12 Years of Collaboration Leads to Successful Expansion in Fort Dodge

Interstates recently completed a significant expansion project in Fort Dodge, IA, for a long-term value-added agriculture client. The project involved adding a new production facility to the client's existing plant.

This expansion highlighted Interstates' expertise in electrical engineering and construction, as well as its ability to be flexible in the face of complex challenges like long equipment lead times and tricky trade congestion. From the start, Interstates had the benefit of trusted, established client relationships and a deep familiarity with the project site, having worked at the Fort Dodge facility on and off for the past 12 years.

Key Challenges and Solutions

In order to meet the tight timeline on this project, design and underground work got underway before all subcontractors were technically under contract. Barry Hale, Senior Project Manager, says, "We were ordering materials and designing our plans before piping was even awarded. To address this, we used the model to make decisions and do our best to avoid any rework." This proactive approach helped mitigate potential delays and ensured the project stayed on track.

Another significant challenge was procurement, as noted by Ben Ruppert, Superintendent at Interstates. "We had some long lead times on equipment that has still not arrived," he says. To overcome this, Interstates and the client collaborated to develop a plan that used a spare client transformer on-site and purchased a temporary transformer. This plan avoided potential Interstates’ construction delays that would have impacted the plant's check-out and start-up process. This creative solution allowed the project to proceed even while waiting for the permanent equipment.

Efficient Coordination and Communication

One major facet of the project's success was the seamless coordination between Interstates' engineering and construction teams. Dylan Schmidt, Site Project Manager at Interstates, noted the benefits of providing multiple services on this project. "There was easy communication between our groups because we are one company, so we never have to wait a month to get an RFI back or to change lighting locations on a panel," he says. This streamlined communication enabled quick resolution of issues and adjustments, improving efficiency.

Additionally, using prefab and industrialized construction methods played a crucial role in the project's efficiency. Schmidt explains, "We used prefab for our underground, feeders, cable tray, and the gear in the electric room. It transitioned some hours off-site for the client." By moving a portion of the labor off-site, Interstates reduced work-area congestion and improved installation speed. Trade stacking was further mitigated when Interstates pivoted half its crew to a night-shift schedule.

Long-term Relationships and Understanding Needs

Interstates' long-term presence at the Fort Dodge facility proved invaluable. "The strong relationships were there already, so conversations were easy to have," Ruppert says. This familiarity with the client and the site minimized rework and ensured that the project's specifications were met without extensive back-and-forth.

Schmidt adds, "It also means we know exactly what they'd like to see for installation. That means minimized rework because you know what they're looking for." This prior knowledge allowed Interstates to deliver a project that met the client's expectations and was completed on schedule and within budget.

Impact and Future Benefits

The successful completion of this project underscores Interstates' commitment to delivering high-quality solutions that meet clients' needs. By overcoming challenges, maintaining constant communication, and leveraging long-term relationships, Interstates ensured that the new production facility would be operational according to the client's plans. Hale says, "Everything is pointing that way. They are expecting to be in operation on time and on budget."

As the client prepares to add a new product to their portfolio, Interstates is ready to continue leveraging its deep knowledge of the facility and its strong client relationships to deliver high-quality results at this location for years to come.