Design-Build Industrial Expansion in Decatur, Tennessee: Two Metal Building Additions Around an Active Manufacturing Operation
Location: Decatur, Tennessee
Industry: Industrial & Manufacturing
Service: Ground-Up & New Construction
The Situation
Sunbelt Solomon needed to expand its transformer refurbishment facility in Decatur, Tennessee with two new pre-engineered metal building additions. One addition was to be constructed around an existing overhead steel beam and overhead door condition. Both additions required full sitework, foundations, structural steel, concrete slabs, building erection, and integrated mechanical, electrical, and fire protection systems, all delivered under a design-build contract.
The Challenge
Constructing a new building addition around an existing overhead steel structure requires sequencing that accounts for existing conditions at every phase. Anchor bolt layout, foundation design, and structural framing all had to be developed around what was already in place rather than a clear site. The 50x30 addition in particular required construction methods that worked within the constraints of the existing overhead beam and door conditions without requiring their removal.
Field conditions further expanded the scope during execution. A topographic survey and underground utility locating effort were required to supplement the original survey information before civil drawings could be completed and stormwater utilities properly addressed. Foundation work required upsized pier footings beyond the original design. Storm drain rework at the 50x30 addition, removal of capped piping, and regrading to final condition were all incorporated as actual site conditions became clear. Fire protection utility components including a fire department connection, detector check valve assembly, and hot box enclosure were added at the point of service as part of the final fire protection layout.
How We Worked
JBrennon provided design-build delivery from engineering and permit coordination through final construction. Site work included excavation, grading, trenching, backfill, drainage tie-ins, demolition of existing concrete and site features including the existing overhang where required, retaining wall waterproofing, and concrete pavement and sidewalks. Foundation work included footing and pier construction, turn-down slabs, and slab-on-grade with reinforcement and anchor bolts sized to the field-confirmed conditions.
Both metal building systems were erected with wall and roof panels, insulation, overhead doors, man doors, welded frames, hardware, trim, and flashing to achieve weather-tight enclosures. MEP scope included fire protection expansion for both buildings, exhaust fan installation, ceiling-hung heaters, electrical distribution, lighting, and power. All added civil, structural, drainage, and fire protection scope identified during execution was incorporated through the design-build process without separate design contracts or delays to the overall delivery.
The Outcome
JBrennon delivered two fully operational metal building additions at the Sunbelt Solomon facility in Decatur, Tennessee: designed, built, and placed into service with all field-condition-driven revisions integrated under the original design-build agreement.
Two pre-engineered metal building additions completed including all MEP and fire protection systems
50x30 addition constructed around existing overhead steel beam and door conditions
Upsized foundations, storm drainage revisions, and fire protection utility components incorporated through design-build process
New topographic survey and underground utility locating completed to support civil design
Both additions placed into service as fully operational, code-compliant expansions of the existing facility