THE PROJECT
When Waukesha Iron & Metal, a 3rd generation family owned recycling service company, needed to expand its facilities, Ford Construction provided the design-build leadership to complete the complex project within strict budget and timeline constraints.
Initially, Waukesha Iron & Metal engaged an architect recommended by the equipment manufacturer. However, Ford quickly identified that the proposed design would likely exceed the budget. When the project went out for bid, the costs confirmed Ford’s concerns. Acting swiftly, Ford redesigned the project in eight days and provided a new estimate within a week and a half. This proactive approach resulted in a solution that met both the company’s functional needs and financial requirements.
The Advantage of Metal Building Construction
Leveraging the advantages of metal building construction, Ford maintained momentum throughout winter conditions, avoiding delays that often affect other building types. By proceeding with a metal building solution, the team delivered three buildings within five months, enabling Waukesha Iron & Metal to bring the facility online and operational in time to meet critical year‑end tax deadlines.
Speed, coordination, communication, and constructability were essential from day one. The buildings range in size from 3,000 to 12,000 sq. ft. and include approximately 50 concrete foundations to support the extensive conveyor systems and specialized processing equipment. Furthermore, the structures were designed with clear, unobstructed spans, giving Waukesha Iron & Metal maximum flexibility for equipment layout, vehicle movement, and future changes in operations.
Design & Construction Highlights
The project showcases Ford’s ability to rapidly respond to client needs, even when it requires redesigning and re-estimating a project to better align with project goals. In addition, the Waukesha Metal & Iron building solution highlights the benefits of metal construction. In this case, it provided clear, unobstructed space ideal for industrial operations and a project delivery method perfect for fast‑tracking schedules under cold‑weather conditions. Additionally, the owner appreciated the variety of material applications integrated to achieve an innovative design.
Metal Building Success
While meeting project timeline and budget goals serves as a measure of success, receiving industry accolades reinforces a job well done. The Ford Team was proud to have this Waukesha Iron & Metal project honored with a Metallic Building Award of Excellence.
Since 2011, Ford Construction has continued to support Waukesha Iron & Metal’s growth by delivering a total of nine metal buildings, demonstrating lasting value and expertise in metal construction solutions.