Innovation and Adaptability at Iowa Chemical Processing Plant

Interstates recently completed an innovative project at a client’s chemical processing facility on a sprawling 60-acre site in Iowa. The facility, the first of its kind in North America, converts corn-derived glucose into 1,4-Butanediol, a key precursor in spandex production, replacing traditional petroleum-based methods. This project highlights Interstates' ability to deliver high-quality electrical and instrumentation construction services while navigating an array of challenges. 

Leveraging Technology for Quality and Efficiency 

Interstates integrated cutting-edge tools like BIM boxes, iPads, and the InterTrak system to uphold rigorous quality standards on this project. BIM boxes provided on-site access to the 3D model, enabling the team to resolve issues promptly. Dustin Arnold, Site Project Manager at Interstates, says, “These tools allowed us to maintain a high level of accuracy and reduce rework in a fast-paced environment.” 

iPads equipped with SmartUse and InterBuild applications streamlined field operations by providing the team with real-time updates and tracking for motor and device installations. Barry Hale, Senior Project Manager at Interstates, notes, “InterTrak was invaluable in producing detailed progress reports, helping both our team and the client manage constraints effectively.” These technological innovations increased efficiency and gave the client transparent, actionable insights. 

Working Through Challenges and Logistical Constraints 

This project faced significant scheduling hurdles, including delays from other contractors and compressed timelines. “We were challenged with a fast-paced schedule and aggressive milestones leading up to energization and checkout,” says Hale. “We had to perform approximately 100,000 manhours of work in just about nine months.” 

Interstates used advanced scheduling tools like Touchplan and Primavera P6, alongside a whiteboard planning system, to maintain momentum. Weekly collaboration meetings and daily planning sessions kept the team agile. “Despite delays from other contractors, we adapted by reallocating manpower and using detailed plans to stay productive,” says Arnold. The team also coordinated with the client to resolve material shortages, avoiding significant disruptions. 

Working in the six-story fermentation building, with its tight spaces and ceilings up to 35 feet high, presented unique challenges. Interstates worked with the client to source a specialty lift that met strict height and weight requirements. “This area was packed with scaffolding and other contractors, so coordination was key,” says Arnold. Despite these constraints, the team completed installations efficiently through meticulous planning. 

Weather added another layer of complexity. Severe winter conditions required the team to shift focus to indoor tasks to maintain productivity. Hale says, “Flexibility in planning allowed us to meet critical milestones despite these harsh conditions.” 

Focusing on Value and Teamwork 

Interstates used value engineering strategies to optimize costs for the client and enhance overall constructability. One notable improvement was the use of MC cable in place of aluminum conduit for roll-out lighting installations, reducing labor costs and streamlining work. “Our proactive approach to value analysis ensured cost-effective solutions without compromising quality,” says Hale.  

Arnold says the use of Interstates’ tracking systems and reports also provided great value. “It allowed the client to more efficiently track not only Interstates’ progress but also the mechanical contractors’ progress via instrumentation installs and motor installs. The client was able to use this information to work through constraints and more effectively plan approaching work,” he says. These efforts, combined with lessons learned from similar projects, help our team deliver long-term value for the client. 

The success of this project, despite many challenges, is a testament to the strength of Interstates’ team. “In construction, I believe a project’s success starts and ends with the team that is built. Even though there were obstacles to overcome, our team persevered to meet the client’s needs. From apprentices to superintendents, everyone contributed to overcoming challenges and exceeding client expectations,” says Arnold.  

Collaboration, innovation, and adaptability were key to delivering a high-quality installation that sets the stage for long-term operational efficiency, making this project yet another good example of how Interstates’ solutions-driven team can deliver success on projects large and small.