Baltic Yachts
- Consideration of chemical safety in new production facilities from the design stage brought cost-efficiency to construction
Founded in 1973, Baltic Yachts is known around the world as a leading builder of advanced composite yachts. When it was decided to centralise the production of all parts for sailing yachts in Pietarsaari in 2020, the planning of an additional production hall was started. "I am very pleased that I was able to engage Protect as a consultant right from the design stage. In this way, chemical safety in the production facilities has been taken into account right from the start," says Tommy Björklund, Production Manager at Baltic Yachts. This is how the project went!
Chemical safety in production facilities is a critical part of Baltic Yachts' operations
When building modern vessels for Baltic Yachts, safety in the production facilities is one of the company's priorities. As lightweight and durable composite materials are processed using highly flammable materials and compounds, the consideration of fire risks and explosive atmospheres is of utmost importance. It is a big picture, as fire and chemical safety management and risk elimination starts first and foremost with the design of the structures, the location of the different spaces and the electrical and ventilation systems.
Tommy Björklund, formerly Head of Production at Baltic Yachts, knew from experience that chemical safety in production facilities is a key issue.should be taken into account in the design of the building. Therefore, fire safety and ATEX experts were brought in from the very beginning of the project.
- This extension will add many different activities and lots of special equipment to the hall. The construction project is therefore already quite different from the construction of a normal hall. For us, the production involves composites, resin, epoxy, adhesives, coatings and other chemicals. I recognised from the start that the project would be a challenge from an ATEX and fire safety point of view," says Björklund. 
Caption: The production of components for top-of-the-range sailing vessels requires, among other things, a machine room, a wood department, a laminating department, surface treatment rooms and various warehouses for materials. Everything at Baltic Yachts is done with skilled craftsmanship.
- We didn't want to get into a situation where we only start thinking about these things when we're ready. That's why Protect's experts are invaluable throughout the planning phase. Protect was the first to be involved in the project, right after the architect. This is much more cost-effective than making changes afterwards," says Björklund.
Retrofitting electrical systems, structures or air-conditioning in finished premises is therefore both challenging, time-consuming and expensive. Drawing up chemical and fire safety plans at the design stage enables premises to meet safety requirements as soon as the building is completed.
- For example, we produce very fine dust and various compounds that can ignite easily. There are large fire loads and we need different facilities for different operations," says Björklund.
- We didn't want to get off on the wrong foot. I have heard of construction projects where fire and ATEX issues were not taken into account at the design stage. Of course, once the facilities were ready for use, there were challenges with compliance," says Björklund.
Read more on the identification of occupational hazards and risk assessment
Ensuring chemical safety in production facilities
- ATEX and fire safety design from the top of the architect's drafts
Once the architect's sketches for the extension were sketched out, Protect and the fire safety consultant were brought in.
- We were able to put together a team that works well together. Everyone has worked well together, which is an absolute requirement for the operation," says Björklund.
- Mapping of premises for operations and chemicals
The use of highly flammable substances and volatile compounds in the air in a facility affects, among other things, the structure and equipment of the facility, so the use of facilities and chemicals was reviewed on a facility-by-facility basis.
- Spatial classification and design options to meet the requirements
Protect drew up the space classifications, assessed the compliance of the equipment and recommended options to meet the requirements. These were used as a basis for guidelines for the implementation of the facility's structures, electrical, ventilation, logistics, hygiene and the use of protective equipment, among other things.
- Updating architectural drawings for structures
Once the other parties were on board, the recipe for expansion was ready. Construction could begin with the certainty that the planned facilities would be compliant.
- Expert advice provides safety and keeps documentation in order
During the implementation phase of the extension, Protect will continue to be involved in meetings to provide its views on uncertainties. A competent consulting partner will also keep the documentation in order and prepare the relevant documents at the end of the project.
See also: Chemical Inventory and Exposure Assessment - download a free worksheet on chemicals management
Protect has become a trusted HSEQ partner for Baltic Yachts, saving their own working time
Björklund praises the cooperation with Protect as very smooth. But this did not come as a surprise. After all, the cooperation with Protect did not start with the construction project of the extension, but rather with the work on the occupational safety and quality system, which began a few years earlier: when the insurance audit revealed shortcomings in the ATEX plans and explosion protection documents, the company started looking for a partner to update the plans and documents.
- We got a hint that Protect is doing these things competently. Protect's CEO Pertti Salo updated the ATEX classifications and explosion protection documents on occasion," says Björklund.
Updating the ATEX plan for the current operation also opened Björklund's eyes to this expansion project, as making changes after the fact did not seem to make sense. The production manager describes his HSEQ partner as a great source of safety, which he can always turn to in uncertain situations.
- This is a really challenging issue that has a big impact on our activities. Of course, the work could also be done internally, but then we wouldn't be doing any other work. Having an expert HSEQ partner allows us to focus on our core competences," says Björklund.
- The cooperation on the extension project has been really smooth, but they also have a lot of consultants with a wide range of experience who we can turn to for other things, such as the behaviour of a material in different situations. Protect's extensive network of experts has given us this added value, as we don't have our own chemists in-house," Björklund says.
Can we help with fire and chemical safety on your production premises?
When you are planning to build a new production facility and need help with the overall planning, development, management and maintenance of safety, we are here to help.