ARCO National Construction Delivers Complex Class A Manufacturing Facility Through Integrated Design-Build Approach

ARCO National Construction delivered a 228,000-square-foot build-to-suit manufacturing facility for Chelsea Building Products in Ruffs Dale, Pennsylvania. Located within the Commerce Crossing at Westmoreland industrial park, the project was developed to support expanding production demands while strengthening the region’s position as a hub for advanced manufacturing.

Designed as a Class A industrial facility, the building integrates high-performance infrastructure, rail-served logistics, and specialized production systems to support long-term operational efficiency and growth.

From the outset, the project required close coordination between building design and Chelsea Building Products’ manufacturing processes. The facility was not simply designed as a generic industrial space, but as a production-driven environment tailored to specific operational needs.

ARCO worked with the project team to align building layout, structural systems, and utility infrastructure with production workflows. This approach ensured efficient material handling, optimized equipment placement, and long-term flexibility as operations evolve.

The resulting design features 32-foot clear heights and 50-by-50-foot bay spacing, allowing for efficient manufacturing layouts and adaptability without compromising structural performance.

A key differentiator of the project is its integration of rail-served logistics, with direct access to the Southwest Pennsylvania Railroad. This connectivity allows raw materials to be delivered efficiently while reducing reliance on truck transportation.

ARCO coordinated site planning, building orientation, and material flow to fully leverage the rail connection. By aligning logistics infrastructure with facility operations, the project delivers a more resilient and cost-effective supply chain solution.

One of the most technically demanding aspects of the project was the integration of approximately 2,800 linear feet of utility trenches required to support specialized manufacturing systems.

These trenches were embedded within the building slab and required precise coordination across structural, mechanical, electrical, and process engineering disciplines. Their layout directly influenced building design, construction sequencing, and long-term operational performance.

ARCO’s design-build approach enabled early coordination of these systems, ensuring constructability while minimizing disruption to schedule. By addressing these complexities upfront, the team delivered a fully integrated facility that supports Chelsea Building Products’ production requirements without compromising structural integrity.

The facility was designed to support high-performance manufacturing operations while maintaining a safe and efficient working environment. Ventilation systems provide one air change per hour to meet operational requirements, while LED high-bay lighting ensures consistent illumination across production areas.

A 60-mil white TPO roof system enhances energy efficiency and durability, and an ESFR fire protection system provides advanced life safety and asset protection. Together, these systems establish a modern industrial environment capable of supporting energy-intensive operations.

ARCO’s integrated design-build delivery model allowed the project team to evaluate structural systems, utility infrastructure, and building performance in parallel. This early alignment reduced design conflicts, improved constructability, and minimized risk throughout construction.

By coordinating complex systems early and maintaining a single point of accountability, ARCO delivered a facility that meets both immediate production needs and long-term operational goals.

The Chelsea Building Products facility represents a significant investment in the Western Pennsylvania manufacturing sector, supporting approximately 140 new jobs and contributing to sustained economic growth in the region.

Furthermore, the facility demonstrates how design-build coordination, logistics integration, and production-driven design can come together to deliver a high-performance manufacturing environment. Through thoughtful planning and technical execution, ARCO delivered a facility that supports efficiency, scalability, and long-term value.