Yard Expansion Complete — Additional Four Acres Now in Service
The four-acre yard expansion announced last fall is complete and has been in active service since Memorial Day weekend. The addition brings the total plant footprint at 10101 Superior Way to approximately 50,000 square feet of indoor manufacturing and 12 acres of finished yard for panel staging, custom-pour work, and long-hold inventory.
What the new acreage is being used for
The primary use of the expanded yard is staging finished panels awaiting scheduled delivery. Over the last two production cycles, our average panel dwell time between strip and delivery has grown appreciably, reflecting extended lead times on the general contractor side rather than any change in our own throughput. When a GC pushes a site start from May to August, panels that were cast on our March schedule sit in the yard for a longer stretch than they used to.
The added acreage lets us continue casting on our internal schedule without needing to reshuffle previously cast work into cramped yard corners. It also opens capacity for a second use case: staging oversize custom precast pours during multi-week fabrication windows, where partial cast-and-stage keeps the casting bay moving on parallel work.
Yard layout and improvements
- Grading and drainage. The expansion parcel was graded to shed water toward the existing site drainage swale on the west side of the property. No panels sit in standing water; no equipment tracks through soft ground.
- Compacted stone base. The full four-acre section is topped with 4-inch VDOT #21A aggregate over compacted subgrade, rated to carry loaded trailer traffic and mobile crane setup without rutting.
- Load-in circulation. A single loop road allows loaded trailers to enter, load, and exit without backing out through the main yard. Loading zones have dedicated tie-down anchors for tarps and strapping.
- Lighting. Six new pole-mounted LED fixtures cover the section for early-morning loadouts and late-evening staging when a delivery is on the schedule for a next-day 6 AM job site arrival.
What this means for contract capacity
From an estimating standpoint, the added yard opens two categories of work we previously had to size carefully against yard availability. The first is larger VDOT and municipal precast contracts — sound wall packages, retaining wall runs, and site-work precast where hundreds of pieces stage over the course of a single delivery window. The second is production for out-of-state jobs where transport scheduling requires holding several truckloads of finished work before dispatching a delivery convoy.
Estimators and specifying engineers can direct questions on capacity and lead times to our estimating team at 1-866-524-3820. Site visits to the expanded yard can be arranged by appointment.