Research & Development Expansion for CaptiveAire
CaptiveAire Systems partnered with Warfel for the Research & Development Expansion in East Petersburg, Pennsylvania. The 36,324 square foot project expanded the client’s existing warehouse facility for growing research and development operations. The addition created a larger space for innovation and training development while tying new work into an occupied facility. The project included two training rooms and modern office space in part of the original warehouse. Because staff continued daily operations during construction, phasing had to account for active work areas and gradual office transitions.
Planning Around Active Operations
Rather than treating the work as a single construction area, the project moved through multiple phases. This approach gave CaptiveAire room to maintain daily operations while staff transitioned into new office areas over time. Utility tie-ins and electrical work required extra coordination, so Warfel scheduled those activities during evenings and weekends. As a result, key building connections could move forward with less disruption to regular working hours. Meanwhile, the phased sequence kept each office transition connected to the larger construction plan.
Coordinating the Research & Development Expansion
Several building upgrades required coordination with existing warehouse conditions. A new sprinkler system was installed throughout the facility, requiring work around existing ductwork and ongoing staff operations. Owner-provided ductwork also became part of the project, requiring flexibility during installation. As installation progressed, communication helped align ductwork, sprinkler work, and renovated office areas within the evolving facility. Therefore, the building systems work remained closely tied to both existing conditions and the new layout.
One of the more technical parts involved raising the floor in the former warehouse area. Warfel collaborated with various trade partners to create a level surface suitable for offices. This work addressed the existing floor condition while meeting the renovated space’s structural and functional needs. Because the warehouse area was changing into modern office space, floor leveling became part of the overall conversion. It also connected the renovation scope to the practical needs of the new office use.
Completing the Research & Development Expansion
The completed Research & Development Expansion brought together expansion, training rooms, office renovations, sprinkler work, ductwork coordination, and floor leveling. Across the 11 month schedule, Warfel worked around active operations while coordinating new work with existing conditions. The project reflects a steady, practical process shaped by phasing, communication, and respect for CaptiveAire’s operations.
