D-A Packaging LLC

Complex Move Management Project Abstract

The relocation of D-A Packaging presented unique challenges, beginning with overall construction project management and coordination between multiple municipalities. D-A’s facility at 5185 National Western Drive was acquired by the City of Denver through Eminent Domain for the National Western Stock Show expansion. Pivotal was involved with the complex move management from the outset, conducting a relocation analysis per the Uniform Relocation Act (URA) for the City of Denver. Over two years, Pivotal assisted D-A in:

• Identifying a suitable new location.
• Coordinating necessary building improvements to meet code.
• Selecting a qualified general contractor.
• Providing overall construction project management.
• Relocating all contents and equipment.

Pivotal managed the deconstruction, transport, and reconstruction of multiple production lines, stored wares, storage tanks, generators, transformers, racks, and private offices from approximately 60,000 SF to a co-occupied facility. Extensive construction improvements were performed at the new facility to accommodate D-A’s hazardous materials needs.

Project Stats

• Client: D-A Packaging LLC
• Origin Facility Size: ~60,000 SF
• Key Challenge: Relocating a chemical production facility with hazardous materials storage, within a strict timeframe due to eminent domain.
• Key Services: Relocation analysis, site selection, construction project management, relocation execution.
• Key Stakeholders: City of Denver, City of Commerce City, South Adams County, Burns McDonnell (engineering design), DCB (general contractor), UHY and The Pachner Company (plan reviews), Rocky Mountain Petroleum.

Project Overview

Pivotal Project Management spearheaded D-A Packaging’s complex move management, which encompassed detailed inventory and hazardous material transport, as well as other critical relocation services. Strategic destination selection and meticulously coordinated construction minimized operational downtime. This ensured continuous operations throughout the intricate move, meeting critical timelines

Initial Relocation Assessment

Pivotal, initially hired by H C Peck & Associates (on behalf of the City of Denver), conducted a comprehensive relocation assessment for D-A. This two-week analysis involved meticulously cataloging all furniture, fixtures, equipment, tanks, racking, and more. This detailed inventory enabled the City of Denver to provide D-A with the necessary relocation funds.

Destination Identification

As the largest single producer of windshield washer fluid in the Western U.S., D-A requires significant on-site methanol storage in above-ground storage tanks (ASTs). Other chemicals (glycerin, propylene glycol, and ethanol) are also stored on-site. Rail access was crucial for chemical deliveries. Finding a location that met these requirements and was approved by the relevant Authorities Having Jurisdiction (AHJ) for hazardous material storage proved challenging.

After months of searching, the facility owned by Rocky Mountain Petroleum was selected. It offered:

• Rail access.
• A pre-existing AST tank farm.
• Additional yard space.
• Approval from Commerce City for hazardous material storage.

D-A subsequently purchased Rocky Mountain Petroleum and merged the two businesses.

Construction Design and Build

Due to the high methanol content in windshield washer fluid, specialized storage considerations were essential. Pivotal assisted D-A in selecting Burns McDonnell as the engineering design firm and engaged UHY and The Pachner Company to expedite plan reviews and permitting due to the tight deadlines. Collaboration with multiple entities was crucial: Burns McDonnell (engineering design), DCB (general contractor), City and County of Denver, South Adams County, and City of Commerce City.

Key construction focuses included:

• Installation of a 3-hour fire wall.
• Construction of a concrete pad for external equipment.
• Reorganization of electrical and plumbing lines.

Pivotal and D-A negotiated revised construction budgets with the City of Denver due to the tight timelines. Pivotal also managed the reorganization of the destination facility prior to construction, removing interior tanks, production lines, and drum lines.

Relocation Execution

The relocation coincided with D-A’s peak season (fall and winter). Minimizing downtime was critical. Pivotal developed a detailed move plan, prioritizing the tear-down and relocation of wash lines, fill tanks, mixing tanks, racking, and product removal. This required precise coordination of electrical, mechanical, plumbing, rigging, transportation, and racking vendors. Pivotal successfully recommissioned the main production lines in less time than the estimated shutdown period. Subsequent phases involved relocating smaller production lines, finished goods, raw materials, and offices.

Additional key aspects of the relocation:

• Relocation of multiple 20,000+ gallon AST tanks (requiring city inspector presence).
• Ground core testing (per city code).
• Acquisition of a new permit for a relocated backup generator.

All contents, equipment, IT and telephony systems, racks, and goods were successfully relocated and installed before the city-imposed deadline.