When Urschel Laboratories – the global leader in foot cutting technology – decided its explosive growth required a massive addition to their headquarters, they came to Tonn and Blank Construction as they have for the past 50 additions. Urschel’s current manufacturing facility in Chesterton, Indiana, built by our team in 2015 is approximately 410,000sqft. The North Manufacturing Plant Expansion marks the Urschel’s third and largest expansion to date, all which have been completed by the Tonn and Blank Construction team.

The manufacturing plant expansion project will add 115,000 square feet of manufacturing space, along with new south and northwest parking lots, exit and entrance roads, storm sewers and sidewalks. Our scope as design-builder also includes procurement and installation of fabrication, welding, machining, assembly and testing equipment, as well as adding a test kitchen to the north plant expansion.

Our virtual construction experts coordinated building utilities by analyzing components and ensuring accurate space allocation. Identifying potential clashes between the structural, electrical, mechanical, and plumbing systems during the design phase is priceless. It allows our team to resolve potential issues in the digital realm long before they morph into costly physical problems on the construction site. We know a seamless execution of this plant expansion is critical to the Owners, so optimizing site logistics helped eliminate project delays and improved site safety and productivity.

This project had multiple phases of concrete pours. Tonn and Blank’s self-perform concrete team poured approximately 3,300 cubic yards for the expansion. By self-performing critical activities such as concrete, we’re able to provide the highest standards of quality, scheduling and cost effectiveness to Urschel Laboratories.

We recently flew a drone through the facility to capture the latest progress – check out this awesome video!

Tonn and Blank is proud to witness the continued growth of Urschel Laboratories and feel honored to be their preferred contractor.