Vibram USA

Manufacturing Factory Rebuild

Project at a Glance

North Brookfield, MA


Caolo & Bieniek Associates, Inc.

Project Type


Project Overview

  • Renovation to all aspects of a dated manufacturing facility to support modern production activities and employee spaces
  • Structural infill and reconfiguration of the building to support a vertical addition and more efficient manufacturing practices
  • Multi-phased project coordinated around the occupied facility’s continuous operations

Vibram, an international rubber sole footwear designer and manufacturer, began its operations in Italy in 1937 when its founder patented the first rubber-soled mountaineering boots. Today, Vibram soles are manufactured across the world and are used by more than 1,000 footwear companies. To modernize manufacturing practices at its 100,000 sq. ft. Massachusetts-based production facility, Vibram will undergo a comprehensive renovation and addition that will improve efficiencies and enhance employee spaces.

The facility, originally built in the 1800s, has received a variety of additions since its opening, resulting in 13 different elevations throughout. The project will begin with the demolition of all interior walls and floor slabs and include soil excavation below the slab-on-grade, in an effort to reduce the 13 current elevations to two. The building’s structural frame will be reconfigured and new interior partitions will be installed, with the goal of creating a more efficient manufacturing process based on Lean strategies. All M/E/P & FP systems will be replaced and heat and odor control systems will be installed. A vertical addition will be incorporated to support new office space and a rooftop terrace, with skylights that will increase building daylighting and connectivity with the outdoors. Additionally, the building’s exterior will be reskinned with a more modern material and design. Sustainable building features will include a photovoltaic array, eco-friendly systems, rigorous waste management requirements and the use of recyclable materials.