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.

As Peoples State Bank expands throughout Wisconsin, an existing bank location in Waukesha presented a remodeling opportunity for the community-focused brand. Milwaukee-based architect Dream Builders, LLC, created a plan to refresh the space, and Ford Construction developed a phased schedule to complete the renovations while keeping the bank operational throughout the construction process.

Design Highlights

The redesign prioritized the customer experience. By removing workstations in the middle of the floor plan, the team created a more welcoming entry sequence with clear sightlines to the teller lines, also improving bank security. A focal stone wall at the teller line reinforces the bank’s brand, a signature element repeated across locations. While the perimeter offices remained untouched, the conference room received updates, including technology enhancements. In addition, flooring was replaced throughout the building, and the lighting and HVAC systems were updated.

Construction Details

While maintaining business operations poses challenges, Ford strategically phased construction to minimize disruptions and maintain a friendly atmosphere for customers. For each phase, the designated work area was sealed to manage dust and debris. As with any renovation, existing site conditions revealed challenges along the way. The Ford Team responded with solutions to address the needed plumbing and fire system updates. From demolition, framing, and drywall finishing to repairing the foundation in the vestibule and the coordination of the curved teller line and etched glass panel installation, the project required the management of numerous subcontractors.

White Stone Community Church understands patience and commitment to a vision. While the congregation invested in remodeling projects to address evolving needs over the years, they continued to raise support and funding for a larger expansion project. The intent was to create a fully integrated worship and gathering space to deepen the connections between members of their faith community.

The project presented numerous construction challenges, including a flat site with significant parking requirements, stormwater demands, and a tremendous amount of poor soil. In addition, the project required material and structural transitions between differing building types, ranging from a 1800s barn and 1980s CMU and brick structure to the new precast expansion. Moreover, the Ford team needed to address meshing the buildings together while maintaining church operations. This process required thoughtful phasing to navigate complicated life safety issues, such as providing a temporary set of stairs to support occupancy permits. Phase I of the project focused on the 25,000-sq.-ft. addition, and Phase II addressed a 14,200-sq.-ft. two-story renovation. In the spirit of community and as a means to lower project costs, church volunteers contributed labor. Under Ford’s guidance, the dedicated members helped with interior demolition, carpentry, and installing the wood floor.

The new expansion provides a welcoming entry and gathering space that unifies the congregation with areas to meet, talk, and pray. From the inviting café and enhanced worship space to a commercial kitchen to support outreach, the expansion enriches the community experience for members of White Stone Community Church.

LifeStriders, a non-profit organization focused on providing integrative and nature-based therapies to those with physical, emotional, and cognitive special needs, sought a partner to support important capital improvement projects. Since 2022, Ford has worked with the organization to construct a new multi-use hay barn while planning for an office facelift and expansion, and discussing future additions to the property.

White Brick Salon promises clients more than a salon visit—it’s an experience. Ford worked closely with the owner to transform a former light fixture showroom in a 15-year-old building into her unique salon vision. The 2,400-sq.ft. floor plan was reworked to support efficiency for the stylists and a more spacious setting for the client. This included creating eight stylist work areas, three shampoo stations, a bathroom, break room and back of house area for storage and laundry.

Miller Mobility is an extensive resource for mobility and medical equipment. As a family-owned business, the owners wanted to provide clients with a true at-home showroom experience. The modern farmhouse aesthetic of their 3,200-sq.ft. building offers a welcoming appeal in its commercial park location adjacent to a prominent hospital. The new retail environment includes showroom and office space as well as inventory storage and an outdoor display area.

Milwaukee Motorwerks had identified an ideal location for its new expanded shop space in an industrial park in Waukesha. The industrial subdivision had high aesthetic and architectural standards for businesses to follow. While many of the businesses offer masonry block facades, Milwaukee Motorwerks wanted to use a material that met the development standards while communicating its brand—a modern, technologically-advanced European automotive specialist.

A custom metal building best served the timeline and budget for the project. It was a less expensive construction process and a faster schedule turnaround. While a custom metal building was determined the best direction for the project, the goal was to create a design that did not look like a conventional metal building. An alternating horizontal pattern achieves the unique façade, and the gray and red color palette creates a striking presence within the industrial park. The horizontal application also complements the masonry style of the neighboring businesses.

For people who like to build, invent, tinker and learn new skills, Milwaukee Makerspace is an environment with all the equipment needed to make things 24/7. From electronics and woodworking to metal work, art, sewing and more, this is a place to tackle that project you have always wanted to—without having to buy all of the tools yourself. The concept has been so successful that the group is expanding by opening a second location.

White Stone is a liturgical community in the midst of growth. While they have plans for a major expansion in the future, a church interior remodel is necessary to address immediate needs while additional funds are raised for the more comprehensive project. Ford has played a key role in developing the plan for the interim remodel and recommending a phased schedule for the renovations with minimal disruption to the congregation.

BEVCO is a family-owned company that manufactures safe, ergonomic, quality seating solutions. Founded in 1947, the company leaders know the importance of investing in their facilities to support growth. In order to complete a warehouse addition, Ford needed to construct a metal building on an existing foundation. As the only bidder willing to reuse the foundation, the Ford team was prepared for the challenges from the start. Together with the surveyor, metal manufacturer and erector, the team was able to address the nuances needed to retrofit the foundation for a modern, clear span metal building. The result is a new, super-insulated structure that includes a single loading dock with hydraulic dock board—ample warehouse space for the successful manufacturer.