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  • PACKAGING CORP. OF AMERICA – Glendale, AZ

PACKAGING CORP. OF AMERICA

Project Description

Client: Packaging Corporation of America
Location: Glendale, Arizona
Project Size: 365,000 sq. ft.
Architect: Fisher Construction Group
Facility Type: Corrugated Box Manufacturing

Blazing Through an Accelerated Timeline

While Making Modifications to Keep the Plant Cool in Arizona Heat

Fisher Construction Group successfully completed a comprehensive tenant improvement (TI) project for Packaging Corporation of America (PCA), transforming an existing warehouse into a state-of-the-art full-line box plant; the largest TI project Fisher has completed for PCA to date. The project involved significant modifications and upgrades to the 365,000 square-foot facility, which included 331,150 square feet of warehouse space.

A key challenge was upgrading the facility’s HVAC system to maintain the originally designed 82°F warehouse temperature, even during the hottest Phoenix days. The existing 24 air conditioning units were supplemented with an additional 6 AC units that were installed on the roof utilizing a helicopter, and 12 heat pumps to compensate for the heat load introduced by the owner-provided manufacturing equipment.

To accommodate the added load from the new AC units, overhead electrical runs, and overhead process piping, Fisher structurally reinforced over 100 existing joists. Additional structural modifications included the removal and relocation of 7 existing loading docks and overhead doors, as well as upgrading 16 manually operated overhead doors to motorized operation. Ten equipment foundations were also installed to support PCA’s full production line, requiring the demolition of nearly one-third of the existing building slab.

A 400 foot two-tiered pipe bridge was constructed alongside the corrugator to support the complete process piping system that includes compressed air, starch, high/ow pressure condensate, steam, electrical, process water, and wastewater systems. A 30-inch-tall epoxy-coated containment wall was built around the wastewater treatment tanks, and a new fire sprinkler system was integrated into the scrap trench, covering both the area above and below the scrap trench conveyor, along with added fire sprinklers for other pieces of equipment. The facility also features a 500-foot rail dock on the west side, equipped with 4 overhead doors and 2 high-speed roll-up doors for efficient material handling.

Strategic planning and precise execution was required to ensure execution of the accelerated timeline, delivering a fully operational facility on target for a smooth transition from their existing Phoenix facility before lease expiration.