August 2022
How DSB Delivered Complex Building Envelope Upgrades on a Fast-Track Manufacturing Expansion
When demand for COVID-19 testing surged during the pandemic, Puritan Medical Products, one of only two manufacturers worldwide producing specialized COVID-19 testing swabs, needed to rapidly expand production capacity. The company selected an existing manufacturing facility in Portland, Tennessee, to support its growth, creating an aggressive schedule that required multiple construction partners working simultaneously to deliver a fully operational manufacturing facility.
Design Systems Builders (DSB) was selected to lead the building envelope improvements, delivering a comprehensive exterior renovation that modernized the facility while allowing interior manufacturing work to progress on schedule.
Delivering a Modern Building Envelope on an Existing Facility
Unlike new construction, this project required upgrading an existing manufacturing facility while preparing it for state-of-the-art medical production.
DSB’s scope included removing the existing roofing system, installing a new Butler® MR-24® standing seam roof, replacing portions of the exterior wall system with Kingspan insulated metal panels, and installing new Butler® wall panels across the production building. Because the facility consisted of buildings constructed during different periods, matching the appearance of the completed campus required more than simply installing new materials.
Solving Complex Building Envelope Challenges
One of the project’s biggest challenges stemmed from a Butler® expansion T.W. Frierson and DSB had completed in 2008. That addition featured a taller building profile than the original structure.
To create a seamless exterior appearance, the owner wanted the Butler® portion of the facility to visually match the newly installed Kingspan insulated panel system. Achieving that goal required DSB to custom-order Butler® wall panels, roof trims, gutters, downspouts, and accessories manufactured specifically to match the Kingspan color system.
The result was a cohesive building exterior despite utilizing multiple metal building systems.
Maintaining Schedule Without Interrupting Progress
Schedule was critical. Rather than removing the existing wall panels before installing the new exterior system, DSB developed an installation approach that allowed new panels to be installed directly over the existing wall assembly where appropriate. This strategy kept the building weather-tight and conditioned while allowing interior work to continue and enabled Puritan to begin manufacturing operations sooner.
The roofing system also required structural modifications. Existing roof framing conditions necessitated adding new roof purlins between the existing framing members before the new roof system could be installed, ensuring the structure met current support requirements.
Self-Performing the Work
DSB’s self-perform capabilities played a significant role in maintaining schedule and quality throughout the project. Crews completed the extensive roof replacement while working through Tennessee’s summer heat, averaging approximately 8,000 square feet of roof removal and installation each day, with roof surface temperatures reaching as high as 130°F.
At various stages of construction, nearly every DSB field employee contributed to the project, allowing the team to scale manpower as the accelerated schedule demanded.
Safety at Every Level
Executing nearly 200,000 square feet of roofing work required an unwavering commitment to safety. Working alongside Cianbro’s safety professionals, DSB provided a dedicated, full-time on-site safety representative for the roofing operations. Comprehensive safety requirements included daily stretch-and-flex meetings, mandatory orientations, PPE enforcement, equipment spotters, COVID-19 protocols, and wearable location-monitoring technology. Over nearly 17,000 labor hours, the project was completed with zero lost-time incidents, a reflection of DSB’s commitment to protecting its people while delivering complex work safely.
Results
The completed facility now supports Puritan Medical Products’ expanded manufacturing operations and was renovated in less than eight months as part of an accelerated, phased delivery approach. The upgraded building envelope provides a durable, energy-efficient exterior capable of supporting one of the nation’s most important medical manufacturing operations.
For DSB, the project demonstrates more than expertise in pre-engineered metal buildings; it showcases the ability to solve complex renovation challenges, coordinate multiple building systems, and self-perform critical building envelope work under aggressive schedules without compromising safety or quality.
Why This Project Matters
Whether modernizing an aging manufacturing facility, replacing an existing roof system, or integrating new insulated metal panels with legacy structures, DSB helps industrial clients extend the life of their facilities while minimizing operational disruption. From complete re-roof systems to custom metal building renovations, DSB delivers building envelope solutions designed to keep facilities operating today while preparing them for tomorrow.
