Zotefoams
Owner
Zotefoams
Location
Walton, KY
Size
53,000 SF
Completion Date
Project Delivery Method
Project Summary
The Zotefoams Walton Full Process Expansion involved the design and construction of a major addition to the company’s manufacturing facility in Walton, Kentucky. The project included a new production building designed to support advanced plastic foam manufacturing processes, including extrusion equipment and high-pressure nitrogen gas processing systems. In addition to expanding production capacity, the project also incorporated renovations to the existing facility to support operations, maintenance, and employee amenities.
The expansion required extensive coordination of building systems, manufacturing infrastructure, and site improvements to support specialized industrial equipment and logistics operations. Civil work, building expansion, new offices, mezzanine levels, and upgraded site circulation were all integrated to ensure seamless production flow while maintaining ongoing plant operations during construction.
Key Features
- Approximately 50,000–60,000 SF manufacturing expansion to accommodate new extrusion and processing equipment
- New plant process area with mezzanines supporting production and equipment platforms
- Installation areas for high-pressure nitrogen gas process vessels and specialized manufacturing systems
- Renovation of existing facility spaces, including maintenance areas, offices, training rooms, and support spaces
- New employee amenities, including break rooms, restrooms, and administrative offices
- Construction sequencing designed to maintain ongoing plant operations and shipping activities during the expansion
Project Photos