Challenge

1. Anchor the brand-new Northern Gateway mixed-use campus with a state-of-the-art manufacturing + office facility, establishing credibility for the development’s master plan.
2. Site planning on a greenfield required infrastructure build-out, stormwater management, and roadway coordination.
3. Facility needed to combine advanced manufacturing floorplate with corporate offices that could attract and retain skilled workforce.
4. $20–25M budget had to be carefully managed against inflationary pressures in 2022–2023, while aligning to a compressed schedule to open in sync with Gateway Sports Academy and Mel’s Village.

Solution

1. Catalyst managed construction of a 130,000-sq-ft hybrid facility (production + administration) designed by RINKA, engineered by Excel.
2. Delivery was fast-tracked: shell and exterior envelope were completed early (Feb. 2024) to allow equipment installation while interior finishes continued.
3. Implemented non-self-perform CM model, securing competitive bids from industrial trade partners for HVAC, process utilities, and clean manufacturing systems.
4. Integrated site with Northern Gateway’s infrastructure, coordinating utilities, roadway alignments, and stormwater to fit long-term campus phasing.

Impact

• Created a modern, scalable hub for American Orthodontics’ operations, securing jobs and manufacturing presence in Ozaukee County.

• Projected to generate 180+ new jobs over four years, boosting regional economic vitality.
• Solidified Northern Gateway’s identity as a destination district, attracting additional tenants to Mel’s Village and surrounding parcels.
• Recognized as one of Daily Reporter’s Top Projects of 2024 for industrial excellence and community impact.