Tonn and Blank successfully delivered the Service Parts Factory Phase 4 – Injection Molding Addition for Subaru of Indiana Automotive (SIA). This project included the construction of a 40,500-square-foot pre-engineered metal building and an adjacent 40,000-square-foot loading dock/container yard. Our team self-performed key aspects of the build, including concrete work, demolition, and the installation of critical structural and safety components.
Despite facing several challenges, our team exhibited exemplary performance, exceeding expectations in various aspects of the project. One of the project’s highlights was the concrete work, particularly the achievement of outstanding flatness and levelness (FF-62.31 and FL 39.29). This surpassed the stringent standards set forth by SIA, demonstrating our commitment to quality and precision. To meet SIA’s concrete specifications, we utilized advanced equipment such as a telescoping laser screed and an elevated platform system. These innovative solutions enabled us to achieve superior results, ensuring compliance with SIA’s requirements.
Throughout the winter months, we successfully excavated, dried, and stabilized 7,000 cubic yards of dirt using lime and cement, laying a strong foundation for the subsequent phases.
March and April saw intensive self-performed work, with 800 yards of concrete formed and placed for footings, columns, and foundation walls. Additionally, a 150 cubic yard machine foundation with embedded anchoring cans and I-beams, along with almost 800 lineal feet of embed angle for trench covers, were expertly executed.
Moving into early spring, our team focused on completing the forming and placing of foundations, dock levelers, and loading dock walls. We also achieved great results with 1350 yards of slab on grade concrete, surpassing quality standards set by SIA.
As June approaches, our efforts continue unabated, with the self-performance of 750 yards of concrete for paving, pads, and sidewalks. An additional 250 yards are scheduled for completion next week, marking the conclusion of exterior concrete work and bringing our total placed yards to 3,150+.
The scope also included erecting a pre-engineered metal building, ensuring it was fully enclosed and weather tight. Additionally, the team executed the installation of crucial mechanical, electrical, and plumbing systems. Masonry block restrooms for both men and women were constructed alongside metals work, which encompassed crane columns, support railings, stairs, and a Mezzanine platform. Exterior stairs connecting low and high bays were carefully crafted, complemented by a finalized metal walkway roof system. Reflective warning cards were strategically placed around the roof perimeter for safety, and the team efficiently demolished an existing exterior wall from Phase 3. To tackle the challenges of winter, a temporary heater was installed inside, ensuring uninterrupted progress throughout the project.
