Airbus Helicopter, Inc.
Airbus Helicopter, Inc. (formerly American Eurocopter) is a 218,000 square feet facility comprised of administrative space, aircraft assembly and support shops, warehouse, and hangar and flight operations support. In addition, the facility also utilizes paint and paint preparation space and equipment with state-of-the-art laminar flow dust collection and down-draft type low emission paint booths. The 100’ x 345’ x 40’ high aircraft assembly space receives natural light through northern clerestory windows and is flanked on both sides by two-story volumes of shop, support and supervisory functions to promote an efficient assembly operation. Two five-ton overhead bridge cranes facilitate aircraft assembly and transportation between work stations, while utility trenches offer the flexibility necessary to accommodate an array of helicopter models. Other spaces within the facility include a150 plus - seat employee dining facility, executive suite, conference room facilities, as well as separate dining and food preparation area for guest and dignitaries.
JESCO Design / Build team completed the original design and construction of Caterpillar’s 180,000 square feet High Performance Extrusions Plant in Oxford, Mississippi. During a tornado in February 2008, the facility was completely destroyed. Because this facility is critical to the production of vital parts shipped around the world, JESCO’s Design/Build team worked closely with the Owner and their Production Team to fast-track the reconstruction process. The primary operations resumed in July 2008 and circumvented major issues with parts production and Owner Customer Satisfaction. Structure heights are 30 feet in most areas and bay size is fifty feet by fifty feet.
Additions to and reconstruction of the office facilities were released later and completed in October 2008. Majority of the work was self-performed by several of JESCO’s divisions including foundations, pits, tilt panels, metal wall systems, steel fabrication / erection and mechanical-electrical systems.
The construction of Genpak Corporation’s Phase I office and manufacturing facility and Phase II warehouse addition included extensive site work, drilled pier foundations, concrete slab-on grade, insulated tilt up wall panels, conventional structural steel framing, and membrane roofing. The office was constructed using masonry exterior façade with structural steel framing, metal studs and drywall, acoustical ceilings, hard tile, carpet, and vinyl tile flooring. The offices include a board room, employee break area and locker room, individual offices, and reception / lobby area.
JESCO, Inc. constructed an addition to the existing GKN Composite Parts Manufacturing Facility for the aerospace industry. Construction included sitework, spread foundations, concrete slab-on grade, conventional steel framing, insulated metal wall panels and modified bitumen roofing. The facility includes a 20,000 square feet clean room and was fully conditioned. Also, installed at the facility are several equipment foundations including autoclaves, nitrogen plant and five-axis cutting machine.
Lakeside Steel Alabama
JESCO, Inc. constructed this 65,000 square foot steel pipe casing manufacturing plant and a 55,000 square foot steel pipe finishing plant for Lakeside Steel Alabama. The steel pipe casing plant is a clear span pre-engineered metal building with two overhead bridge cranes. Building foundations are conventional concrete spread footings. The interior slabs include extensive equipment foundations, pits and trenches for the process equipment. The JESCO team was delighted to use several divisions within our organization to design and install the buildings, process mechanical and electrical systems, and process equipment. The equipment includes an uncoiler, accumulator and hydrotester. The site work includes a fifteen acre stone lay down yard and seven hundred linear feet of rail spur. The finishing plant includes threading, heat-treat, upsetter, and inspection areas.
The Continuous Cast Facility is approximately 100,000 square feet with multiple levels in the melt furnace / casting area and a cut-off basement. The Maerz furnace is used for the scrap copper process and, as an alternative, the Southwire furnace is used for melting down clean copper wafers. The key components of the facility include the large melt furnaces (which are fed by large bucket elevators) along with refining and induction holding furnaces in preparation for casting. After the melting, a continuous ribbon of copper is cast and then cut off into billets by a flying saw in the basement. Billets are then transported for further processing and extrusions in the adjacent tube mill.
JESCO utilized a Design / Build approach to construct the manufacturing facility including the MEP system’s which entailed: inert gases, compressed air, furnace cooling water, electrical and controls. In addition, JESCO also set most of the casting equipment.
North American Lighting, Inc.
JESCO, Inc. constructed the 638,000 square feet (Phases I, II & III) tail light manufacturing and assembly facility for North American Lighting (A Koito Group Company). The building delivery was through a design-build process to meet the intricate details of the Owner’s needs and to minimize the design to construction phase time line. The fully air conditioned facility employed the use of a conventional structural frame, a single ply adhered roof system, and architectural metal exterior walls. The 18,000 square feet office contains administrative offices, MIS functions, Human Resources, training areas, and primary employee breakrooms. The plant proper includes a molding department, two large clean rooms, assembly areas and distribution / warehousing, three (3) overhead cranes, tooling room, BMC area, cold storage mezzanine, tornado shelters, torrit room, and ancillary offices.
PACCAR Engine Manufacturing Plant
This approximately 623,000 square foot facility composed of a Manufacturing Building, Office and Administration Building, and Cafeteria was designed for the manufacture of new diesel truck engines.
This leading-edge facility will enhance PACCAR’s integration of technology in design, engineering, and manufacturing. It will be the most technologically advanced and environmentally friendly commercial vehicle diesel engine facility in North America.
This facility manufactures 12.9-liter and 9.2-liter diesel engines for Kenworth, Peterbilt, and DAF vehicles. The company also is putting a technology center on this 400-acre site near the Golden Triangle Regional Airport.
Quote from Owner:
“PACCAR is pleased to locate its engine facility in one of the most dynamic and progressive areas in the Southeast. The Columbus site provides superb proximity to our dealers, customers and strategic supplier partners.”
Merit Award Winner
Roll Form Group, Inc. (USA)
Through the design-build process, JESCO, Inc. constructed this 140,000 square foot manufacturing facility for the Roll Form Group (USA), Inc. A manufacturer of sheet piling and highway guardrail, this facility consists of 120,000 square feet of manufacturing area and 20,000 square feet of office and employee facilities. This project showcased massive equipment foundations, process trenches, uncoiler foundations, flying saw foundations, and looping pits ranging in depth to 16’ below finish floor. The building also includes four - 35 ton overhead bridge cranes and a rail spur that extends through the building.
Schulz Xtruded Products, LLC
This 190,000 square foot stainless steel seamless pipe manufacturing plant consists of a 58,800 square foot Hot Mill area, 109,200 square foot Cold Mill area and 22,000 square feet of ancillary areas. The facility is conventional framing with a TPO roof system and tilt-up concrete walls with R-20 insulated wall panels above. The plant also includes a thirty-two foot deep Vertical Press foundation, Horizontal Press, Extruder foundations, furnace foundations and seven overhead bridge cranes. This facility covers all facets of pipe production from billet to finished pipe ready to ship to customers.
This 110,000 square feet injection molding manufacturing facility was constructed in Florence, Alabama for TASUS Corporation, a plastic component firm for the automotive industry. As the Design-Build contractor for the project, JESCO was responsible for the facility’s construction and development of all disciplines of design including architectural, structural, mechanical, electrical, fire protection and civil.
The main structure consists of a pre-engineered building with horizontal metal wall panels and a TPO roofing system. The interior design accommodates the use of two (2) 15-ton overhead cranes and equipment mezzanine. Other building components include a rebar reinforced floor slab, masonry wainscot, silo & chiller foundations, dock equipment & trailer restraints, buss duct & compressed air systems, roof top HVAC systems, ESPF fire protection system with booster pump and process equipment foundations. A thirteen thousand square feet office space was also included. Located on a ten (10) acre site, this project’s design incorporates the provisions for future expansion.