At Bassett Mechanical, we specialize in delivering complex, multi-trade projects with precision, speed, and a strong commitment to quality. By integrating planning, fabrication, and field execution, our teams help customers meet demanding schedules while maintaining safety and operational continuity.
Our work at Conagra’s Darien, WI facility, is a prime example. Faced with a highly compressed schedule, challenging winter conditions, and a critical production deadline, our team successfully delivered a new tunnel freezer system and supporting infrastructure—without compromising safety, quality, or productivity.
Project Overview
Bassett partnered with Conagra and an engineering firm to execute a comprehensive system upgrade, delivering a fully operational refrigeration, HVAC, plumbing, and process system. The project scope included:
- Installation of a new tunnel freezer system
- Design and construction of a large structural valve and access platform
- Installation of ammonia refrigeration piping and valve systems
- New process air handling (desiccant) unit
- Installation of a new intercooler/circulator vessel
- Extensive plumbing and process piping scope
- Supporting HVAC and mechanical systems
This project required seamless coordination across multiple disciplines and a unified approach to delivering on a tight timeline.
The Challenge
- Aggressive schedule: Originally planned around limited annual shutdown windows (Memorial Day and Thanksgiving), the timeline was further compressed, requiring execution within weeks instead of months.
- Weather delays: A planned Thanksgiving crane pick was canceled, pushing critical structural work into winter conditions and costing nearly a month of progress.
- Existing conditions: The roof structure could not support new equipment, requiring a completely new elevated platform that ties into the existing building steel.
- Tight working conditions: Installation on insulated metal panel (IMP) roofing created additional access and coordination challenges.
- High stakes: Production downtime is costly, making precision, speed, and reliability essential.
The Solution
Advanced Planning & VDC Integration
Bassett’s Virtual Design & Construction (VDC) team played a critical role from the start:
- Developed a highly detailed 3D model to coordinate all trades
- Used laser scanning to capture existing conditions and eliminate unknowns
- Identified and resolved potential conflicts before field installation
- Drove CNC fabrication, enabling precision-fit components
This level of planning ensured that what was designed digitally translated seamlessly to the field.
Prefabrication for Speed & Efficiency
To overcome schedule constraints, the team leaned heavily into prefabrication:
- Structural platform components were built in large, preassembled sections
- Mechanical and piping systems were fabricated off-site whenever possible
- Assemblies were staged for rapid installation during crane picks
The result: installation durations were significantly reduced, allowing the team to recover lost time and maintain progress toward the deadline.
Precision Installation
The structural platform—one of the most complex elements of the project—was:
- Fully coordinated to integrate with the existing building steel
- Installed using dual cranes for maximum efficiency
- Set in approximately a day and a half, compared to an anticipated multi-day install
Thanks to detailed planning and prefabrication, installation required minimal field reworking; every connection was aligned as intended.
Collaboration Across Teams
This project was a true team effort, involving coordination across Bassett’s office, shop, and field teams, including:
- Metal fabrication and design teams
- VDC specialists across piping, process, and sheet metal
- Refrigeration, plumbing, HVAC, and structural teams
- Shop and field foremen, installers, and startup personnel
Strong collaboration extended beyond Bassett, with frequent planning and coordination alongside Conagra and other trade partners.
Overcoming Complexity
This project stood out not just for its size, but for its complexity:
- Extensive coordination with existing infrastructure
- Integration of multiple systems within a constrained footprint
- Real-time problem-solving as conditions evolved
- Managing multiple contractors while maintaining the schedule
To stay on track, the team increased manpower, maximized productivity during favorable weather windows, and maintained a strong focus on safety and efficiency.
Results
- Met the critical production deadline
- Recovered schedule despite weather delays
- Reduced installation time through prefabrication
- Achieved high-quality, accurate installation
- Delivered a fully operational system ready for startup
- Maintained minimal disruption to plant operations
Conagra was highly impressed with the team’s ability to execute under pressure and deliver quality work in a short timeframe—strengthening the partnership and creating opportunities for future collaboration.
“This project is a great example of what can be accomplished when you combine strong planning, teamwork, and a commitment to getting the job done right. Despite weather delays and a compressed schedule, our team stayed focused, worked efficiently, and delivered a high-quality result for the customer,” said Ryan D., Project Manager
We are Creating Customers for Life®
Projects like Conagra Darien highlight what sets Bassett apart:
- Total Project Integration – One team coordinating multiple trades
- Advanced VDC Capabilities – Driving accuracy and efficiency
- Prefabrication Expertise – Reducing field time and risk
- Ability to Execute Under Pressure – Delivering results on critical timelines
Dorn says, “We have a team of highly skilled professionals who pay close attention to detail and take great pride in their work. For us, doing things the right way isn’t an option; it’s the only way. That commitment has earned us a customer for life and created continue opportunities to strengthen our relationship.”
Watch It Come Together
Check out the time-lapse video of the platform installation to see this complex project come to life!
