Pratt Industries is a green company that walks the talk. Pratt is the world’s largest privately held 100 percent recycled paper and packaging company. Their combined manufacturing operations save the equivalent of more than 50,000 trees every day.
When Pratt wanted to expand its Lewisburg, Ohio, operation, they brought Miller-Valentine on board to design and construct the new facility because of our longtime relationship with their Lewisburg Container division, for whom we had built a plant in 1986, plus two subsequent additions in 1991 and 1995.
Now up and running, the 354,000-square-foot tilt-up facility includes manufacturing operations, research and lab space, warehousing, shipping and receiving and office space. In Pratt’s words, it is an “environmental showpiece.” At full capacity, the building will be one of the most environmentally friendly corrugated box factories in the country—saving as many as 10,000 trees a day and employing the latest in water reclamation technology, which will eventually reduce the discharge into the local sewer system to zero.
Through snow, sleet and . . .
This project presented some rather unique challenges on several fronts.
- The winter of 2013/2014 was one for the ages—one of the worst in 30 years. For example, it caused a two-plus month delay in getting the roof on.
- All utilities ended at the neighboring Lewisburg Container building, so our work site did not have power service until the end of March—two-thirds of the way into construction.
- A critical piece of the project was the 150-foot-long connector building running between the new Pratt factory and Lewisburg Container facility next door. It had to traverse a 7.5-foot change in elevation. An elevator system for the conveyor line was needed so that product could be transported between the two plants. By connecting the plants, Pratt has taken the equivalent of 30 semitrailers off the road every day.
- Pratt’s new internationally sourced equipment arrived during construction. With Miller-Valentine contractors and Pratt’s equipment installation subcontractors working side-by-side, often in the same space, we held daily scheduling and safety briefings attended by all workers. Quality standards were maintained, and our work was completed with no compromise of the building structure or Pratt’s machining.
We were as committed to meeting our deadline as the weather was bad. We found solid solutions to each obstacle and worked seven days a week, meeting the tight guaranteed completion date as promised.
“Miller-Valentine’s Engineers and Site Superintendent were not only easy to work with, they approached obstacles and problems intelligently and with one goal in mind, satisfying our timeline,” says Tom Forscht, Director of Engineering, Corrugating Division. “We no longer see them as our general contractor, but as part of our team.” The Ohio Valley Chapter of Associated Builders and Contractors awarded the Pratt Industries Corrugating Division project with an “Award of Excellence” at their annual banquet held on April 16.
We are pleased to announce that Pratt Industries has selected Miller-Valentine Construction to build their new 361,200-square-foot corrugating facility in Beloit, Wisconsin.
Central Ohio is home to a concentration of aviation industry powerhouses, New York-based FlightSafety International among them. The multifaceted company is the world leader in professional aviation training and is a supplier of flight simulators, visual systems and displays to commercial, government and military organizations.
Miller-Valentine Construction has worked with FlightSafety on multiple projects going back to 1999—in Columbus, Ohio, as well as in Hebron, Kentucky, by the Cincinnati/Northern Kentucky International Airport.
Our latest project, FlightSafety’s new learning center in Columbus, Ohio, is to be built in two phases—an approach that will best meet their needs, current and growing. Phase one was completed in December. A 54,806-square-foot concrete tilt-up building, the facility includes 13 advanced technology pilot and maintenance training classrooms, 12 briefing and debriefing rooms, facilities for 12 graphical flight-deck simulators, administrative office space and bays for six full-flight simulators.
Room with a view
Without doubt, the building’s marquee feature is its massive, two-story aluminum and glass curtain wall, through which passersby can stop to view the flight simulators in action. Each operates on an electronic motor base—moving around, accelerating, banking, raising and lowering, offering visual cues (such as night or reduced visibility) and simulating normal and abnormal flight situations—everything to replicate the sensation of piloting an aircraft.
A design-build project, Miller-Valentine worked with FlightSafety from conception to design through construction completion and delivered the building on a very aggressive schedule. K4 Architecture, The Kleingers Group, and Steven Schaefer Associates completed the Design/Build Team. The simulators required two months to receive, assemble and be certified by aviation authorities. Consequently, in order to deliver the facility to FlightSafety on time—with fully installed and operating simulators—half of the building needed to be 100 percent completed, up and running in just six months.
The new learning center will eventually replace FlightSafety’s current Columbus facility. The project’s second phase will include an addition of approximately 100,000 square feet, providing space for more classrooms, flight simulators and other advanced training equipment. The exact timing and size of the addition will be driven by FlightSafety customers’ needs. In the meantime, FlightSafety’s new learning center is providing industry-leading training to prepare pilots and maintenance personnel to operate aircraft in an ever-more complex airspace environment.
Ensuring jobsite safety. Period. There is nothing more important to Miller-Valentine Group. From Miller-Valentine leadership throughout our organization, we observe the keys to superior safety without compromise.
In fact, April marked an important safety milestone for Miller-Valentine with more than 761,359 work hours without incident. According to the Bureau of Labor Statistics, Miller-Valentine is 100 percent below the national average in lost time injuries since 2011.
Our record of safety is not just good for our Associates. Nurturing a culture of safety is also good for business. Having a good safety record on the jobsite saves our customers time and money. Being alert to and analyzing potential hazards, combined with our ongoing training and education initiatives, help to bring our team home safely each day.
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Miller-Valentine can help companies preserve capital, while reaping the benefits of fresh, new space designed exactly to their specifications and branded with their own identity.
At Miller-Valentine, we make jobsite safety a priority. Every day, we challenge all Associates to apply, train, inspect and monitor safety procedures and practices. And it is working. On April 30, Miller-Valentine marked an important safety milestone, achieving more than 761,359 work hours without incident.
To thank Team Miller-Valentine members for their contributions to reaching this milestone, we presented all field Associates with new safety boots—symbolic of their unwavering commitment to the principles of safety to which we adhere each day.
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