Polyglass U.S.A. Inc., a leading manufacturer of roofing and waterproofing solutions, announced the expansion of their manufacturing plant facility in Waco, Texas. In 2017, Polyglass opened its fifth manufacturing plant in Waco. It is the largest of Polyglass’ state-of-the-art manufacturing facilities. 

"The plant brought economic growth and development to the area when the plant opened, and with the expansion, Polyglass hopes to bring more opportunities to the local community," the company said in a release.

The project is expected to be completed and the facility open for use by the end of 2023.

Project Details

The expansion consists of three parts: a new production line, warehouse expansion and site improvements. The new product line is an owner furnished and installed system. The warehouse expansion is 100,000 square feet and includes structural concrete foundations, concrete slab on grade, conventional structural steel framed building with bar joist, decking and insulated metal wall panels, built up modified bitumen roof system, basic mechanical systems, ESFR fire suppressions system, four new loading docks, 1000 square feet office expansion, and 210,000 square feet of exterior concrete paving. Surrounding the building is 3,800 linear feet of concrete curb and gutter, improved site drainage, fire water utilities, fencing, outbound scales, fencing and pavement markings.

The project comes with some challenges due to the construction occurring while the existing plant continues day-to-day operations. The construction site is tight and requires constant communication regarding the number of trucks incoming for product shipment as well as those related to the construction. The limited space requires quick, out-of-the-box thinking to keep the construction progressing without disrupting the current manufacturing/shipping processes.

Polyglass is partnering with Corporate Contractors Inc. (CCI), to plan and execute the expansion project. CCI provided the engineering and architectural design services, as well as the construction management for Polyglass. Polyglass and CCI are also partnering with 15 local companies and contractors to complete the details of the new manufacturing facility.

“The Polyglass staff are a great group of individuals that bring many years of experience, and not just manufacturing. They all have working knowledge about construction and the various processes as well. This is something that does not happen with most construction projects,” said Dennis Williams, project manager for CCI. “The Polyglass group is very willing and cooperative with daily changes that occur on site. It is nice to work with a group that is 100% engaged from the beginning and all throughout the design and construction phases. The owners’ deep involvement and a 'boots on the ground' approach is a great value to the construction team.”