BTD Manufacturing

Situated on a 33.3-acre site, the facility is built to support efficient production flow, streamlined material handling, and long-term operational growth. The warehouse component was a critical driver for the project. Prior to this facility, BTD’s warehouse operations sat off-site, about 45 minutes from the campus, adding complexity to material movement and day-to-day operations. Bringing manufacturing and warehouse functions together under one roof strengthens operational efficiency while also giving BTD room to grow.

Before vertical construction began, the project team navigated permitting, and coordinated stream and wetland mitigation credits with the U.S. Army Corps of Engineers (USACE) for two creeks onsite. Significant grading challenges across the first 20 acres called for extensive excavation and fill to establish a stable building pad. The scale of that early work produced two large soil stockpiles, underscoring the complexity of the site.

Rather than treating the excess material as waste, the team saw an opportunity to create long-term value. With future expansion already in view, excavated soil was preserved for reuse in Phase Two. This approach reduced export, limited future import needs, and supported a more strategic path forward for site development.

Every element of the facility was designed with BTD’s manufacturing operations in mind. The building includes specialized press foundations, provisions for future equipment pit foundations, and a drive-in loading dock built to accommodate a 20-ton overhead crane. After permitting and construction began, the project team worked with the client’s insurance company on fire protection and product storage requirements, while addressing water-source infrastructure challenges tied to volume and flow capacity as the surrounding community continued to grow.

A 360-linear-foot crane beam spans the length of the facility, allowing materials to move directly from the drive-in dock to production equipment. Aligning crane operations with BTD’s workflow improved efficiency, reduced material handling, and supported a safer, more controlled manufacturing environment.

From Design-Assist planning through final delivery, the project balanced immediate performance with future scalability. Strategic grading, thoughtful material reuse, permitting coordination, and comprehensive infrastructure planning built a strong foundation for continued growth across the site.

Delivered on schedule, the BTD Manufacturing facility strengthens the company’s presence in the Southeast and provides a high-performing, purpose-built environment built to support the next generation of metal fabrication.