Briefly describe the design highlights or unique features of this project:

JHA Companies provided comprehensive engineering design and construction management services for the renovation and reconfiguration of a 40,000-square-foot fabrication facility. The project was initiated in response to the client’s expansion across multiple markets, which led to a need for operational consolidation and the relocation of fabrication processes from a recently closed remote facility over 300 miles away.

What specific challenges did you face during this project, and how did JHA Companies solve them?

One of the most significant challenges of the project was that the facility needed to remain fully operational throughout construction. JHA worked in close coordination with on-site project managers and facility staff to develop and execute a carefully phased plan that minimized disruption, preserved production output, and maintained safety within the active workspace. The project involved extensive modifications to existing infrastructure, including substantial electrical system relocations and structural reinforcement of the concrete floors to support new loads and minimize vibration. JHA collaborated directly with operators from the closed facility to ensure proper layout, installation, and functionality of the relocated equipment and processes. In addition to design and construction management, JHA also coordinated with local regulatory authorities and provided support in securing all necessary building permits and approvals. By managing regulatory compliance and staying closely engaged with both contractors and regulatory agencies, JHA helped streamline project timelines and avoid costly delays. With numerous moving parts and evolving operational demands, JHA’s full-time, on-site construction management over the course of two years was essential to the project’s success—ensuring real-time problem-solving, quality control, and seamless integration of new systems into the existing, active facility. The design effort focused on consolidating the existing operations to optimize program adjacencies. The project involved substantial electrical system relocations and reinforcements to the concrete floors to support the new loads and mitigate vibration. JHA also worked directly with operators from the closed facility to ensure the building updates would adequately support the relocated processes and that equipment was properly positioned. With numerous moving parts, effective communication was crucial to maintaining uninterrupted production. To ensure project success, JHA provided full-time construction management for two years, addressing unforeseen challenges and ensuring the seamless integration of the new systems.