Alston Construction completed a tenant improvement project that is converting an existing industrial building in Edison, New Jersey, into a state-of-the-art medical laundry processing facility for Nixon Medical.
Designed to strengthen Nixon Medical’s service network throughout the Northeast, the approximately 70,000-square-foot facility will serve as a centralized processing hub between the company’s operations in Hartford, Connecticut, and the Mid-Atlantic region. Once complete, the facility will help support the company’s continued growth while improving distribution and operational efficiency.
A Complex Renovation from the Ground Up
Unlike a typical tenant improvement, this project began with very little existing documentation. The aging building, originally constructed decades ago and expanded over time, had no original drawings available, requiring Alston’s design-build team to verify existing conditions through extensive field investigations before construction could begin.
The original structure also presented unique structural challenges. Exterior wall panels contained post-tension reinforcement that required ground-penetrating radar (GPR) scanning before new dock doors, piping penetrations and utility openings could safely be installed. Similar investigations were required throughout the building slab before trench drains, equipment pits and underground utilities could be added for Nixon Medical’s processing systems.
Further complicating the work, portions of the warehouse floor included multiple slab layers that measured from 12-14 inches thick—far beyond what is typically encountered in industrial renovations. The team carefully evaluated each area before cutting into the floor, ensuring the existing structure remained protected while accommodating the specialized process equipment.
Coordinating a Highly Specialized Facility
As the design-build contractor, Alston worked closely with Nixon Medical, design partners and equipment suppliers throughout the project to coordinate the building’s complex mechanical, electrical and plumbing systems.
While Nixon Medical supplied its specialized washers, dryers and processing equipment, Alston designed and installed the infrastructure needed to support those operations, including steam, compressed air, softened water, tempered water and wastewater systems, along with the boiler room and associated process piping.
Because every utility connection had to align precisely with manufacturer specifications, the project required extensive coordination between the design team and equipment vendors to ensure each system integrated seamlessly.
Staying Flexible Through Unexpected Challenges
The project faced several unforeseen obstacles, beginning with a four-month permitting delay tied to a neighboring property issue. Rather than allowing the schedule to stall, the team adjusted sequencing and began installing overhead mechanical systems that could be completed ahead of permit release, helping preserve valuable time once construction fully resumed.
Shortly after permits were approved, another surprise emerged. During planned roof replacement work, the existing roof deck was found to be significantly deteriorated. What began as a limited roof scope quickly became a complete roof deck replacement. Working closely with the owner, Alston documented the conditions, evaluated options and implemented the full replacement, providing Nixon Medical with a long-term solution that protects both the building and its investment in specialized equipment.
Throughout construction, Alston also coordinated closely with multiple owner-directed equipment installers whose delivery schedules evolved as equipment arrived from overseas. Frequent coordination meetings helped align installation activities, maintain safe working conditions and kept the project moving despite changing circumstances.
Delivering Long-Term Value
Projects like Nixon Medical demonstrate the value of a collaborative design-build approach when transforming older industrial facilities into highly specialized operational environments. By combining thorough field investigation, proactive problem-solving and close coordination with the owner and design partners, Alston is helping deliver a facility that will support Nixon Medical’s long-term growth while positioning the company to better serve healthcare customers across the Northeast.
