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DLR Group Inc.
an Arizona corporation
6225 North 24th Street, Suite 250
Phoenix, AZ 85016
Monday August 11, 2025
Jorge Gastelum
Development Services Director /City Engineer
jgastelum@elmirageaz.gov
623-876-2976
Planning & Zoning
Jose A. Macias, Senior Planner (TAC Facilitator)
jmacias@elmirageaz.gov
623-876-2996
Re:
Project Name: CAVCO Manufacturing Facility Build-to-Suit
DLR Group Project No.: {30-25172-00}
Pre-Application Project Narrative – Cavco Manufacturing Facility Build-to-Suit
Dear Jorge Gastelum and Jose Macias,
1. Application Request:
Cavco Industries, Inc. respectfully submits this application to the City of El Mirage for the development of a new
state-of-the-art manufactured home production facility. This project seeks site plan approval and necessary
permitting to support the establishment of a major manufacturing hub that aligns with long-term economic
development goals and industrial land use planning within the City of El Mirage.
2. Location and Description:
The project is located at 13201 W. Joe R. Ramirez Road, El Mirage, AZ 85335. The new Cavco El Mirage
Manufacturing Facility will be a climate-controlled, high-performance production campus for manufactured
housing.
The facility features:
•
Two mirrored production lines sharing a central cabinet shop, mill shop, and countertop build area
Development Services Department
Monday August 11, 2025
Page 2
•
A dedicated chassis build shop
•
Administrative offices, employee lunchrooms, and supporting service buildings
•
Covered and uncovered storage areas
•
Exterior parking for employees and product staging
Total approximate facility area:
*See Overall Site Plan for building locations
Facility Component
Square Feet
Main Manufacturing Building
504,000
Including Offices &
Lunchrooms (46,000 SF)
Material Storage Structures (4)
45,000
Covered Storage (Awnings)
65,000
Chassis Shop Buildings (2)
26,350
Total
640,350 SF
3. Historical Data:
The site has been previously surveyed (Land Survey dated May 2019) and is currently undeveloped. There are
no known historical structures or constraints on the property.
The site is within the Planned Area Development (PAD) 00-08-01 as approved by Council on 08/24/2000. The
site is zoned I-2 Industrial. Industrial development borders the site to the East, North and South. East of the site
is also zoned Industrial but remains vacant agricultural land. The Site and surrounding area’s current
jurisdiction, General Plan designation, zoning, and land use are outlined in Table 1, Surrounding Property
Information below.
Table 1: Surrounding Property Information
Location
Zoning
El Mirage 2020 General
Plan Land Use Designation
Current Use
Project Site
I-2 Industrial
Commerce\ Industry Park
Vacant
North
I-2 Industrial
Commerce\ Industry Park
Consolidated Resources Inc.
Recycling & Arcadia Cold Storage
East
I-2 Industrial
Commerce\ Industry Park
Vacant
South
I-2 Industrial
Commerce\ Industry Park
Carmax Wholesale Auction and
Production Center
West
I-2 Industrial
Commerce\ Industry Park
Cives Steel Company
4. Aerial Map:
See Appendix A for the enclosed aerial map, which identifies the project site boundaries, surrounding land uses,
and adjacent roadways.
Development Services Department
Monday August 11, 2025
Page 3
5. Operational Aspects of Use:
Once operational, the facility will support full-scale manufactured home production with the following attributes:
•
Production of manufactured homes via two independent lines
•
Onsite fabrication of components such as cabinetry, countertops, and chassis
•
Use of adhesives, paints, and insulation systems consistent with modern home manufacturing
•
Exterior staging of completed units on asphalt rear yard prior to shipment
•
Integration of Owner-Furnished, Owner-Installed (OFOI) equipment, including weld jigs, CNC systems,
dust collectors, forklifts, and paint booth systems
Anticipated number of employees:
•
For Day 1 operations: approximately 228 employees (half capacity)
•
At maximum capacity: 455 employees
•
With both production lines active, Cavco anticipates utilizing around 80% of its maximum
manufacturing capacity
Shift schedule: one operational shift
Employee parking: 465-stall surface lot
Waste collection and recycling: Refuse and recyclable materials will be handled by Parks and Sons of Sun City.
6. Parking Strategy and Waiver Request
The project proposes surface parking designed to align with the operational realities of Cavco’s El Mirage
Manufacturing Facility. Based on the anticipated maximum workforce of approximately 455 employees, the
conceptual site plan currently provides 465 parking spaces to accommodate peak future staffing. At initial
occupancy, the facility will employ approximately 228 employees (about half capacity). When both production
lines are active, Cavco anticipates operating at roughly 80% of maximum staffing, resulting in an estimated 372
employees on site during peak shifts.
The City of El Mirage has authorized the project team to proceed with a Request for Design Exception to reduce
the total number of required parking spaces. This request is supported by the following factors:
•
The facility is a single-user, shift-based operation with predictable staffing levels and minimal visitor
traffic.
•
Customer or retail traffic is nonexistent, as all production and assembly occur within a secured,
climate-controlled manufacturing environment.
•
A significant portion of the building’s ground-level square footage will be occupied by manufactured
homes under construction, further reducing the functional intensity compared to generalized industrial
uses.
•
The reduced parking plan will minimize unnecessary paving and impervious surface area, aligning with
sustainable site design practices.
The Design Exception is intended to right-size the parking supply to match the facility’s operational needs while
maintaining adequate circulation, emergency access, and capacity for future growth.
Development Services Department
Monday August 11, 2025
Page 4
We look forward to working with City staff to finalize the Design Exception and ensure the parking supply is right-
sized to the facility’s actual needs while maintaining adequate circulation, emergency access, and future
flexibility.
7. Proposed Building/Structure Heights:
•
The primary manufacturing building and other vertical structures will reach a maximum height of
approximately 56 feet to the top of the highest parapet.
8. Proposed Infrastructure:
Water & Wastewater Infrastructure:
•
Internal looped water distribution system for water and fire services connecting to the existing water
line in Joe R. Ramirez Road
•
Business sewer connection to the existing sewer interceptor in Joe R. Ramirez Road
Utilities and Services:
•
Water – EPCOR
•
Wastewater – EPCOR
•
Electrical – Arizona Public Service (APS)
•
Communications – Cox and/or CenturyLink
•
Refuse – Parks and Sons of Sun City
•
Natural Gas – Southwest Gas
•
Police & Fire – City of El Mirage
Onsite Systems & Equipment:
•
Full automatic sprinkler system installed in accordance with NFPA 13 throughout the facility
•
Central compressed air system and utility trenches to distribute services to production line points-of-
use
•
Fall protection and multiple overhead crane lifting infrastructure
•
Dust and fume collection systems with code-compliant suppression
•
Roof system engineered for solar panel load and overhead cranes
9. Conditional Use Permit – Outdoor Storage of Manufactured Homes
This application includes a request for a Conditional Use Permit (CUP) to allow the outdoor storage of completed
manufactured homes in the rear portion of the Cavco El Mirage facility site. The storage area is essential to
facility operations, providing temporary staging space for units that are finished and awaiting shipment or
transport.
Outdoor storage is proposed only for fully assembled, factory-built homes that are ready for delivery. The homes
will be stored in a designated asphalt-surfaced rear yard on the South, Southeast, and Southwest portions of
the site, behind the primary manufacturing building.
Development Services Department
Monday August 11, 2025
Page 5
The storage area will be fully screened by an 8-foot-high concrete masonry unit (CMU) wall along the front
(North) side facing Joe R. Ramirez Road with chain-link fence that wraps around the remaining perimeter of the
site, consistent with zoning ordinance requirements. The West, South, and East property lines are interior lot
lines within the PAD zoning and do not face a public way. No storage will occur in the front yard visible from Joe
R. Ramirez Road, with exception of Display Model Homes as shown on the enclosed Site Plan.
This use supports the core manufacturing function of the site and meets the intent of the Employment/Industry
(EI) zoning district and PAD00-08-01 by enabling efficient logistics and streamlined product movement. The
following considerations further support the CUP request:
•
Compatibility: The site is within an industrial district (I-2) and surrounded by similar or complementary
uses. The stored units are not active inventory or raw materials, but completed homes staged for a
limited time.
•
Screening and Visual Impact: The 8-foot-high opaque CMU wall facing North toward W Joe R Ramirez
Road and perimeter chain-link fencing along the three interior lot lines will prevent visibility from public
rights-of-way or adjacent properties, minimizing visual and aesthetic impacts.
•
Traffic and Access: Deliveries and outbound shipments will be managed internally with circulation
coordinated to prevent congestion or disruption to public streets.
•
Safety and Operations: The homes will be stored in a stable, unoccupied condition. No utilities will be
active in the units during storage. Fire access and emergency vehicle clearances will be maintained
throughout the rear yard.
We respectfully request approval of the CUP as part of this application and are prepared to coordinate with staff
on any conditions of approval related to site screening, storage limits, or layout adjustments.
10. Proposed Phasing:
The project is anticipated to be developed in a single phase to allow for unified commissioning and streamlined
startup of manufacturing operations. If construction or permitting constraints arise, limited phasing may occur
but will not affect the overall operational functionality upon completion.
11. Planning Staff Coordination:
Following coordination with the City of El Mirage planning staff (specifically Jose A. Macias), we were advised
that a formal solar glare study is not required at this stage of review. Per the planner’s direction, this narrative
serves to affirm that the rooftop solar Photovoltaic (PV) system will be designed and located to avoid glare
impacts on Luke Air Force Base flight paths. Measures such as appropriate panel tilt, anti-reflective coating,
and solar layout design will ensure no adverse impacts on air traffic or pilot visibility.
12. Other Pertinent Information:
•
Hazardous Materials: The project will store and use materials typical of a homebuilding facility (e.g.,
adhesives, paint, and sealants). All hazardous materials will be stored in designated areas compliant
with local fire and environmental safety codes.
Development Services Department
Monday August 11, 2025
Page 6
See attached APPENDIX B – HAZARDOUS MATERIALS INVENTORY & COMPLIANCE SUMMARY, for more
information.
•
Combustible Materials & High-Piled Storage Considerations:
Cavco anticipates storing significant quantities of combustible building materials such as lumber,
plywood, and OSB sheathing used in the production of manufactured homes. These materials will be
stored in four dedicated open Materials Storage Structures (1–4), each ranging from approximately
10,500 to 12,000 square feet with 30-foot building heights, as shown on the enclosed Site Plan. These
structures will be constructed of pre-engineered metal and are separated from the main manufacturing
building by a minimum of 25 feet to the rear of the site.
Storage racks within these open storage structures will exceed 12 feet in height, which constitutes
high-piled combustible storage per applicable fire codes. As such, it is anticipated that these buildings
will be required to be equipped with automatic sprinkler systems and designed in accordance with the
applicable provisions of the 2018 International Fire Code (IFC) Chapter 32 – High-Piled Combustible
Storage, adopted by the City of El Mirage. While final sprinkler system design will be as a deferred
submittal, Cavco is committed to full compliance with fire protection regulations, including coordination
with the El Mirage Fire Marshal to confirm hazard classifications, aisle spacing, storage layouts, and
suppression requirements.
•
Security: The site will include perimeter fencing, a controlled access gate system, and both interior and
exterior surveillance cameras.
•
Sustainability: Rooftop solar panels are integral to the energy strategy, reducing grid reliance and
aligning with Cavco’s long-term sustainability goals.
•
Design Excellence: The facility aims to achieve a 30-year useful life with durable exterior materials such
as tilt-up concrete, pre-cast systems, or PEMB are under consideration. The final design will prioritize
durability, performance, and aesthetic alignment with Cavco’s brand.
Sincerely,
DLR Group
Tim Thielke, AIA, NCARB
Workplace Leader | Principal
Encl: Project Narrative, Site Plan, Traffic Impact Statement, Owner’s Authorization Letter
cc:
Mark Hendricks, RLB
Steven Strobel, RLB
Jeff Chrisman, CAVCO
Cameron Tomasbi, CAVCO
Nader Tomasbi, CAVCO
Colin Baker, Willmeng
Erik Warren, Willmeng
Josh Teates, Willmeng
Zach Hilgart, Colliers
Tristan Stevens, Colliers
Richard South, DLR Group
Jon Schewe, DLR Group
Development Services Department
Monday August 11, 2025
Page 7
APPENDIX B – HAZARDOUS MATERIALS INVENTORY & COMPLIANCE SUMMARY
A.1 Purpose Of This Appendix
This appendix provides a preliminary summary of hazardous materials anticipated to be used, stored, or
handled at the proposed facility. The purpose is to support code compliance reviews under the International
Fire Code (IFC), City of El Mirage Fire Department requirements, and applicable zoning and site development
standards. This inventory is based on representative materials currently used at similar Cavco facilities.
A.2 Summary Of Materials
Material Type
Representative Products/Trade
Names
Typical Use Case
Typical Container
Size
Storage Type
Adhesives
Pemco 5100, N5200A/B, Sta-Put
Red, Tile Epoxy, Fastbond 30NF
Cabinet, wall panel, tile
setting
1–5 gal cans, 55-
gal drums
Flammable Storage
Cabinet
Sealants/Mastics
DS50 mastic, roof cement, silicone
caulk, butyl tape
Weather sealant, roof,
joint work
10-oz tubes, 1–5
gal pails
General Storage /
Flammable Storage
Paints & Coatings
PPG/I.C.I. paints, spray paints, clear
poly, PittTech primers
Interior/exterior
finishing
1–5 gal cans, 13-
oz spray
Flammable Storage
Cabinet
Solvents/Cleaners Lacquer thinner, adhesive remover,
equipment cleaner
Surface prep, cleaning 1–5 gal
containers
Flammable Storage
Cabinet
Compressed Gases Propane cylinders
Torch work, forklift fuel 20–100 lb
cylinders
Exterior Cage/UL-
Approved
Cements & Glues
PVC/CPVC/ABS cement, primer,
wood glue
Plumbing and
cabinetry adhesives
Pint–1-gal
containers
General Storage
Grouts &
Compounds
Pro Set Plus thinset, grout, spackle,
joint compound
Flooring, wall finishes
25–50 lb bags,
5-gal pails
Dry Storage / General
Storage
Specialty Products Solid surface adhesives, hot melt
glue, HVAC mastic
Manufacturing
processes
1-gal kits, glue
sticks
General Storage
A.3 Hazard Classifications
Regulatory Category
Examples from Inventory
Flammable Liquids (Class IB/IC)
PU adhesives, lacquer thinner, spray paints, epoxy
components
Development Services Department
Monday August 11, 2025
Page 8
Regulatory Category
Examples from Inventory
Combustible Liquids (Class II/IIIA)
Oil-based caulks, mastics, clear poly
Pressurized Gas (Class 2.1)
Propane cylinders
Irritants / Sensitizers
Polyurethane Part A (isocyanate), solvent-based cleaners
VOC-Emitting Materials
Adhesives, thinners, paints
A.4 Estimated Maximum Quantities On Site
Material Category
Estimated Daily-Use Volume
Estimated Bulk Storage (Max)
Adhesives & Sealants
<10 gallons
~55 gallons (1 drum)
Paints & Coatings
<15 gallons
~30 gallons (multiple cans)
Solvents / Cleaners
<5 gallons
~10 gallons
Propane (Forklifts)
2–4 tanks (20–40 lbs ea.)
Stored in exterior cage
Cement/Joint Compounds On-demand use only
<500 lbs dry
All quantities are below the Maximum Allowable Quantities (MAQs) per IFC Table 5003.1.1(1) for control areas
in sprinklered buildings.
A.5 Storage & Safety Provisions
•
Indoor Flammable Liquids will be stored in UL-listed flammable storage cabinets with spill containment.
•
Outdoor Compressed Gas (Propane) will be stored in approved gas cages on concrete pads per NFPA
58.
•
Eye wash stations, ventilation, and spill control kits will be provided per OSHA and IFC standards in
manufacturing and chemical storage areas.
•
Secondary containment will be used for all large-volume liquid containers.
•
SDS sheets will be maintained on site and available to emergency responders.
•
A full Hazardous Materials Management Plan (HMMP) and Hazardous Materials Inventory Statement
(HMIS) will be prepared during the construction permit phase if required by the Fire Department.
A.6 Code Compliance Summary
Code / Regulation
Compliance Strategy
IFC Chapter 50
Inventory < MAQ; storage cabinets used; fire
sprinklered
NFPA 30 / 58
Flammable and gas storage separated and
compliant
OSHA 29 CFR 1910
Labeling, ventilation, PPE, and training in place
City of El Mirage
Pre-App disclosure provided; full submittal upon
permit
Development Services Department
Monday August 11, 2025
Page 9
A.7 Notes
•
Quantities and materials will be verified and finalized during construction drawings and permitting
phase.
•
No hazardous waste is generated or stored on-site beyond typical construction-related residue.
•
The project team is committed to safe handling, labeling, training, and compliance with all applicable
fire, environmental, and worker safety regulations.