Industrial Plant Expansion
MidAtlantic’s work for Acme Box was a two-year long expansion and phased renovation of an industrial corrugated box processing plant in Hatboro, PA. Work began with full site development, including construction of an approximately 850 foot long, 10 foot high retaining wall, placement of 10,122 CY of imported fill material, expanded parking for shipping vehicles and plant employees, and augmentation of existing utilities.
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Location
2700 Turnpike Dr
Hatboro, PA 19040
Completion
Winter 2022
Market
Industrial
Scope
Two-year long expansion and phased renovation
Partners
ACME Corrugated Box Company
Firstrust Bank
Philips & Donovan Architects
Charles E. Shoemakers, Inc.
Alderson Engineering
Provident Engineering Corp.
"In 2020, Acme Corrugated Box engaged MidAtlantic Construction to construct our (approximately) 80,000 square foot addition to our existing manufacturing facility. We had to do all of this, while continuing to operate our existing business, install over $25 million in new machinery and keep our customers satisfied. Their constant communication with our team members, innovative problem-solving abilities, and tenacious efforts were key factors that ensured the project's outstanding success. For us, the most critical element of the project, besides an outstanding structural result, was to continue to operate our business and make this invisible to our customers. Mid-Atlantic took a keen interest in our production processes and worked hand in hand with our Operations Leadership team to ensure minimal disruptions on a weekly basis. We confidently endorse MidAtlantic Construction for future projects, as their expertise and commitment to excellence consistently deliver exceptional outcomes."
Expansion
Once site preparations were complete, work began on the 80,000 SF open-area warehouse addition. The addition utilized tilt-up, precast concrete panels and structural steel to achieve the required 40’ high exterior walls. A taller, 60’ high section is nested within the addition and extends into the structure of the existing building. The concrete slab is recessed three feet below surrounding areas at this location which, in conjunction with the higher ceiling, allows the facility to accommodate Acme Box’s new, fully automated racking system with two stacker cranes. The addition’s 16’ of additional height required a structural overbuild of adjacent portions of the original structure, raising the roof a full 3’ in these locations.
Renovation
The renovation portion of this project connected the newly built addition to the existing building, including the installation of concrete foundations for a new corrugator which spanned nearly the combined length of the addition and previously existing building: approximately 450 feet. Renovation work also included second floor office space, 2,500 SF of structural steel roof replacement to accommodate added snow loads, installation of a 3-stop elevator, a loading dock renovation, and construction of an upper mezzanine level with conference rooms featuring high-end finishes.
Phased Approach
The project was completed in multiple phases to minimize disruption to the owner’s plant operations, including delivery, installation, and commissioning of the new corrugator. The multi-phased logic was established to allow:
- The new addition to be completed in time for corrugator delivery.
- The new corrugator to be installed and commissioned prior to shut-down and removal of the original corrugator.
- Once the original corrugator was removed, existing building renovations and the 2nd half of the high-rack section to be completed.
- Final paving and site finishes to be the final step, also occurring across multiple phases to avoid disruption of shipping operations.
