Keystruct Projects

Former Manufacturing & Warehouse Facility Gains New Life as Distribution Center

Kelly Tetkoskie February 19, 2019
New 485 Distribution Center, St Johns Church Road, Shiremanstown, PA

When Quaker Oats closed their manufacturing plant and warehouse in Shiremanstown, PA, the 712,500 SF building was left vacant for years, before a new owner brought a vision to repurpose the building for an updated use. Keystruct Construction led the Design/Build team and worked closely with the owner, Endurance Real Estate Group, to create a multi-tenant, modern distribution center from the old structure.

During the initial pre-construction meetings, Keystruct worked with Endurance and SAA Architects to determine the best approach to create the tenant spaces. The original facility had been constructed in stages, beginning in 1995, leaving broken transitions between the interior spaces, and a chaotic exterior appearance.

The initial work involved selective demolition of the existing warehouse, including removal of the front and end walls, roof, roof steel, steel columns and selective interior demolition. Following this demolition work, the existing structure was ready for interior renovations and a new building envelope. The more extensive demolition involved the 310,500 SF multi-story office and former manufacturing space, including all multi-story vertical structures, foundation walls, slabs, and footers. The complete removal of these areas made way for the construction of a completely new warehouse space.

As with any long-term construction project, winter weather conditions impacted the construction in early 2018. Fortunately, the project was able to stay on track by coordinating the work on the renovation of the interior spaces when the weather was uncooperative. Additional challenges arose while connecting to the existing building systems, requiring the superintendent to work closely with the individual subcontractors to ensure the renovated and newly constructed portions of the building were tied-in successfully.

Traffic control on and around the site also presented some challenges. Because the project site is directly adjacent to a rail line, material deliveries had to be coordinated so the deliveries were not delayed due to rail activity. Additionally, because of the disruption to traffic flow on the adjacent roadway due to the rail activity, deliveries and traffic control around the jobsite were scheduled to reduce impacts to local drivers during rush hour time periods.

The finished 485 Distribution Center is a 453,000 SF modern, bulk warehouse, with multiple loading docks, and significant trailer storage and vehicle parking. The renovated portion features enlarged overhead doors with new concrete ramps to access the raised floor from the exterior, employee breakroom and kitchen, and office spaces. The finished space in the renovated portion is 244,000 SF with 28’ clear height. The newly constructed warehouse space features a separate storefront entrance and 209,000 SF of space with 32’ clear height. The new 485 Distribution Center is conveniently located near Interstates 81 and 83, and the Pennsylvania Turnpike.

Demolition of Multi-Story and Manufacturing Spaces
Demolition of Multi-Story and Manufacturing Spaces
Erection of Wall Panels for New Warehouse Section
Erection of Wall Panels for New Warehouse Section
New Loading Docks for the Renovated Warehouse Space
New Loading Docks for the Renovated Warehouse Space
New Warehouse Space Loading Docks
New Warehouse Space Loading Docks
Storefront Entrance to New Warehouse Space
Storefront Entrance to New Warehouse Space