireproofing Coordination

Approximately 90% of steel assemblies required fireproofing. To support the fast-track schedule, MSI managed 24/7 coordination with JT Thorpe in Texas, tracking every assembly through all stages: • Fabrication release • Galvanizing completion • Arrival at JT Thorpe • Fireproofing start and end • Inspection and release • Final delivery to Martinez site This real-time tracking ensured uninterrupted progress and on-time delivery of all fireproofed components.

6. Galvanizing Operations

With 100% of assemblies requiring galvanizing, MSI worked closely with Inmermek to secure an unprecedented 1-day turnaround time for each delivery. MSI deployed a dedicated QC crew on-site at the galvanizer to: • Receive and clean assemblies • Label and prepare pieces for inspection • Coordinate immediate release to fireproofing or shipment This minimized bottlenecks and ensured galvanizing never became a critical delay on the schedule.

7. Inspection Coordination

All inspections were executed in collaboration with Worley, with inspectors integrated into every stage of the workflow. Inspections occurred: • At MSI’s fabrication facility during active production • At the galvanizer during cleaning and post-galvanizing • Prior to shipment to JT Thorpe • During fireproofing processes • Before final shipment to the Martinez site This continuous inspection approach ensured all materials met the required standards while keeping pace with the accelerated schedule.

8. Detailing Performance

The detailing team performed exceptionally under extreme time constraints. Highlights include: • Completing full project detailing in just 2 days using preliminary design • Turning around revised shop drawings within 12 hours for each design update • Ensuring all documentation aligned with Worley’s latest revisions Their efficiency was critical to enabling fabrication to begin immediately and continue without interruption.

9. Hardware and Quality Documentation

As required for refinery work and AISC standards, all galvanized hardware required ROCAP and associated testing. MSI’s purchasing team proactively: • Secured compliant hardware • Coordinated all testing and certifications • Ensured full documentation was ready for Worley and the Owner’s QA/QC requirements

10. Logistics Execution

MSI’s logistics team successfully coordinated one of the most complex material flows we have managed: • Raw material pickup • Shipment to MSI fabrication • Delivery to galvanizing • Transport from galvanizing to JT Thorpe (Texas) for fireproofing • Final delivery to Martinez refinery All completed within a 4-week window, involving approximately 42 truckloads, including additional grating shipments from Texas. This required constant tracking, communication, and precision scheduling across multiple states and vendors. Conclusion The Martinez Refinery project demonstrates MSI’s ability to execute high-complexity, fast-track refinery and industrial projects while maintaining the highest standards of quality, safety, and coordination. Through our integrated approach—covering detailing, procurement, fabrication, galvanizing, fireproofing, inspections, and logistics—MSI delivered a successful project under one of the most aggressive schedules in the industry. MSI looks forward to supporting Worley and other partners on future projects requiring reliability, technical expertise, and exceptional schedule performance.