Construction of the new Uline distribution center, 1 million-plus square-foot facility in Pleasant Prairie, Wis., was completed in the summer of 2009.

The new Uline distribution center in Pleasant Prairie has a circumference of nearly one mile and more than a million square feet of storage space. (Photos courtesy of ACH Foam Technologies.)


Construction of the new Uline distribution center, 1 million-plus square-foot facility in Pleasant Prairie, Wis., was completed in the summer of 2009. The circumference of the Uline Distribution Center is nearly one mile, and its massive roof required the installation of 2.75 million board feet of Foam-Control EPS insulation. Foam-Control is manufactured by ACH Foam Technologies nationwide.

According to Phil Hunt, Vice President of Materials Management for Uline, material costs - as well as long-term thermal performance and speed of installation - were key factors in choosing Type II Foam-Control EPS insulation for the enormous roof. “Managing the costs to build, heat and cool a facility like this required a high level of scrutiny during the design and construction phases,” Hunt explained. EPS roof insulation was selected for the project because it provided all of these benefits in addition to meeting the project’s aggressive construction schedule. “After researching the cost and long-term performance of the different types of insulation available, we determined that EPS provided the most thermal protection for the least cost,” Hunt said.

The massive roof required the installation of 2.75 million board feet of Foam-Control EPS insulation from ACH Foam Technologies.

The Uline Distribution Center

The large steel-framed structure consisted of pre-cast concrete walls and a structurally sloped steel roof deck. The roof design incorporated 245 skylights to provide natural light while reducing electrical costs. One layer of 2.5-inch Type II Foam-Control EPS roof insulation was installed over a steel roof deck in a ballasted EPDM assembly. The membrane manufacturer, Firestone, awarded the project with its full system Red Shield warranty.

“Due to the size, location and fast-tracked schedule of the Uline project, it was imperative that quality materials were delivered in a timely and consistent manner,” explained Chris Busalacchi, Vice President of Schranz Roofing and Sheet Metal, Milwaukee, Wis. “ACH’s understanding of these requirements and their commitment to fulfill them played a big part in making the project successful. We have worked with the people at ACH Foam for many years and consider them a valuable supplier of roof insulation to our company.”

Expanded polystyrene has been used nationwide for 40 years in commercial roof insulation applications for its cost-effective, long-term R-value and easy to use tapered systems. Foam-Control EPS is available in a variety of densities, thicknesses and sizes and comes with a 20-year thermal warranty. It contains no CFCs, HCFCs, or HFCs, is easily recyclable, and is a nationally recognized component of LEED-certified projects.

ACH Foam Technologies has been manufacturing environmentally friendly EPS for over four decades, and with locations throughout the United States, ACH Foam Technologies is positioned to offer convenient and valuable solutions for its customers.

For more information, visit www.achfoam.com.

SIDEBAR: Uline Distribution Center

Pleasant Prairie, Wis.

General Contractor

CG Schmidt
Milwaukee, Wis.

Roofing Contractor

Schranz Roofing & Sheet Metal
Milwaukee, Wis.

Architect

Eppstein Uhen


Application

EPDM ballasted assembly using 2.75 million board feet of 2.5-inch Type II EPS Foam-Control Roof Insulation from ACH Foam Technologies installed over a steel roof deck