The Job Challenge

When one of the nation’s top mattress pad and pillow manufacturers faced an extensive reroofing project, they couldn’t afford disruptions—or dust and debris contamination. TuffWrap’s SmartSeam Suspended Cover System provided the interior protection the bedding company needed during reroofing – keeping the manufacturing facility functional and employing construction.

The facility, built in the 1970s, required the removal of two previous roofs before installing a new one. Removing the two aging roofs meant a high risk of dust and debris infiltrating production areas, threatening product quality and equipment.

The job required the prevention of dust and debris from entering the company’s storage and production areas and potentially damaging sensitive bedding products and equipment. Louisville Bedding’s day-to-day operations needed to continue without interruption.

In addition, ensuring the safety of the employees and protecting the products throughout the project were of utmost importance.

TuffWrap Solution

TuffWrap® Installations installed a temporary ceiling to protect against dust and debris falling from the roof deck during construction. The SmartSeam® Suspended Cover System provided complete dust and debris containment and uninterrupted operations.

Working within a tight work period, on 11 consecutive nights, our team secured the facility while addressing key concerns.

  • Create safe access points for the lifts
  • Ensure the capture of dust and debris
  • Protection of specialized work areas near the ceiling
  • Protect equipment, products, and other valuable assets
  • Meeting strict project deadlines

TuffWrap kept employees safe and products pristine — all while finishing ahead of schedule.

 

Conclusion

SmartSeam protects the bedding company. The 100% IBC Code-Compliant and FM-approved SmartSeam temporary ceiling barrier system kept dust and debris from entering the manufacturing facility. In addition, the Louisville Bedding Company, the largest manufacturer of mattress pads and toppers and one of the top bed pillow producers remained fully operational during the major reroofing project. The SmartSeam® Suspended Cover system protected the facility, ensuring the reroofing project commenced ahead of the projected schedule.

This solution effectively minimized the impact of the reroofing process on the company’s operations, ensuring protection for the facility, its workers, and its products. This successful outcome met the client’s expectations and reinforced the quality of TuffWrap’s service.

“TuffWrap has been great to work with. The project manager I worked with was very impressive. His skills and customer service presented the TuffWrap company in a very positive way. I also see the excellent support network you guys have in place. Great effort by all! I look forward to seeing you guys here, probably next year sometime when we do the next one. ”

– C. Price, Process Engineer, Louisville Bedding Company