Flexible expertise guides construction of sustainable denim factory for Saitex
Project facts
- ClientSaitex
- ChallengeConstruction process to review variation orders which were leading to spiralling investment costs.
- Date2021
- SolutionExpert review cuts projected design variation costs by 50%.
- LocationVietnam
The challenge
A new boutique fabric mill for Saitex in Vietnam is setting new standards for sustainability in the industry. Aiming for LEED Gold certification, it requires no fresh water for its processes and has capacity to generate 4MW of energy from 15,000 solar panels on its roof. Besides that, the mill only produces with environmental friendly fibres and chemicals as well as doing its indigo dyeing with the smart indigo system.
Saitex specialises in premium denim, pfd and over-dyed products. It already has a reputation for leading the way in sustainable manufacturing practices in garment manufacturing and is in the process of transforming its business from linear to circular. The new fabric mill is the most technologically advanced in Vietnam, from spinning, preparation with rope dyeing technology, weaving and finishing. The new factory has a final capacity of 2 million meters of fabric a month and can produce 750 tons of yarn.
The solution
Expert review cuts projected design variation costs by 50%
Saitex called on assistance from Royal HaskoningDHV early in the construction process to review variation orders which were leading to spiralling investment costs. Through our input, Saitex was able to contain the increases and reduce additional investment needed by 50%. Saitex then engaged Royal HaskoningDHV to provide owner engineering services to help manage the construction activities. This included undertaking a selected review of the method statement and design solution and overseeing quality, scheduling and financial management.
The result
Piping engineers step in with solution to keep progress on track
One of the additional benefits for Saitex of having direct access to our multi-disciplinary team was that it could rely on wide-ranging expertise to solve issues as they arose. One such issue was the design and implementation of the process piping when it became clear that the process consultant based in Italy would be unable to travel to the site due to pandemic travel restrictions. Our piping engineers stepped in and carried out technical and commercial evaluations for the tender package on site. They coordinated the design with the consultant and vendors, supervised the work and undertook inspections as needed.
As well as detailed technical expertise, Saitex drew on our high-level project management experience to increase efficiency in decision making and supervision.
In partnership with our client, we introduced changes which streamlined activities and supported optimal oversight and decision making while significantly reducing the time our client needed to allocate to site meetings.
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