Subzero

Summarize the project's program, features and achievements?

A new 600,000-square-foot manufacturing and distribution facility has been completed in Goodyear, Arizona, marking a significant investment in regional growth, innovation, and sustainable industrial development. Located along the Loop 303 corridor, the facility occupies a 36-acre site and serves as a major operational hub, combining several functions under one roof. These include the manufacturing of outdoor kitchen equipment, plastic injection molding, and national distribution operations. The facility complements an existing distribution center in the area, further expanding the company’s footprint in the Phoenix metropolitan region.

Designed with efficiency and scalability in mind, the facility features advanced robotic and automated systems, particularly in its assembly lines, which enable precise, high-quality production processes. A two-story mezzanine houses modern office spaces, presentation rooms, and collaborative work environments that support innovation and operational coordination. Sustainability was also a key priority in the facility’s design, with energy-efficient HVAC systems and environmentally conscious building practices implemented throughout. Its location near major transportation routes enhances logistical capabilities, allowing for faster delivery times and reduced shipping costs across western markets.

This $118 million project is expected to generate significant economic benefits for the region, including over $600 million in projected economic activity and $5.6 million in property tax revenue over the next decade. In addition, the facility is forecasted to create 143 new jobs within five years, offering competitive wages and expanding local employment opportunities in manufacturing and logistics. The project has already gained recognition, receiving a major regional award for its impact and excellence in industrial development.

The facility’s grand opening was celebrated with a ribbon-cutting ceremony attended by city officials and community leaders, underscoring its role in supporting local economic development. This new operation represents a strategic investment in long-term growth, providing the infrastructure needed to meet increasing demand while reinforcing a commitment to sustainability and community partnership.

What obstacles were overcome related to the schedule, budget, program, specification, site, etc. on this project?

Completing the Sub-Zero facility was a remarkable achievement that required overcoming numerous challenges, tight deadlines, and constant coordination. One of the most significant hurdles was the compressed timeline—a 10-week schedule from foundation work to the first tilt panel lift for a 600,000-square-foot facility. Delivering such a large-scale project at this pace required intense planning, long nights, and rapid problem-solving as unexpected issues arose throughout the process.

Adding to the complexity, several tenant improvement (TI) changes were introduced after construction had already begun. These included modifications to accommodate the foundations for crane-based robotic assembly lines, which required coordination across design, engineering, and construction teams without slowing progress on site. The development team had to adapt quickly and work closely with all stakeholders to implement these critical changes while maintaining momentum.

The site itself presented unique challenges. The land had been held for nearly two decades, and early in the process, there was the need to collaborate with a neighboring landowner to align on a shared vision for the site layout. Sub-Zero originally envisioned a 400,000-square-foot building, but expanding it to 600,000 square feet proved to be a smart decision, enabling future growth while saving long-term costs.

Additional obstacles included removing a floodplain, coordinating utility access, and securing sewer connections—each requiring detailed coordination with city officials and service providers. Through teamwork, flexibility, and relentless problem-solving, the project team succeeded in delivering one of the most complex and rewarding industrial builds in the region.

Please communicate any engineering complexities or unique features of the panel design for this project?

The engineering of the concrete panels at Sub-Zero presented a unique set of challenges that required precise planning, expert coordination, and innovative solutions. Among the most complex elements was the design and installation of an exceptionally large spandrel panel measuring 12 feet tall and 57 feet wide—one of the most significant single tilt panels used on the project.

The sheer size and weight of this panel demanded specialized structural analysis to ensure it could be safely formed, lifted, and installed without compromising integrity. The engineering team had to account for lateral forces, lifting stresses, and long-term load-bearing performance. Custom rigging and bracing solutions were developed, and lift points were meticulously calculated to maintain balance and prevent cracking during the tilt-up process.

In addition, the sequencing of panel erection was tightly choreographed to accommodate the site’s accelerated schedule and the overlapping trades working simultaneously within tight tolerances. The presence of integrated openings and embedded steel for future architectural and functional elements further complicated the casting and erection processes.

The 12’ x 57’ spandrel panel exemplified the coordination between structural engineers, the tilt panel contractor, and field crews. Every aspect—from mix design to curing procedures and crane capacity—had to align perfectly. The successful placement of this panel not only demonstrated the technical expertise of the team but also set the tone for the high level of quality and performance expected throughout the rest of the facility’s construction. It stands as a testament to the engineering ingenuity that made the Sub-Zero facility possible.