Ball Aerospace and Technologies Corp.
Boulder & Westminster, Colorado
90,000 sf New Construction
$28M Total construction cost
Increased cleanroom capacity by 60%
Ball Aerospace and Technology Corporation (BATC) recently undertook its largest facilities expansion in over twenty years. CPI was hired as part of the BATC Capacity Expansion Program (BCEP) and construction management team to oversee six projects across two sites in Boulder and Westminster.
Each project offered unique challenges including:
Remodel work in occupied buildings
High-bay manufacturing spaces
Cleanroom environments & testing labs
A 10m anechoic RF range & a large thermal vacuum chamber
Annual cash flow targets mandated by Ball Corporate
There were four separate design teams involved that CPI managed as a part of one overall program. During the multi-year effort, CPI provided cost control for the entire program, project management during three phases of construction, and start-up/commissioning validation for all completed projects. By working with the program team, Owner’s staff, designers, and construction contractors, CPI was able to meet every cash flow target perfectly and all projects were completed on budget and met BATC’s scheduled occupancy dates.
As part of our services, The CPI Group developed several new technology tools and a cost reporting process given to BATC for ongoing use. The program’s monthly invoices were processed through our cost control database directly into BATC’s accounting system saving hundreds of hours of data entry and eliminating errors. Our team built a cleanroom materials database providing the design and construction teams a list of materials approved by BATC’s internal quality control and EH&S groups. CPI also redefined how project construction costs were allocated and reported to corporate accounting. By using cost segregation methods and designing a standard process, CPI generated over $1 million in savings and tax avoidance for the Owner. This new cost control process has been adopted as the standard process for BATC’s facilities group and will continue to provide benefits for years to come.