Reconfigure existing process infrastructure
The Texas facility reconfigured reactor systems, reused storage and blend tanks, and integrated new controls and distribution piping to support a new resin
Practices
Progressive design-build enables fast-tracked resin production expansion
A leading chemical intermediates manufacturer needed to expand resin production while working within tight budgets, aging infrastructure, and aggressive schedules. In Texas, the challenge involved repurposing existing systems to support a new resin formulation without disrupting operations. In Illinois, the company sought to relocate and install new process equipment in an existing building on a fast-tracked schedule. The manufacturer partnered with CDM Smith to deliver both projects using a progressive design-build approach. The manufacturer partnered with CDM Smith to deliver both projects using a progressive design- build approach.
Accelerate delivery with progressive design‑build
Early engineering began while design decisions were refined, allowing procurement and construction planning to proceed and reduce schedule risk
Apply advanced modeling and laser scanning
CDM Smith conducted laser scanning during preliminary engineering, forming the basis for detailed 3D modeling that supported precise platform, piping, and structural design
Execute full-scale industrial retrofits
The Illinois project installed more than 20 major equipment pieces and extensive piping, electrical, structural, and concrete systems in nine months
Together, the Texas and Illinois projects demonstrate how progressive design-build helped the manufacturer meet firm deadlines while working within aging facilities and limited documentation. “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,” said Jim Calderone, our director of industrial design-build. In Texas, early engineering and transparent bidding enabled resin production and quality testing to begin before final electrical upgrades were complete, supporting regional consolidation goals. In Illinois, a fast-tracked retrofit delivered a new resin production system within nine months. “The key driver for progressive DB was the timeline. We had a hard end date because another site had to be shut down,” said the client’s project manager helped the manufacturer meet firm deadlines while working within aging facilities and limited documentation.