Industrial Plant Expansion
MidAtlantic’s work for Acme Box was a two-year 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' long x 10' 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.
The phase approach is further outlined below.
Location
2700 Turnpike Dr
Hatboro, PA 19040
Completion
Winter 2022
Market
Industrial
Scope
2 year 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 completed, construction began on an 80,000 SF open-area warehouse addition designed to support Acme’s advanced logistics operations. The structure features tilt-up precast concrete panels and structural steel framing to achieve 40-foot-high exterior walls. A taller, 60-foot-high section is strategically nested within the addition and extends into the existing building footprint. To accommodate Acme’s fully automated racking system—featuring two stacker cranes—a specialized area was constructed with a recessed concrete slab, set three feet below the surrounding floor and paired with the increased ceiling height.
To support the vertical expansion, a structural overbuild was performed on adjacent portions of the original facility, raising the existing roof by three feet. This highly coordinated effort allowed for seamless integration between the new and existing structures while delivering the height and clearance required for the next-generation storage and retrieval system.
Renovation
The renovation phase of this project focused on seamlessly integrating the new addition with the existing facility, highlighted by the installation of concrete foundations for a new corrugator system spanning nearly 450 feet—extending through both the new and existing structures. Additional renovations included the construction of second-floor office space, the replacement of 2,500 SF of structural steel roofing to accommodate increased snow loads, and the installation of a new 3-stop elevator to improve vertical access throughout the building.
The scope also included a full renovation of the loading dock area and the addition of an upper mezzanine level, which houses conference rooms finished with high-end materials, offering both functionality and a polished, professional environment.
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 site redevelopment and building addition to be completed in time for corrugator delivery.
- The new corrugator 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.
