Urschel Laboratories – North Plant Expansion

As the design-builder and construction manager for Urschel Laboratories’ new 115,000-square-foot North Plant expansion, Tonn and Blank Construction has continued a long-standing partnership with Urschel Laboratories, the global leader in food cutting technology. This latest addition to the Chesterton, Indiana headquarters accommodates the company’s growth and adds essential manufacturing space, advanced equipment, and expanded site infrastructure.

A Legacy of Excellence in Industrial Construction
Our history with Urschel Laboratories spans 50 years, beginning with the construction of their original factory and evolving into a trusted partnership that has seen Tonn and Blank manage over 50 expansions for the company. This includes the landmark project in 2015 when we built Urschel’s state-of-the-art 410,000-square-foot headquarters, and now the North Plant expansion marks Urschel’s third and largest expansion to date.

Project Details and Scope
The North Plant expansion adds 115,000 square feet of manufacturing space and includes significant site improvements, such as new south and northwest parking lots, updated storm sewers, sidewalks, and new entry and exit roads. Additionally, our scope as design-builder included the procurement and installation of specialized equipment for fabrication, welding, machining, assembly, and testing. We are also adding a test kitchen for Urschel’s continued innovation.

Our virtual construction team coordinated utility layouts to identify potential clashes in structure and utilities early in the process. By addressing these issues in the digital environment, we ensured a smoother execution on-site, preventing costly delays and improving overall safety and productivity.

Self-Performed Concrete Work and Structural Advancements
By self-performing concrete activities, Tonn and Blank maintained stringent control over quality, schedule, and cost. Our ACI-certified professionals oversaw the placement of approximately 3,300 cubic yards of concrete for the expansion, and our ironworkers installed an impressive 200 tons of steel in the structure.

Our ability to self-perform critical tasks, like concrete pours and structural work, provides Urschel with consistent high standards and project continuity. As we worked through challenging site logistics – transforming parking lots, enlarging stormwater ponds, and adapting site access – our team’s flexibility and commitment to quality ensured the project remained on schedule and met the highest standards.

A Commitment to Innovation and Excellence
As the project reached its final stages, with finishing work on asphalt, curbs, sidewalks, and MEP systems underway, Tonn and Blank has once again demonstrated our commitment to designing and building world-class facilities for industrial manufacturers. We’re proud to continue our legacy with Urschel Laboratories and look forward to the enhanced capabilities this expansion will bring to their operations.