Miller Bros. Construction Reports: 2023 Progress and Completions
New home for additional press line at Hydro Cressona
MBCI worked alongside Hydro Cressona to incorporate an additional extrusion press line within their growing campus. Press 19 is a 3,000-ton indirect press, capable of producing profiles from 10 to 100 millimeters, or approximately 0.4 to 4 inches, used in a wide variety of industrial applications ranging from consumer products to automotive components.
In order to accommodate this new press line MBCI, in collaboration with Hydro, planned and constructed an 11,000 square foot pre-engineered addition complete with a 20-ton overhead maintenance crane. The new press line stretched into their existing facility requiring the removal of approximately 35,000 square feet of existing floor slab and machine foundations. All this to accommodate new underground utilities and foundations associated with the new Press 19 runout line. The MBCI team poured more than 3,700 cubic yards of concrete foundations and floor slabs throughout various phases. Quandel Concrete supplied the concrete used across the entire project duration of 19 months.
Aluminum cast house addition at Hydro Cressona
Hydro Cressona contracted MBCI to construct a 44,000 square foot addition to the existing cast house. The aim of this Bay 0 project was overall improvement in the efficiency of the melting-casting operation–an outcome essential to the entire facility.
Project highpoints include, a new aluminum scrap shredding operation, a truck ramp to dump scrap for the shredding process, a new railroad spur, switch, and dock for receiving product by rail, a series of robust concrete storage bins to store the shredded material, extensions to the on-site scrap train rail system, HVAC upgrades to the cast house, and overhaul of the entire underground infrastructure in this area. More space for outside storage was created upon the demolition of a 225-foot-tall chimney stack, along with removal of a disused building housing an obsolete coal-fired boiler.
MBCI completes abandoned mine discharge project
In 2022 MBCI started the Otto Abandoned Mine Discharge (AMD) project near Branchdale and completed it in 2023. This mine drainage reclamation project involved removing and rebuilding sediment ponds, as well as shaping and stabilizing the incoming stream. The work required installation of concrete curb aerators and drainage flume, land clearing, laying storm pipe, earthwork and fencing.
According to Stream Restoration Incorporated, the Otto Colliery Airshaft Discharge is one of the largest sources of abandoned mine drainage in the Schuylkill River watershed. The discharge originates from a former airshaft of the Otto Colliery and contributes a significant streamflow to Muddy Branch. Muddy Branch flows from the western boundary of the watershed to the West West Branch of the Schuylkill River which then joins the West Branch of the Schuylkill River.
Because of iron and other metal loading from the Otto Discharge and other AMD sources, the West Branch of the Schuylkill River was designated “impaired” on the Penna. Department of Environmental Protection List of Impaired Waterways.
MBCI completes fit out for NorthPoint Development
NorthPoint Development reached out to MBCI to complete a tenant fit out within Building One of its Mahanoy Business Park in Mahanoy and Ryan Townships. Box Partners is taking occupancy of a sizable portion of the space in the 1.2 million square foot structure located just off Burma Road.
The project began with the erection of an interior wall 645 feet in length and 45 feet high to separate areas of tenancy within the building.
Several other noteworthy projects for NorthPoint Development included a 2,700 square foot shipping office fit out with four remote restrooms along with and a separate fit out of 3,800 square feet within NorthPoint Building Eight in Nanticoke.
A fit out refers to the process of making interior spaces suitable for occupancy. The process typically includes activities such as partitioning, flooring, lighting, heating, ventilation, and HVAC systems. It frequently involves the installation of office space, restrooms, break rooms, and other amenities required for the smooth operation of a large logistics building.
Our team performed restoration work after a vacancy occurred in NorthPoint’s Building Four on Tradeport Road in Ashley, Pa.
We have started work on a 6,076 square foot fit out for Wise Foods in Building Four.
Locker room building addition completed for new Niagara Bottling facility
Family owned and operated since 1963, Niagara Bottling is a leading beverage manufacturer in the U.S.
MBCI has served for many years as their contractor of choice for improvements and maintenance in their three local facilities. Now the relationship coninues with a fourth location recently completed in Hazle Township, Luzerne County.
Management found that a larger locker room was necessary. We were tasked with building a matching addition to the new structure to house the dressing area. We created a space for 250 lockers with appropriate seating and an ADA-compliant auto handwash station. New sidewalks, exterior lighting, and area for smokers completed the package.
MBCI completes fit out for US Capital Development
Upon a recommendation from NorthPoint, US Capital Development secured our services to create an office fit-out within its newly constructed 400,140 square foot Class A specialty distribution facility in Tobyhanna, Pa.
The scope of work included creating a large space for a breakroom, restrooms, private office and open office area.
US Capital cited our reputation for price, quality and on-time completion among the reasons for choosing MBCI. The project finished right on time.
Windows and doors replaced at Carpenter Technology - Reading Operation
Carpenter Technology - Reading Operation called on MBCI for the removal and replacement of 140 windows and three exterior door packages on a three-story structure comprising varied interior and exterior finishes.
All this while the office remained in daily use. Our MBCI team planned and executed the work to minimize disruption to office operations.
Site preparation for EMD Electronics - Hometown
Our MBCI team performed excavation services for EMD Electronics - Hometown to prepare a site for the erection of a new multi-story building destined to house multiple manufacturing processes supporting production of specialty industrial gases.
New truck gate shelter for Walmart DC 7030
Walmart Distribution Center 7030 Pottsville tasked MBCI with the demolition and replacement of their existing truck gate guard shelter.
Our team completed the project through the use of temporary office trailers to house Walmart employees while we undertook the work, allowing uninterrupted operations for the Walmart team.
MBCI upgrades office for BlueTriton Brands in Saratoga Springs
BlueTriton Brands, Inc. is an American beverage company formerly known as Nestlé Waters North America, Inc. The company produces and distributes many brands of bottled water throughout North America. MBCI, sharing a long relationship with BTB, recently completed a project at their Saratoga Spring New York facility to upgrade existing office space with renovations that included a new server room and security access controls. The project was completed in mid-December. In addition, MBCI served in several other projects in 2023 supporting maintenance upkeep at their bottling facility in Breinigsville, Pa.
Multiple projects completed at Sunsweet Growers in Fleetwood
Our MBCI team completed multiple projects in 2023 at the Sunsweet Growers facility in Fleetwood to aid in sustaining activities related to processing and maintenance. The company produces and distributes prunes, prune juice, cranberries, apricots, nectarines, pineapples, mangoes and dates. Among many tasks, our work included additional building maintenance items to support their ongoing commitment to sanitary conditions in their processing equipment spaces.
MBCI at Tobyhanna Army Depot
Tobyhanna Army Depot enlisted MBCI to install a mass foundation for new fabrication equipment designed to support the Depot’s mission of producing parts for military use.
MBCI upgrades for Pennsylvania DEP
Upgrades at two Pennsylvania DEP offices in Phillipsburg and California, Pa. included new interior LED lighting to increase energy efficiency and the installation of 10 Electric Vehicle Charging Stations with capacity to add 10 more in future. Work was completed in the fall of 2023.
MBCI completes renovations for Schuylkill Haven High School
MBCI completed renovations during the summer break at the Schuylkill Haven High School Gym Entry. Upgrades to the interior included new display cases, ceilings, lighting, flooring, entry doors, painting, and cabinetry upgrades for the concession stand.
Sisters Early Learning Center opens in Frackville
Schuylkill Chamber of Commerce staff, government officials, and business community members joined two sisters in a celebratory ribbon cutting event in early May.
In 2021 two sisters from Frackville became aware of and bought, before it ever hit the market, an empty tract of land on the north end of town offered for sale by the former owner of an out-of-use daycare business (closed in 2019).
Sisters Jill Simons and Hollie Bindie, owners of Sisters Early Learning Center, selected MBCI for a comprehensive design build contract, including a boundary survey, Phase One and limited Phase Two environmental site assessments, land development plan, stormwater management design, NPDES permitting, landscape/lighting plans, architectural, structural, plumbing/HVAC, and electrical plans.
The result became a new 10,100 square foot single story structure consisting of nine classrooms with individual child lavatories, kitchen, meeting room, resources rooms, reception, playground area, and rear patio.
Construction began in September 2022 and was completed by April 2023.
Helicopter lifts 62 roof exhaust fans at Hydro Cresonna
As part of our ongoing project involving a 35,000 square foot addition to the cast house at Hydro in Cressona, MBCI collaborated with Antz Energy Systems of Shenandoah to conduct removal and replacement of roof-mounted fans at the facility on May 5, 2023.
Other critical members of the team that day were the pilots and ground crew of Midwest Helicopter Airways who carried out the lift. We began with a test run two weeks earlier using a crane to remove six old fans and lift six new ones in place. This proof of concept established that all was ready. At MBCI, safety is always of critical concern.
Midwest Helicopter Airways, based in Willowbrook Illinois, specializes in heavy lifting in the construction industry using 1950s-era Sikorsky S-58T helicopters that are capable of lifting loads up to 4,500 lbs. Interestingly, there were two pilots in the helicopter on lift day. One was dedicated to piloting removal of the old fans, and the other was focused upon setting the new fans down in the right place. The Midwest ground crew conducted the pre-lift safety briefing.
Thirty-one obsolete fans were taken off the roof that day: each weighing 1,500 pounds. These were replaced with new fans weighing 1,000 pounds each. Sixty-two fans, a total weight of almost 39 tons of old and new equipment, were moved at a rate of little more than two minutes per lift.
Antz Energy directed the charge on the fan work and will perform the fan connections and start up.
MBCI job progress continues at Hydro Extrusions in Cressona
The Hydro Extrusion plant in Cressona, Pa. is one of the largest facilities of its kind in the world.
In the final months of 2022 Hydro tasked MBCI to engineer and construct a 35,000 square foot metal addition to its Bay-Zero building. The new structure will be used as additional space for storing and processing recycled aluminum. The use of recycled aluminum helps to reduce Hydro’s carbon footprint, which is a significant target for the firm.
The scope of work involved the brick-by-brick demolition of a 225-foot-high chimney stack as well as the teardown of a boiler house that was longer in use.
We are installing a new railroad spur.
And the installation of new—and the relocation of existing—underground public utilities has proved to be a very challenging piece of the project.
The work on the addition began with tearing away a wall of the existing building, followed by the installation of metal studs for a new parapet wall.
The completion of all work on the site is anticipated by January 2024.
MBCI completes multi-structure project for J.F. Rohrbaugh & Co.
J.F. Rohrbaugh & Co. — a manufacturer of specialty pallets, custom shipping boxes and crates, prefabricated turnkey framer wall panels and mulch — hired MBCI to design and build a new manufacturing facility in Oxford Township, Adams County comprising five separate buildings on a 95-acre site along Brickyard Road.
The project included a 125,000 square-foot manufacturing plant with attached two-story office, two warehouses — one of 11,200 square feet and another of 9,100 square feet — an 11,200 square-foot maintenance building, and a dust collection building of 700 square feet to house an extensive dust collection system.
Site activity began in May 2022 with the demolition of old concrete pads, foundations, a huge underground steel rotunda, draft tunnels, old railroad tracks, brushwood removal and everything else that needed to go.
Due to less-than-stellar soil conditions (as well as underground tunnels) MBCI installed more than 1,300 impact piers prior to starting any buildings. The impact pier method consists of installing columns of compacted stone in groups to increase bearing pressure and diminish settlement under structural footings and concrete slabs.
Since there was no sewer connection nearby, MBCI installed a three-quarter-mile-long sewer extension along Brickyard Road and connected properties along the route to the new extension. In addition, MBCI set down 2,000 feet of new railroad track creating a spur to the manufacturing campus.
Scheduled completion of the project was April 30, 2023. Thanks to the efforts of the team and a mild winter the project concluded five weeks ahead of schedule. The owner took possession earlier than anticipated, getting a jump on launching business operations.
