Getting construction efficiencies in a row
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AGCO Corporation expanded its Jackson, Minnesota facility to increase production of agricultural equipment. The expansion included a new manufacturing plant, warehouse, and visitor center. AGCO utilized a design-build approach with Christensen Construction to coordinate the complex and evolving construction plans within a tight schedule. Butler building systems were used throughout to enable the design flexibility needed and help meet requirements for the facilities. The completed expansion has increased AGCO's manufacturing efficiency and features a showcase visitor center.
Getting construction efficiencies in a row
- 1. 15BUILDING PROFIT SPRING 2013 Getting construction efficiencies in a row W ith fertile economic conditions in the forecast for the global agricultural market, the future looks bright for North American farmers. That’s great news for ACGO Corporation as well—a leading global manufacturer of agricultural equipment headquartered in Duluth, Georgia. The growing demand for 200- to 300-horsespower wheeled row crop tractors was one of the primary reasons why AGCO decided to expand its domestic manufacturing footprint. AGCO chose its existing Jackson, Minnesota, facility for the expansion based on several key factors. For starters, AGCO had already built a solid track record in the Jackson community, and the company was very familiar with the area’s experienced, hard-working labor force. Additionally, Jackson’s Midwest location offered efficient access to transportation and infrastructure support. While choosing to expand its operations may have been a relatively easy decision for AGCO, finalizing the right plans for the project proved to be much more of a challenge. The main stumbling block was how to approach a high-profile visitor center, called the Intivity Center, that AGCO had planned as part of the overall project. Several design firms and architects were considered, but none were able to capture the vision AGCO had for the Intivity Center. John Sandison, Facilities Manager for AGCO, recalls the challenges the company faced in getting on the same page with the design firms. “They were coming in with very high-end finishes,” he says, “but the cost was high end as well.” Sandison ultimately contacted Steve Christensen of Christensen Construction Company, a Butler Builder® located in Estherville, Iowa. Christensen Construction had worked with AGCO on several small projects in the past, and Sandison had a high comfort level with the company. A design-build solution enables AGCO Corporation to complete its complex expansion effort. by Curt Bussen photography by D. Altman Fleischer BUILDING AN IMAGE AGCO’s 58,000-square- foot expansion is a testament to the company’s commitment to the North American agricultural market, bringing a manufacturing plant, a warehouse, and a visitor’s center all under one roof.
- 2. 16 A meeting of the minds Since Steve Christensen had previously worked with AGCO, he had a leg up in understanding the company’s construction needs and objectives. “As soon as I talked to Steve,” says Sandison, “it really clicked for him in terms of what I was looking for.” Christensen confirms how smoothly the entire process went. “John Sandison called me in, and we toured and reviewed several projects through which we determined what met their vision,” he says. “We then put together proposal drawings and ultimately a colored rendering for submission to AGCO Corporate for approval.” The Jackson expansion project had three The AGCO project utilized design-build to coordinate construction efforts on a tight schedule—with each construction phase of the project being contingent on the previous phase’s completion. BUILDING PROFIT SPRING 2013 Getting construction Efficiencies in a row
- 3. 17 making Christensen Construction’s design- build approach all the more critical. “Design- build is the only construction method that would make this possible,” says Christensen. “It allowed us to adapt the design as we went along.” AGCO’s first commitment was to the building size and column locations, which allowed Butler Manufacturing™ to begin production of the facility’s structural, roof, and wall systems. From there, Christensen Construction and AGCO went through many changes with regard to the interior design. Variables that needed to be accounted for included crane locations, rack layouts, design equipment, an in-floor drag chain assembly line, process pits in the floor, and a showroom layout that needed to accommodate 60,000-pound tractors. The design was constantly evolving up until the time the building was complete. Other factors further complicated the construction process. For instance, the new facility had to be built to meet FM Global requirements, which don’t always match the state’s building code requirements. Again, design-build provided the flexibility that was needed. “In our Intivity Center, many key design elements were still evolving literally weeks “Design-build is the only construction method that would make this possible” Steve Christensen BUILDING PROFIT SPRING 2013 distinct phases: the visitor center, as well as a warehouse addition and a manufacturing addition. Christensen presented a Butler systems construction design-build approach, and AGCO approved the project in early January of 2011. Design-build makes the difference AGCO needed its new warehouse area to be completed by July 4th of 2011 in order to move materials out of the old facility and start expansion of the production line. With such an aggressive timeline, maximizing construction efficiency was of utmost importance. The fact that the plans were constantly changing added to the project’s complexity, Butler Builder® : Christensen Construction Company, Estherville, Iowa Size: 58,000 square feet Butler® Systems: Landmark™ 2000 structural system, MR-24® roof system, TextureWall™ panel wall system, Butler Thermawall™ wall system AGCO Corporation
- 4. 18 “We needed that ability to turn on a dime, change direction and make these little changes and still be able to comply with all of the code requirements” John Sandison before we opened the building,” says Sandison. “So, we needed that ability to turn on a dime, change direction and make these little changes and still be able to comply with all of the code requirements and get things done very quickly.” Butler® systems add efficiency and versatility Facing such a complex and dynamic construction plan, Steve Christensen knew that systems construction, and namely Butler® products, would play a key role in meeting the project’s strict timelines and building requirements. The Landmark™ 2000 structural system was used in all three areas of the new facility, providing wide-open interior spaces with minimal columns. Additionally, the warehouse and Intivity Center incorporated conventionally built trusses into a hybrid structural system design. These trusses were supplied by Christensen Construction. The hybrid structural solution was particularly critical in the visitor center, enabling Christensen to create spacious 75-foot bays. With huge field sprayers and tractors maneuvering inside, creating open expanses was an absolute necessity. The exposed joists in the center were painted white to provide an attractive interior appearance. The MR-24® roof system was used exclusively on the AGCO project, including both on the new buildings and the existing structure. Its proven weathertight protection, low maintenance, and long lifespan assured the performance that AGCO needed. Christensen created a slope-build-up system for the reroof solution. “This enabled us to project the new taller roof out over the shorter existing building to eliminate a snow drift problem and avoid an interior gutter,” says Christensen. Butler wall systems were used extensively throughout the new facility as well. A Butler Thermawall™ system is featured in the warehouse area, providing a clean, attractive The Butler systems did more than create an attractive exterior building appearance. They helped AGCO meet the stringent requirements as mandated by FM Global—including enhanced R-value and added wind resistance. BUILDING PROFIT SPRING 2013 Getting construction Efficiencies in a row
- 5. 19 “The reception has been amazing” John Sandison BUILDING PROFIT® Spring 2013 Vol. 34 No. 1 Editorial Director: Lesli Crawford Editor: Curt Bussen Editorial Assistant: Andrew Moore Art Director: Karen Frost Designer: Samantha Zid Building Profit® is published on behalf of the Butler Builder® organization by Noble, in cooperation with Butler Manufacturing™ . Editorial Office: Noble Phone: (417) 875-5354. Printed in U.S.A. © 2013 BlueScope Buildings North America, Inc. All rights reserved. Butler Manufacturing™ is a division of BlueScope Buildings North America, Inc. P.O. Box 419917, Kansas City, MO 64141-6917. May be reprinted by permission only. 19 appearance both inside and out. In the visitor center, Christensen incorporated TextureWall™ panels above a glass façade exterior that runs almost the entire length of the building’s front side. The performance of the Butler systems also played a critical role in meeting the FM Global requirements as mandated for the project. AGCO chose to incorporate 3-inch Butler Thermawall panels for increased R-value— and to assure FM Global approval. Additionally, the MR-24 roof system met FM Global’s added wind reinforcement requirements. Putting all the pieces together The three distinct aspects of the AGCO project, and their domino-like dependence on each other’s completion, called for a high level of coordination and communication at every phase. “The design-build approach allowed us to meet the July completion date for the warehouse, but not without a lot of extraordinary effort that required us to build it in 30 days after record rainfall in May and June,” says Christensen. As if uncooperative weather weren’t enough, Christensen and his crews also ran into bad soil conditions and had to perform soil corrections on the site. Through all of the adversity, Christensen Construction was able to provide AGCO with a new facility that has become a source both of highly efficient manufacturing and highly regarded design. The new production facility includes a 16,000-square-foot extension of the current assembly line, as well as the incorporation of a 42,000-square-foot kitting center. This advanced system enables AGCO to efficiently deliver parts and material to the assembly line for production. Meanwhile, the Intivity Center has become a sparkling showcase that hosts visitors not only from the surrounding area, but literally from around the world. Guests are regularly awed by its serpentine walls, interactive displays, and immaculately clean appearance. Perhaps the most unique element of the visitor center is a crawler that was cut in half and placed into the side of a wall. John Sandison couldn’t be happier with the results of AGCO’s expansion effort. “The reception has been amazing,” he says. s BUILDING PROFIT SPRING 2013