Cirrus Facility 5 Completed

Cirrus Facility 5 was completed earlier in 2015 in Hermantown, Minnesota, transforming a long-unfinished 38,500-square-foot office building into an aviation manufacturing, research and development facility for Cirrus Aircraft.

The facility includes a loading dock with leveler doors, overhead doors and a surface parking lot. It was the seventh project Kraus-Anderson completed for the client.

Cirrus Aircraft Corporation employed approximately 600 people in nearby Duluth, its headquarters and main manufacturing location, and operated an additional manufacturing facility in Grand Forks, North Dakota.

Cirrus Director of Facilities Alan Jusczak and Kraus-Anderson Project Manager Andy Towner shared details about the Facility 5 project.

What Was the Building Used for Before the Renovation?

TOWNER: It was an unfinished building. Construction had been halted by the developer because of the economy, and it had not been used in seven years.

Its original intended use was as a commercial office building. The previous work had enclosed the building, completed underground work and backfilled the site, but the project was left unfinished.

What Were the Main Challenges of the Cirrus Facility 5 Project?

JUSCZAK: The challenge was taking a partially built building that had been started in 2007 and had sat cold for seven years, then working within the existing building layout to meet Cirrus operational needs.

TOWNER: The biggest challenge was performing all the dirt work and concrete work inside the building. The equipment produced exhaust, so we had to make sure fresh air was brought into the building to maintain safe conditions.

Renovating an unfinished structure for advanced manufacturing required coordination around existing conditions, construction sequencing, ventilation and the client’s operational goals. Learn more about manufacturing construction and adaptive reuse.

How Did the Construction Team Manage Exhaust and Indoor Air Quality?

TOWNER: We used indoor air monitors, and Lee Hauble, the superintendent, was constantly balancing keeping the building heated with bringing in enough fresh air to maintain safe conditions.

Indoor air monitoring and ventilation planning were important because interior earthwork and concrete operations occurred inside an enclosed building during winter construction. Learn more about indoor air quality considerations.

How Did Winter Weather Affect the Project Schedule?

TOWNER: Weather was a major factor. We battled cold temperatures while constructing the loading dock addition.

We worked closely with our concrete subcontractor, Home Menders Incorporated, to provide temporary heat and cover. With the amount of construction activity in the region, there was also a shortage of ground-thaw heaters.

The Kraus-Anderson Duluth office coordinated internally across projects to schedule heater use. Because one project had heaters rented for the season, the team could share them. That worked well and helped save costs.

How Did Kraus-Anderson Help Address Project Challenges?

JUSCZAK: Kraus-Anderson helped address the need to build a loading dock off the back of the facility, the complication of a water table at 4 feet or less, the tight occupancy schedule and winter working conditions.

Were Special Measures Needed to Maintain Client Operations During Construction?

TOWNER: No. Cirrus moved in after construction was complete.

However, the team completed significant coordination around owner-provided equipment. Fortunately, Cirrus Facilities Director Alan Jusczak was detailed and organized.

How Did the Project Deliver Value for Cirrus Aircraft?

TOWNER: Yes, the project had a tight schedule, and we met the deadlines. We were also able to return more than $30,000 to the client.

JUSCZAK: Kraus-Anderson provided a strong project foreman who kept subcontractors on time and on budget. Through value management and careful decisions by Kraus-Anderson and Cirrus, the building functioned as intended and operating costs were lower than expected.

The project highlights how facility renovation, detailed planning and collaboration can help industrial clients bring unfinished space into productive use. Explore aviation construction, industrial operations expansion and the Kraus-Anderson Duluth office.

In this interview, Cirrus Aircraft and Kraus-Anderson discussed the transformation of an unfinished Hermantown office building into an aviation manufacturing, research and development facility. The discussion covered industrial renovation, indoor air quality, winter construction, loading-dock construction, tight scheduling, owner-provided equipment and lower-than-expected operating costs. Learn more about manufacturing facility renovation, aviation construction and strategic facility planning.