AmeriLux International Building Expansion

Project Summary:

Design/Build Contractor: Bayland Buildings, Green Bay, WI

Excavation Contractor: Carter Trucking & Excavating, De Pere, WI

Electrical Contractor: Metzler Electric, Green Bay, WI

Construction has begun on a 21,000 square foot expansion to our current warehouse facility! It is anticipated that the expansion will be completed by September of 2012. The purpose of the building expansion project is to provide our customers with improved service, a higher level of efficiency, and a larger selection of "in stock" inventory than ever before. In addition to the increased warehouse storage capacity, we will be adding another slitter table, increasing the number of orders that can be processed daily.


Expansion Update: November 6th, 2012

AmeriLux International’s new building expansion is now complete and most of our trailer inventory has been moved inside. With 21,000 square feet of expanded capacity, floor-to-ceiling racking, a new slitter table equipped to cut and rip sheets at an angle, and a larger accessories room, the expansion will allow us to provide our customers with quicker lead times and a larger selection of in-stock inventory.

Working with Bayland Buildings was truly a positive experience from start to finish. Bayland Buildings kept the expansion project on schedule and on budget. Brian Peters, Director of Operations at AmeriLux International, had this to say: “This was one of the most efficient and well-executed projects that I have had the pleasure of working on. The incorporation of our Lexan* Thermoclick polycarbonate sheet into the building design made this project a resounding success. Lexan* Thermoclick* is an excellent way to bring daylight into a building and a practical way to provide natural light for our warehouse team.”

As AmeriLux moves forward with its strategic growth plans, we will continue to explore ways of improving our business – to be more efficient and more effective. To grow, we will constantly strive to provide superior customer service, technical support, and product support to our customers ensuring their continued success. Our mission is to continue to work hard every day to exceed our customers and partners expectations and build long-term relationships.

expansion completeexpansion completeinventory moved insideinventory moved inside


Expansion Update: October 19th, 2012

While inventory continues to be moved in and organized inside the building expansion, work is being done outside to the parking lots. Crews are removing and replacing failed asphalt in the east parking lot. A drainage pipe will be installed for proper disposal of all storm water accumulated on the site. Compaction of the crushed stone base is underway as expansion to the main parking lot continues. Weather-permitting, the crew will begin laying asphalt next week.

east parking loteast parking lotmain parking lot expansionmain parking lot expansion


Expansion Update: October 12th, 2012

Tile floor in the shipping & receiving office, break room, and new bathrooms has been laid. Rack assembly is complete and inventory continues to be moved inside and organized. A climate controlled server room has been created and is being setup to house the main computer servers.

tiling finishedinventory movinginventory movingserver room


Expansion Update: October 4th, 2012

The time-consuming task of rack assembly and moving inventory continues. This upfront investment of hard work will be well worth having most of our inventory housed within the warehouse. One objective of this building expansion project is to provide our customers with improved service and shorter lead times. Having a larger selection of in-house inventory along with managing it more efficiently will help us reach this goal.

rack assembly continuedrack assembly continuedrack assembly continuedrack assembly contined


Expansion Update: September 28th, 2012

The final phase of the building expansion is underway. Outside: Exterior lighting was added to the building for safety and security. Next week, blacktop will be installed on both the east and west sides and the final landscape will take shape. Inside: Tile installation is underway in the new restrooms. Rack installation is being completed and inventory is moving in.

completed amerilux expansionamerilux completed exterior expansioninterior racking installationamerilux interior expansion


Expansion Update: September 20th, 2012

The new racking system is being installed this week maximizing vertical space in the expansion. This additional racking space will allow us to increase inventory levels and provide us with opportunities to add several new products; further diversifying our product and service offerings.

amerilux new rackingamerilux new warehouse rackinginstalling new racking systemexpansion new racking


Expansion Update: September 14th, 2012

The final interior touches are being completed on the expansion. A few electrical items and some HVAC work is all that is left to do. Inventory is already being moved into the new space. Black top was laid at the back of the expansion for additional parking and truck access. New racking has arrived and will be installed next week.

final interior workinventory moving inblack top for add'l parkingnew racking arrived


Expansion Update: September 11th, 2012

Ceiling lights have been installed and the entire interior of the addition is now painted a bright white. A second rough wall opening has been cut connecting the existing building to the new expansion. Racks and material in the existing warehouse are being moved to allow free passage between the two spaces. Other finishing touches include: Safety yellow painted on the columns and bollards; Trim work around the openings.

lighting completefinish interior paintingpainting yellow columnswhite interior


Expansion Update: September 7th, 2012

The interior work on the addition continues. Installation of the fire protection system is complete. Painting of the structural steel white will finish up next week. Overhead heaters are being installed. Junction boxes are now in place and soon the new building expansion will be all lit up!

interior painting continuesinterior paintingheater installationheater installation


Expansion Update: September 5th, 2012

Subcontractors continue to work on the interior of the expansion. A fire protection system, consisting of a series of pipes and sprinklers suspended from the ceiling, is currently being installed. The expansion project reaches another major milestone! A large rough opening was cut into the existing wall connecting the addition to the existing building.

fire protection systemfire protection systemfire protection systemwall opening


Expansion Update: August 30th, 2012

The painting of the structural steel white is nearly complete. Electricians continue to run conduit for power and lighting. Fire-rated drywall was installed in accordance with local building code. The HVAC contractor is now on site to begin the heating, ventilation, and air conditioning work.

interior electrical workinterior electrical workinterior electrical workfire rated gypsum installation


Expansion Update: August 28th, 2012

With the exterior almost complete, efforts have moved to the interior of the expansion. The structural steel is being painted white to match the insulation; giving the addition a clean finished appearance. Electrical conduit is being installed to run wiring through for lighting.

completing exteriorpainting steelpainting interior structural steelinstalling electrical conduit


Expansion Update: August 23rd, 2012

In just a couple of days, the masons have completed the block work on the front of the new addition - matching the existing building perfectly. The result is a seamless transition from old to new. Crews have also completed the installation of the blue 40mm Lexan* Thermoclick* on the west side of the expansion. With only some final metal work to be finished on the front, the addition will soon be completely enclosed.

masory workmasonry workmasonry workmasonry work complete


Expansion Update: August 21st, 2012

With the metal standing seam roof nearly complete, all that is visible from ground level is a clean white vapor barrier. Crews will soon be able to work rain or shine on the interior components of the building expansion. Equipment and materials for the masonry front block work is already on site.

roof near completitionroof near completitionroof nearly completeroof nearly complete


Expansion Update: August 17th, 2012

The exterior steel has been completed on two of the three sides of the new expansion. The installation of 40mm Blue Lexan* Thermoclick* is finished on the north side of the building and is now being installed on the west elevation. The crew has completed the first section of the roof; providing the first covered portion of the building expansion..

thermoclick installationexterior steel completion north wallcompleted exterior steel north elevationroof installation begins


Expansion Update: August 13th, 2012

With the steel skin exterior complete on the north side of the expansion, the crew has moved to the east elevation. As installation of the steel exterior continues, finishing touches are being put on the structural steel connections and bracing. Building materials continue to arrive on site such as insulation and steel for the roof.

Installation of steel skin continuesFinishing structural touchesinstallation of exteriorsteel skin installation


Expansion Update: August 9th, 2012

The structural framework is complete. Crews are now installing a steel skin exterior to match the existing warehouse. On the north and west elevations, 40mm Blue Lexan* Thermoclick* is being placed above the steel skin. Lexan* Thermoclick* is an excellent way to bring daylight into a building and a practical way to provide natural light for our warehouse team. To learn more about Lexan* Thermoclick*, please Click Here.

steel skininstalling exterior steel skin40mm blue thermoclicklexan thermoclick


Expansion Update: August 7th, 2012

All the primary steel framing members are up. To tie the structure together, crews are attaching smaller braces and supports to the frame. They are also attaching horizontal girts to the exterior columns. The exterior steel skin will be attached to these horizontal girts. The combination of these pieces working together will allow the building to not just enclose the space but support a load and resist forces.

Attaching Horizontal GirtsAttaching Frame SupportsHorizontal GirtsFraming Exterior Skin


Expansion Update: August 2nd, 2012

With the majority of the steel in place, it is easy to see the actual size and unique features of the warehouse expansion. The use of web joists in the construction creates a center span wide enough to accomodate the slitter table and full 48' length sheets. This unobstructed space will allow the warehouse crew to process orders of all sizes quickly and efficiently.

Steel Erection ContinuesSteel Erection ContinuesSteel Erection ContinuesSteel Erection Continues


Expansion Update: July 31st, 2012

The steel arrived late last week. As the structural members were delivered, crews organized the columns and beams around the site near their final location. A crane was on site early Monday morning to start erecting the building. With web joists placed on top of the beams, the final shape and size of the addition is starting to be seen.

amerilux steel erectionamerilux steel erectionamerilux steel erectionamerilux steel erection


Expansion Update: July 24th, 2012

The majority of the concrete has been poured. While the concrete is curing, miscellaneous projects are being completed. The flat work has been sealed. A sidewalk was created to connect the building entrance to an additional parking lot which will be located on the side of the new addition. Power was trenched to light poles for the new front parking lot.

Misc project while concrete curesMisc project while concrete curesNew sidewalkPower for new light poles


Expansion Update: July 20th, 2012

Cement trucks arrived early this morning. Power buggies were used to quickly transport the concrete to the far edges of the slab. A large self-propelled laser screed leveled the concrete while workers tended to the smaller areas and detail work. Once the concrete had time to set up, ride-on trowels were used to provide a finished surface.



Expansion Update: July 17th, 2012

With the stone bed set and the perimeter form work in place, crews are making the final preparations for concrete. A plastic vapor barrier was placed over the gravel. This vapor barrier will help control the moisture in the finished warehouse. Reinforcing mesh has been added to strengthen the concrete floor. The site in now ready to have the concrete poured.



Expansion Update: July 12th, 2012

The site work is finished except for the final touches. Crews have finished the final grade for the flat work and have been busy digging the exterior footings and building form work. Holes have been dug for the column foundations and the rebar has been placed. Power buggies and ride-on-trowels are now on site; ready to begin pouring the interior pads.


Expansion Update: July 10th, 2012

With the majority of the site work complete, crews are now turning their attention to the existing warehouse and how it will connect to the new expansion. The existing exterior steel is being removed in areas to prepare for the passage ways between the new and existing structure. Surveying crews are working to layout the footprint of the new building expansion.


Expansion Update: July 5th, 2012

Removal of the west parking lot is underway and the clearing and excavation of the expansion site has begun. The excavation crew was busy earlier this week removing dirt and debris leveling the site. Installation of the stone base is underway - leveling and compacting of the crushed stone is nearly done. Ground preparation for the concrete foundation of the building expansion is nearing completion. Site electrical work has begun.


Expansion Update: July 2nd, 2012

The first step in our building expansion project was the expansion of our front parking lot area, including tree, shrub and topsoil removal. Installation of the crushed stone base, asphalt paving and parking lot striping is complete. The new parking lot provides additional parking spaces to accomodate the business growth and job creation at AmeriLux over the last several years.


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