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May 27, 2016

Construction Award • Private building
$25 million-$50 million

Photo courtesy of Merit Construction Northwest
This Pierce County manufacturing plant operated 24 hours a day throughout construction.

Toray Composites of America expansion

Location: Frederickson, Pierce County

General contractor: Merit Construction Northwest

Owner/developer: Toray Composites of America

Primary designer: BOE Architects

Merit’s Toray Composites of America project involved an over-100,000-square-foot manufacturing plant expansion, including office space, manufacturing floorspace, warehouse space, employee locker rooms and a break room.

The building is composed of structural steel with concrete slab-and-grade beams and elevated concrete decks. The building envelope includes insulated metal panels, storefront window systems and a 60-mil thermoplastic polyolefin (TPO) roof over metal deck and insulation.

The existing plant was a 24/7 facility, which added logistical challenges to the project. Work required connecting new electrical, mechanical and plumbing systems to the existing systems. Shutdowns were coordinated within small scheduling windows, limiting impacts so that production of the existing plant could continue.

Additional infrastructure included expansion of the fire, sewer and storm-drainage systems as well as parking. More than 60,000 square feet of asphalt paving and 132 parking stalls were added for employee parking and for better shipping and receiving flow to the plant.

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