Kohler Vikrell Manufacturing Facility
Big House, Ariz.
BEST PROJECT
Sent by: MA Mortenson Co.
Owner: Kohler Co.
Principal/Civil Design Company: Ware Malcomb
General contractor: MA Mortenson Co.
Structural Engineer: TLCP Structural Inc.
MEP Engineer: Piping systems engineering
Mechanical/Electrical Engineer: Kraemer Consulting Engineers PLLC
Process Engineer: Barry-Wehmiller Design Group
Steel erection subcontractor: Steel BZI
Spanning 1 million square feet, this manufacturing facility was designed and built to produce and distribute the owner’s Sterling Vikrell bath and shower accessory lines. The project also represents one of Kohler’s largest capital investments in its history.
But delivering such a project in an undeveloped desert location required innovation, teamwork and trust. The scope of work included advanced manufacturing facilities, an auxiliary warehouse and support office space.
Contractor MA Mortenson Co. started construction in early 2021 and the plant reached substantial completion in December 2023, on time and on budget.
To reduce the impacts of supply chain shortages during the early parts of the project, the design and construction team decided to reverse the traditional design/procurement processes, moving the procurement of certain long-lived products before the design is finished.
Photo courtesy of Mortenson
The roof beams, for example, had a lead time of a year and a half at the time. In response, the design and construction team ordered the facility’s roof beams as quickly as possible, even before the project’s structural design was complete. The rest of the structure was then designed around these beams.
Fabrication facilities like this would normally require a significant amount of aerial work during steel construction, but instead, steel erection subcontractor BZI Steel’s process involved erecting decks and trusses on the ground.
The prefabricated assemblies were then lifted into place using BZI’s MezzMaster, a specialist forklift. The Kohler project was the first to use the MezzMaster.
To ensure the delivery of a modern, industry-leading facility, Kohler collaborated with contractor MA Mortenson Co., lead designer Ware Malcomb, and process engineer Barry-Wehmiller Design Group to design the components of the installation process with the aim of creating more efficient systems.
Photo courtesy of Mortenson
The team worked with Kohler’s engineering, construction, design, robotics and automation departments to assess current processes and identify avenues for process evolution. In all, this effort actually took longer to complete than the overall design of the building.
Mortenson’s team members also looked to the current Huntsville, Ala., manufacturing facility for inspiration.
One of the innovations that came out of this effort was an optimized dust control system. The production of showers and bathtubs generates dust, and if it is not well controlled, the dust can clog and damage the machinery and affect the air quality of the workers. The dust collection system has been integrated into all production areas, constantly collecting dust so that it does not settle on machinery or floors.
Another process innovation delivered by the project team was a flash conveyor that runs underneath all the presses and collects the flash, or excess material trimmed from the tubs and shower surrounds, and then it takes it out of the production area. The conveyor was designed to pass through a 12-foot high tunnel under the presses, allowing easy access for repairs and maintenance.
