Koch Foods - Plant B

This 402,000 sf ready-to-eat (RTE) chicken processing facility is located adjacent to Koch Foods’ existing RTE facility. The proximity of the two buildings allows the management team to oversee both operations from a centralized location. To accommodate the new facility, the team performed a 20’ cut through mostly rock to bring the site to the same grade level as the existing plant. Additionally, a creek running through the site had to be rerouted.

Design & Construction
The building enclosure is a combination of tilt-up concrete panels and insulated metal panels (IMP). The team self-performed the installation of IMP walls, ceilings, ductwork, and doors. Given the aggressive schedule, the mechanical systems were designed concurrently with steel erection to ensure timely completion. A key logistical challenge was optimizing the tight, shared site without disrupting daily operations at the adjacent facility, including using their entrances and parking lot.

Unique Features & Future Planning
The design accounted for future expansions to minimize rework as the facility grows. Unique features include a mix of IMP and tilt-up envelope construction, and a virtual twin of the production space was used to prevent delays during construction. The project was optimized to deliver a larger-than-expected asset within the given timeline.

Virtual Design and Construction
Our VDC team worked with the team to virtually model the space. This helped the project team and subcontractors to identify conflicts in both the processing space and the offices, and to prefabricate large portions of the refrigeration and process piping.