A Crowning Achievement

  • Client:  Crown Holdings, Inc.
  • Location:  Nichols, NY
  • Size:  535,000 SF
  • Architect:  Margulies Hoelzli Architects
  • Responsibility:  Design Build / Construction Manager
  • Construction Period:  14 Months

Crown Holdings, Inc., a leading supplier of metal packaging products worldwide, is operating its first greenfield facility in the United States in more than twenty years thanks to Blue Rock Construction.

The new 535,000-square-foot manufacturing plant Blue Rock built in Nichols, NY features:

  • 168,000 SF warehouse
  • 41,000 SF unloading area
  • 30,000 SF expansion area
  • 16,000 SF office area

Equipped with two manufacturing lines, the state-of-the-art plant has the capacity to produce 7,000 specialty cans a minute and 1.6 billion cans per year.

Along with the Nichols facility, Crown operates fifteen beverage can plants in North America, manufacturing aluminum cans ranging in size from 7.5-ounce to 16-ounce, as well as a variety of beverage can ends.

During construction, the massive size of the New York plant, which sits on 40 acres, required the use of helicopters to deliver mechanical components for its heating, ventilation, and air-conditioning units.

Midwest Helicopter Airways transported a total of 44 lifts, which included (11) 2,650-pound heaters. The Midwest crew and the project team from J&K Plumbing and Heating did an excellent job executing the airlift plan.

Blue Rock’s design-build project team also enjoyed a great partnership with  Margulies Hoelzli Architecture and Greenman-Pedersen, Inc., which provided mechanical, electrical and plumbing, and fire protection design services.

Construction took 14 months to complete.

“I would like to take this opportunity to thank you all for your efforts in completing the Nichols plant,” said  Mark Liptrot Project Manager for CROWN Technology. “It was a pleasure and a privilege to have met and worked with (Blue Rock). I wish you all the very best for the future and maybe one we will cross paths again.”

Crown dates back to 1892 and is one of the leading metal packaging companies in the world. It employs 23,000 people worldwide.


Building a Tower for Sekisui

Blue Rock completed renovations to SEKISUI Polymer Innovation’s 340,000-square-foot manufacturing campus in Bloomsburg, PA with some dramatic results.

Eight months after construction started, the facility now includes a new four-level, 72-foot Blend Tower. SEKISUI SPI, a worldwide manufacturer of specialty polymers, will use the 4,800-square-foot tower to manufacture advanced materials used in aerospace and mass transit applications.

The Blend Tower also includes two large roof hatches to allow a crane to remove or add equipment when needed.

Before (above) and after (below) photos of the Blend Tower. 

Along with the tower, the SEKISUI SPI project included interior and facade renovations:

  • A new 10,000-square-foot appLab™, which is a process area to turn raw product into prototype applications, features an interior mezzanine for office space, plus a workshop area
  • A 4,600-square-foot facade upgrade featuring Sage glass and insulated metal panels to its Customer Collaboration and Finance offices
  • Full remodel of existing finishes and fixtures in the locker room

Renovations took five months to complete.

The remote office area before renovations (above) and after (below)

Expansion for Godshall’s Quality Meats

Phase 1:  Blue Rock renovated and expanded Godshall’s production facility in Lebanon, PA with a 38,000-square-foot addition that features two main levels for production and another mezzanine for offices.

The main levels include cold storage, clean rooms, packaging and washing rooms, plus production and storage areas. Most of the facility is conditioned to 36 degrees F, while other areas are set between 60 and 70.

Phase 2:  Blue Rock re-purposed one existing large room into five new blast chillers and one stick room. Work included:

  • Cutting and removing existing slab
  • Excavating and removing enough materials to provide new floor drains
  • Providing a new mud slab with electric heating system
  • Insulated metal panel walls
  • Epoxy flooring

Phase 3:  Fit-out work consisting of expanding existing restrooms, providing a new insulated metal panel locker room and wash room.

Blue Rock Delivers Urban’s “Lifestyle Center” at Devon Yard

  • Client:                                   Urban Outfitters, Inc.
  • Location:                              Devon, PA
  • Size:                                        44,200 SF
  • Architect:                             NewStudio Architecture
  • Responsibility:                  Construction Management
  • Construction Period:      13 Months

After many years of planning, Blue Rock is very proud to deliver Urban Outfitters Inc.’s highly anticipated “vibrant Devon Yards lifestyle center” in Devon, PA.

The 44,200-square-foot center features dining, retail and event spaces including:

  • A two-level, large format Anthropologie store that also includes a BHLDN wedding store (22,000 SF)
  • Terrain Garden Center (4,700 SF)
  • Terrain Garden Cafe (3,500 SF)
  • Terrain Events Center (8,000 SF) to host private events
  • Amis Trattoria restaurant (6,000 SF)

The five freestanding buildings sit on six acres across the street from the Devon Horse Show on Lancaster Avenue in Devon, PA.

Thanks to NewStudio Architecture, Devon Yard maintains the pastoral setting as a tribute to the Devon Horse Show grounds. NewStudio’s design incorporated local materials such as Pennsylvania field stone and reclaimed barn wood, existing Waterloo Gardens gates, and features a vernacular farm and greenhouse style

“It’s probably the best project that I’ve ever been a part of with Blue Rock,” said Project Executive Cameron Barr.  “We’ve done some great projects at the Navy Yard, taking historic buildings and restoring them, but I think with all the different retail components combined with the retail store, it’s just beautiful. It was just an amazing project.”

In order to create space for this unique facility, the project required demolishing about two city blocks of buildings at the former Waterloo Garden site.

“There was one existing main building, four greenhouses, a three-story office building, and four residential homes we had to demo as well,” said Barr.

Once the six-week demolition project was finished, construction took another nine months to complete.

While constructing the buildings, there was a need to start tenant improvements at the same time.

“This was a big deal considering some of the buildings didn’t even have roofs yet because they were polycarbonate roofs with long lead times,” said Barr. “We literally had structures built and had to tarp the entire roof and sides so that we could start running duct work and electric all underneath.

“That was probably one of the biggest challenges, not having a full enclosed building prior to starting TI work.”

The project also called for meticulous coordination with subcontractors, inspectors, tenant supplied materials, and even some road work that included rebuilding half of Devon Road while it remained open to traffic.

“We wanted to take this really unique environment and mix it with the right tenants to create a consistent experience, a place where people will want to come and stay for a while,” saidDave Ziel, Chief Development Officer for Urban Outfitters, Inc.

In August 2018, Devon Yard opened with rave reviews.



New Headquarters for SJ Glass & Door

Blue Rock is constructing a new 70,000-square-foot headquarters for South Jersey Glass & Door in Vineland, NJ, just a half mile away from its current location.

The new building will be on a section of a roughly 26-acre farm, and feature approximately 26,000 square feet of office space. The remaining space will be used for fabrication and assembly of glass and glazing systems.

Completion is expected in Fall 2019.

“South Jersey Glass is not only a client, but also a very reliable subcontractor for Blue Rock,” said Blue Rock Vice President Jason Quenzel. “They consistently perform well and deliver a high-quality product.”


Princeton Golf Performance Center

Blue Rock is design-building a 1,500-square-foot Princeton Golf Performance Center for The Department of Athletics, Princeton University, at the Springdale Golf Club, which is “nestled among the beautiful buildings of Princeton University and Theological Seminary”.

The new building will incorporate a training area and a ball-flight monitor area, which opens to the existing driving range

The all-season practice facility will also feature:

  • Four hitting bays
  • A driving simulator
  • Meeting room
  • Kitchenette
  • Men’s and women’s lockers

Site work started October 8, 2018 and completion is set for March.

The course is home for the Princeton University men’s and women’s golf teams.

Formed in 1895, Springdale is one of the oldest golf clubs in New Jersey.