Key Highlights / Scope of Work
The existing, owner owned and occupied, 42,000 sq. ft. warehouse was renovated for Vertex as their Manufacturing Center.
Challenges Faced
Logistical limitations prevented the use of exterior rigging, requiring all equipment to be brought in through a single garage bay. The space was further complicated by a compact layout and a newly constructed mezzanine housing the mechanical room. Above the clean rooms, dense, layered ductwork limited future accessibility for testing, insulation, and balancing. The existing sharply pitched roof could not support the weight of the pipe and ductwork. The project schedule was divided into six phases, each with distinct Temporary Certificate of Occupancy (TCO) milestones.
Solutions and Innovations
The space limitations demanded detailed sequencing and coordination between Cox and Consigli. The steep roof required coordination of supplemental support steel, including options for bottom-of-pipe and duct supports. Equipment release, duct and pipe fabrication, installation, and startup were all phased accordingly to align with the project timeline.
Results / Outcomes
Cox successfully delivered the project within the constraints of an occupied building and a compressed timeline. Through close collaboration with partners, the project was delivered on schedule, with all mechanical systems fully operational and optimized for the facility’s manufacturing needs.
