When EFCO Corporation outgrew its facility in Monett, MO, they hired Crossland to build a new warehouse. We also expanded their production with additional storage space and new personnel offices. Early consultation with the Crossland Design-Build team helped EFCO determine that we could best achieve their various needs by breaking the construction of one large building into three phases.
The total project included 172,850 SF; the hub being a 150,000 SF metal building to serve as EFCO’s central warehouse and final assembly location. The building contained 27 dock stations for better product flow when unloading materials. A structure for small parts was added to the existing plant, allowing more efficient transportation of raw materials and other products to the final assembly area.
Crossland also built a two-story office pod for managers and key personnel, and a two-story hardened breakroom and bathroom area, which housed additional offices. Both hardened spaces were constructed from fully grounded and reinforced CMU with concrete lids. A curtain wall near the south office complex displays company products.
The EFCO project began with demolition in September, so crews were pouring concrete against the approaching winter season. By the time construction began, the team had faced the challenge of hanging cold materials in a monumental size building with wet and muddy conditions. Additionally, not having site laydown capacity meant heavy machinery and materials had to arrive in a specified sequence, so they were available when needed and off the job site once used.
These challenges made communication critical to success, so teams met weekly to maintain the schedule. By utilizing Crossland’s excellent self-perform crews for the concrete, steel, and carpentry, we effectively controlled the critical path and overcame the weather obstacles to deliver the project on time.
As with all projects, safety was a top priority throughout the EFCO project. Due to the enormity of the steel and materials involved, crews held daily safety meetings, so the team was aligned and prepared for all tasks.
Crossland completed the EFCO building project in remarkable time, and the final structure is very impressive. Our teams helped EFCO realize a dream beyond what they thought was possible by utilizing the Design-Build delivery method. Crossland demonstrated what we can bring to the table and encouraged them to continue planning forward accordingly.