Jayco Hawaii – Project Spotlight
Western Steel’s pre-engineered solutions in Hawaii for Jayco emphasize open floor plans and ample natural light to enhance productivity and efficiency.
Project Spotlight
Big Island Grown
Net‑Zero Cultivation & Distribution Facility
Big Island Grown sought to create more than a standard cultivation building—they aimed to build a high-performance, net-zero energy facility aligned with Hawaii’s clean-energy vision. Western Steel Buildings partnered with their team to deliver a two-story, 35,000 sq. ft., fully climate-controlled steel structure designed for cannabis cultivation, processing, and distribution.
This facility supports precise environmental control while operating on a renewable power system that combines rooftop solar with hydroelectric generation. Western Steel engineered the structure with a full mezzanine level, insulated metal panels, and corrosion-resistant materials ideal for Hawaii’s coastal climate. The resulting building delivers modern efficiency, strict environmental stability, and long-term durability while supporting the client’s sustainability goals.
Project Scope & Scale
- Use: Cannabis Cultivation, Processing & Distribution Facility
- Building Size: 35,000 sq. ft.
- Layout: Two-story facility with full mezzanine (joists & decking)
- Frame Type: Pre-engineered clear-span steel structure
- Wall System: Insulated Metal Panels (IMP) for climate stability and antimicrobial performance
- Roof System: Standing seam metal roof with integrated solar array
- Environmental Control: Integrated systems for humidity, temperature, air filtration, and clean-room style spaces
- Interior Components: Grow rooms, processing rooms, drying/curing rooms, secure storage, packaging, office/support areas
Key Challenges
- Achieving net-zero energy in a tropical, high-humidity climate.
- Integrating a full mezzanine without sacrificing headroom or operational flow.
- Designing a roof structure that supports both solar panel layout and proper rainwater drainage.
- Providing an interior-ready, antimicrobial, climate-controlled envelope capable of handling cannabis cultivation requirements.
- Ensuring long-term corrosion resistance in a coastal island environment.
Solution / Approach
- Used insulated metal panels for both roof and walls to minimize energy load, improve thermal stability, and support sanitary operations.
- Engineered a full mezzanine system to maximize usable space within the same footprint.
- Designed a 1:12 roof slope suitable for solar efficiency and effective drainage.
- Integrated renewable energy systems (solar + hydroelectric) into the building’s electrical and mechanical planning.
- Applied corrosion-resistant steel components suitable for Hawaii’s coastal climate.
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Unique Features
- Net-zero energy performance driven by solar and hydroelectric power.
- IMP building envelope offering superior insulation, antimicrobial surfaces, and weather-tight protection.
- Full mezzanine for expanded productivity without increasing footprint.
- Climate-controlled clean-room environments for all cultivation stages.
- Engineered to maintain consistent indoor conditions despite Hawaii’s environmental variability.
Building Specifications
- Structure: Pre-engineered metal building
- Envelope: IMP roof and wall system
- Mezzanine: Full joist-and-deck system spanning second-floor areas
- Renewable Integration: Solar-ready standing seam roof + hydroelectric compatibility
- Interior: Controlled-climate clean-room zones
- Roof Slope: 1:12
“Nestled between the mountain and the sea, our 35,000 square foot, purpose‐built production facility uses innovative techniques and technology to provide premium and sustainable, indoor‑grown crop for our community. Using clean room protocol, climate control technology and strategic construction allows us to grow our craft without the use of herbicides, pesticides or fungicides.”
— Dylan Shropshire,
CEO at Big Island Grown
Sustainability / Compliance
- Achieves net-zero energy through on-site renewable generation.
- IMP envelope dramatically reduces HVAC loads.
- Steel structure provides long lifecycle, reduced material waste, and lower maintenance needs.
- Clean-room materials support sanitary cultivation compliance.
- Designed to meet Hawaii’s strict environmental performance and operational standards.
Results & Benefits
- Enabled Big Island Grown to expand operations into a renewable-powered, net-zero facility.
- Improved product consistency through precise and stable environmental controls.
- Reduced long-term operating costs via energy-efficient envelope and renewable power integration.
- Delivered a structure with durability and corrosion resistance suited for island environments.
Build your next high‑performance, sustainable facility with Western Steel — where purpose, form, and energy efficiency unite.
Western Steel Buildings is SolutionCentric.®
We started Western Steel to create solutions to the major challenges of our industry. Western Steel Buildings is SolutionCentric.® Client problem solving is at the core of what we do. Every day, our team looks for the opportunity to proactively help projects go right.
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