Savannah River Nuclear Solutions’ (SRNS) Containment Fabrication Facility (CFF) has achieved a remarkable milestone by completing the fabrication of one of the largest containment huts in its history. This initiative exemplified the CFF team’s contributions to worker protection, environmental safety and mission success at the Savannah River Site (SRS).

The Containment Fabrication Facility team completed one of the largest huts ever built for H Canyon’s recycle vessel vent fan replacement. Front row: Ray Hux, Ashley Gray, Rober Moyer, James Cook, Tomasita Ray, and Tim Barnes.

Stretching an impressive 20.5 feet wide, 27 feet long, and 14 feet high, the hut features a 5’ x 5’ airlock door, a roll-up flap door, multiple access ports, and several windows designed for visibility and functionality. The hut was used for recycle vessel vent (RVV) fan replacement in support of the Site’s H Canyon, the only operating, production-scale, radiologically-shielded chemical separations capable facility in the United States. In the H-Canyon Facility, the RVV system functions alongside other ventilation systems, involving fan assemblies and dampers to manage air and gases.

“The CFF provides expertise and experience in containment fabrication to help minimize the spread of contamination to protect the workers and the environment,” said Tim Barnes, Manager, Radiological Operations Support Center.

“In 2025, we supported many facilities across the Site, fabricating approximately 2,500 containments to help make the mission safer.”

From Concept to Creation: Protecting Workers and the Environment At its core, containment fabrication is about safeguarding the lives of workers and ensuring the surrounding environment remains uncontaminated during operations involving radioactive or hazardous materials. The CFF team specializes in creating unique soft-sided solutions, from large-scale containment huts — like the one built for the RVV fan replacement — to intricate glove bags used for smaller, precision-based tasks. Containment huts act as portable enclosures, minimizing the risk of contamination by isolating hazards and maintaining controlled environments. CFF planners work closely with engineers, radiological control experts, and customers to conduct detailed site walk-downs for every containment project. The proposed design is carefully reviewed by specialists before being sent to the shop floor for fabrication. Skilled craftspeople translate the design into reality using radio frequency sealing technology and durable materials such as laminated vinyl, nylon, and poly-fabrics.

The RVV fan replacement hut took approximately one week to fabricate and presented unique challenges due to its size.

The team reconfigured their manufacturing space, relying on creativity and teamwork to overcome logistical barriers. The sealing process required the use of blowers for inflation and an innovative combination of sewing techniques.

“Building something this large takes teamwork and precision,” said Robert Moyer, a 20-year planner at the CFF. “We put our expertise to the test, from scheduling and procuring materials to inflating and testing every square inch for leaks.”

The SRS CFF team has fabricated tailored solutions onsite since 2001, complementing the procurement of many supplies and services from external sources. In addition to supporting SRS operations, the facility has extended its expertise, producing containment solutions for the Federal Bureau of Investigation, the Department of Homeland Security, and the DOE’s Hanford Site.

Inside the massive containment hut. “The CFF is an indispensable part of the Site’s broader effort to ensure safe nuclear operations in support of DOE and the National Nuclear Security Administration,” said Andy Tisler, Senior Vice President, Infrastructure Modernization and Sustainment. “Protecting our workers and the environment through containment solutions is our responsibility. The CFF is an integral part of protecting our workforce from potential hazards, contributing to the safety and success of every mission.”