CASE STUDY: PALERMO’S OFFICE & PRODUCTION EXPANSION
Food production facilities require careful planning, strict sanitation standards, and precise coordination—especially when renovations take place within an active plant. When Palermo’s Pizza partnered with Kelly Construction & Design, the project involved upgrading office spaces, improving production areas, and constructing a new building addition, all while keeping operations running and meeting aggressive deadlines. The result was a series of strategic improvements that enhanced both employee spaces and production efficiency.
OFFICE REMODEL: UPGRADING EMPLOYEE SPACES
The office portion of the project focused on creating a more functional and comfortable workspace for employees. Existing ceilings, flooring, and lighting were replaced to modernize the environment and improve overall efficiency.
New spaces were added to better support daily operations, including additional offices, a locker room, a mother’s room, and a frock room. The lab area was also upgraded with new countertops, sinks, appliances, and a durable epoxy floor designed for easy cleaning.
Restrooms were renovated with new fixtures, while the break room was reconfigured with a new layout, cubbies, improved lighting, and power for vending equipment. As part of the remodel, the fire suppression system was reworked to accommodate the new spaces and ceiling layouts.
PRODUCTION AREA IMPROVEMENTS
Upgrades within the production space focused on sanitation, durability, and operational improvements. Dock
operations were enhanced by replacing one dock leveler and adding a second, along with new dock seals.
Throughout the production floor, stainless steel finishes were installed to improve cleanability and durability,
including 4-foot-high stainless wainscoting and protective coverings for columns and bracing up to 10 feet.
All floor drains were replaced with sanitary drains equipped with lockable, removable basket strainers.
Additional improvements included hands-free faucets at hand-wash stations and upgraded LED lighting throughout the space.
PHASE 1: ADDITION & FREEZER CONNECTION
The first phase of the building addition required creating a new opening through an existing concrete masonry wall to connect to an adjacent freezer
space operating at –5°F. To maintain the freezer temperature during construction, a temporary insulated enclosure was built while work progressed on the expansion.
The team removed the existing floor to install a thermal break and new footings before insulating, backfilling, and pouring new concrete. After shoring the wall, a section of CMU was removed and a steel lintel was installed to support the opening. A new bump-out structure with a two-hour fire rating was then constructed, along with a fire door and high-speed roll-up door.
This phase also included widening an overhead door from 8 feet to 12 feet and constructing new footings, frost walls, slab work, and a concrete silo
pad.
A TIGHT TIMELINE
The contract was signed on June 22, 2023, and the silo pad needed to reach 4,000 PSI by July 31 for silo delivery scheduled the following day. During excavation, the team discovered the facility’s main high-voltage power feeds ran directly beneath the planned addition.
Excavation had to proceed carefully to avoid damaging the lines, and engineers quickly designed a structural bridging solution. Using 5,000 PSI concrete, the silo pad successfully cured to 6,000 PSI by July 28, ahead of the deadline.
PHASE 2: NEW PRODUCTION ADDITION
The second phase added a 2,000-square-foot insulated metal panel (IMP) building supported by structural steel and finished with an R-30 membrane roof. The new space included an epoxy floor, fire sprinklers, and a cleanable dropped ceiling designed for food production environments.
Supporting infrastructure included a 2,500-gallon precast grease interceptor, a sanitary pumping crock for floor drains, and a stand-alone 30-foot steel tower to support a new HVAC unit.
During construction, delivery of the insulated metal panels was delayed due to a manufacturing issue with the exterior metal skin. While installation had originally been scheduled for late August, the panels were ultimately delivered on September 27. Despite the delay, the team adjusted sequencing to keep progress moving toward the owner’s planned production startup of October 16, 2023.
DELIVERING RESULTS
The Palermo’s project required creative problem-solving, detailed coordination, and careful scheduling to complete improvements within an active production facility. Through phased construction and proactive planning, the project delivered upgraded office amenities, improved sanitation and efficiency in production areas, and new facility space to support Palermo’s continued growth.
