Accelerating Project Delivery to Expand Resin Production

A chemical intermediates manufacturer faced the challenge of repurposing existing infrastructure to support a new resin formulation—on a tight budget and an even tighter timeline at its Texas facility. CDM Smith responded with a progressive design-build approach that delivered a flexible, cost-effective solution and helped consolidate operations in the region.

Strategic Shift in Production

To produce a different resin, the Texas plant had to reconfigure its reactor system, reuse storage and blend tanks, and integrate new controls and distribution piping. With limited time and resources, the company turned to a partner that could move fast, think creatively, and get results without compromising quality.

The original client request called for traditional engineering services and tank fitness inspections, but the proposed construction timeline was unrealistic. CDM Smith recommended a progressive design-build (DB) delivery method to streamline the process and reduce delays. This approach enabled early-stage engineering to begin while final design decisions were still being refined, saving valuable time and allowing greater adaptability.

Engineering Around Constraints

One of the key challenges involved designing a new platform over the existing blend tanks. The structure had to be carefully integrated with the canopy, equipment, curbing, utilities, and process piping. To navigate these constraints, CDM Smith conducted a laser scan during preliminary engineering, which served as the foundation for detailed 3D modeling across all disciplines.

In addition, new distribution piping and pumps were installed to transfer resin to drum and truck loading stations or to existing batch tanks for further processing. Modifications to the reactor and thin tank were also required to accommodate new ingredient additions, sparge rings, and control system components.

“There were a lot of little details, like pipeline design, structural, all the construction documentation, electrical,” says Jim Calderone, CDM Smith’s director of construction services. “The client team liked that they could work with one firm for the design and construction. Everything was transparent, and they could see bids as they came in.”

Electrical System Overhaul

The project also revealed issues with the plant’s aging electrical infrastructure. The system lacked the documentation and capacity data required for permit approval. CDM Smith conducted an outage investigation and designed a new incoming service switchboard, along with a starter rack for the new pump motors. These upgrades were essential to meet permitting requirements and ensure long-term reliability.

“The electrical service to the plant was a challenge, given the lack of documentation because of the age of the plant,” explains CDM Smith project manager Kevin Montesano. “We recommended a new service and an upgrade to the main switchgear, and that was the path eventually chosen.”

Although the lead time for switchgear and the permitting process extended the construction schedule, the plant was able to begin resin production and quality testing before the final electrical components were installed. This helped to enable the project to still be completed on time and within budget, allowing the client to achieve its goal of consolidating operations in Texas.

Resin Production in Illinois

Building on the success in Texas, the manufacturer partnered with CDM Smith for a second major initiative: the Resin Expansion Project at its Illinois facility.

This project relocated and installed a new batch reactor and thin tank system to produce resin. An existing building at the Illinois site was repurposed to house the new process, with a fast-tracked schedule in which construction was completed in just nine months.

Full-Scale Retrofit

The Illinois project was a comprehensive industrial retrofit, encompassing:

• Installation of over 20 major equipment pieces, including a reactor, mix tank, condensers, decanters, and multiple pumps and agitators
• Extensive piping systems for glycol, oil, solvent, steam, vacuum, nitrogen, and scrubber systems, with tie-ins to existing infrastructure
• Electrical upgrades featuring a new 480V MCC with VFDs, grounding systems, LED lighting, and full instrumentation wiring
• Structural steel fabrication and erection, including platforms, supports, and modifications to accommodate new process equipment
• Concrete foundations and elevated slabs, demolition, and excavation to support the new layout
• Construction management and safety oversight, with full-time on-site supervision and quality control

As with Texas, the Illinois project leveraged a progressive design-build model to accelerate delivery. CDM Smith began engineering while procurement and construction planning were underway, enabling early bid packages and faster mobilization. 

Model for Expedited Project Delivery

Together, the Texas and Illinois projects highlight the benefits of progressive design-build. By embracing this delivery method and leveraging CDM Smith’s integrated engineering and construction expertise, the resin manufacturer overcame tight timelines, aging infrastructure, and limited internal resources—achieving operational consolidation and production expansion with speed and efficiency.