Project Rodeo

Knauf Rises as a Towering Industrial Landmark

Mcgregor, TX

When Knauf Insulation needed to build one of the largest recycled glass processing facilities in the region, they turned to our team to transform their vision into reality. What started as a pre-COVID design quickly evolved into something much more ambitious – a towering manufacturing complex that processes recycled glass into insulation materials, visible from miles away across the Texas landscape.

The Knauf Project represents more than just construction; it’s a testament to adaptive problem-solving and collaborative partnership. Originally designed as a pre-engineered metal building, we pivoted to tilt-wall construction to help control costs after COVID-related price increases. This decision required us to engineer and erect massive concrete panels – some reaching 75 to 80 feet tall – creating a technical challenge that showcased our expertise in large-scale industrial construction.

The facility’s scale is genuinely impressive. At nearly 140 feet tall with a smokestack extending 200 to 300 feet into the sky, this manufacturing plant dominates the McGregor, Texas skyline. The 650,000 SF complex spans 170 acres and houses sophisticated equipment that transforms recycled glass into insulation through an intricate process from the high-temperature furnace end all the way to the finished product warehouse.

Working in a design-build capacity, we took ownership of both the design evolution and construction execution when the original project team became unavailable post-COVID. This meant coordinating not just our own trades and subcontractors but also managing relationships with Knauf’s specialized vendors and equipment installers – a complex dance of scheduling and logistics that required constant communication and flexibility.

One of the most technically demanding aspects involved installing a 220-megawatt electrical substation complete with transformers, providing us with valuable experience that translates directly to data center and other high-power industrial projects. The electrical coordination alone presented unique challenges as supply chain disruptions made securing specialized equipment particularly difficult.

The interior spaces reflect Knauf’s partnership with USG, featuring specialty ceiling products in conference rooms and break areas that highlight both companies’ commitment to innovative building materials. These finished spaces provide a striking contrast to the industrial manufacturing floor, where the real magic of glass-to-insulation transformation happens.

Throughout the 29-month construction period, scope changes became a constant reality. What began as a $79 million contract grew to over $102 million as Knauf refined their vision and added capabilities. Rather than viewing these changes as obstacles, we embraced them as opportunities to deepen our partnership and demonstrate our ability to adapt without losing momentum.

The community impact of this project extends far beyond the impressive skyline addition. This facility represents significant job creation and economic development for the McGregor area, while also advancing sustainability goals through its core mission of recycling glass waste into useful insulation products.

Project Facts

Industry Sector: Industrial
Cost: $79,000,000
Size: 650,000 SF / 170 Acres
Delivery Method: Design-Build
Owner: Knauf Insulation, Inc.
Architect: Merriman Anderson Architects, Inc.