TruStile Doors Headquarters

Completion Date: May 2020
Size: 269,000 SF
Location: Denver, CO
Type of Project: Office, Light Industrial, Build-to-Suit
Ryan Responsibility: Design-Build Construction

We build stories

Overview

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A leading manufacturer of custom architectural stile-and-rail doors, TruStile Doors needed to consolidate and expand its Denver operations into a single headquarters.

After costing out remediation, the decision was made to locate a different project site, and despite limited options, one was located nearby. The new site still presented many challenges, including multiple intersections, line rebuilds, environmental cleanup and grading issues. Permitting involved approximately two dozen permits and entities, requiring extraordinary due diligence, as we complied with Colorado water rights, EPA emissions standards, and the company’s dedication to stewardship. Meanwhile, our field team leaders doubled down on recruiting highly skilled workers in a busy, competitive market.

Design of the sloped building—which evolved throughout the project—required utilizing every square inch to fit the site, meet grading and control costs, and make the building work. Specifications included a state-of-the-art dust collection biomass boiler system to heat and cool the entire building from waste production, and installation required complex coordination with domestic and foreign vendors. The project utilized one of the largest installations of a new storm retention technology in the nation, to offset the site restriction challenges.

The resulting two-story, 260,000-SF manufacturing warehouse and office facility doubles production capacity and expands workforce potential, while providing a stunning Mountain Modern space for entertaining TruStile’s customers and vendors.

Sustainability

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The headquarters of TruStile Doors reflects Ryan’s commitment to the incorporation of sustainable real estate solutions that help protect the planet while achieving clients’ goals. Combining a forward-thinking approach with sustainability-focused technologies, the Ryan team collaborated to implement an innovative dust collection biomass boiler system that uses the facility’s waste to heat and cool the entire building.

Installing this biomass boiler was a game-changer, as it can produce 10,000,000 BTU (British thermal unit, or the measurement of cooling capacity) per ton of solid fuels consumed. As a result, the HVAC system can consume an estimated 40% of the available energy produced by the biomass boiler during the peak winter heating demand and as little as 20% of the available energy during the spring and fall. This allows for other building operations to utilize the excess energy.

At the time it was built, this project also utilized one of the largest installations of a new storm retention technology in the country—including a large underground detention system— to offset the site restriction challenges of being located within a 100-year floodplain and tight site constraints, which did not allow for traditional detention. The Ryan team also remained thorough and committed, completing the required environmental cleanup from contaminated soils on the project site.

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