American Polyfilm, Inc. – New Construction

15 Baldwin Drive
Branford, CT 06405
www.apiusa.com

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Since 1998, American Polyfilm, a family-owned company, produces made-to-order blown polyurethane films serving medical, performance textiles, protective garments, food processing and petroleum markets.

Installation of pre-engineered steel panels.

Cranes used to erect steel framework.

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The Business Situation

Growing demand and a new line of medical products required additional manufacturing capacity and the consolidation of production, storage and administrative functions that were located in multiple sites.

CHALLENGE
To construct a new, state of the art, energy efficient facility, which features a 4-story steel tower that rises above the roofline to enable the blown film manufacturing process and to allow the film to cool and cure as it is drawn upward.

SOLUTION
The new 27,500 sq. ft. Varco Pruden pre-engineered steel building includes a continuous beam frame system with tapered beams and interior columns. The exterior integrates a 24-gauge steel, galvalume coated, standing seam roof system with 26-gauge, galvalume, steel panel rib siding.

The interior includes a panel rib liner in production areas and dividing partition wall between warehouse and production areas. A 54 ft. high x 30 ft. wide x 100 ft. long landmark production tower rises above the roofline.

Architectural elements include careful window placement, single slope roof, window and door canopies, galvalume siding, polished concrete floors in offices, ceramic tile in bathroom and shower stalls, stainless steel cladded reception counters, and interior glass and wall systems.

Energy efficiency is a building hallmark. Skylights and windows provide natural daylighting with LED lighting throughout the facility. The EnergyStar rated HVAC system creates a positive air pressure environment that is “pumped up” with more filtered air than the outdoor space and minimizes the amount of untreated air infiltrating the building when doors are opened. The sloped roofing system was designed to maximize solar gain for a planned future PV Solar system installation.

Distinctive Approach To “Team Building” 

APi owners had originally intended to find and buy an existing building for Munger to renovate and retrofit to suit their needs. After evaluating many prospects that required drastic building modifications, Munger recommended that they construct a new facility on a beautiful 5.3 acre site perfectly suited for APi’s corporate headquarters and operations center.

Starting with a basic shell the team of APi, Terry Architecture and Munger worked side by side during iterative design,construction and estimating while the work was being done.They anticipated constant change in scope with ability to navigate multiple change orders that eventually lead to the optimal finished product.

“We had the ability to envision, but be practical,” said Munger’s project manager, Joe Pierandi. Anthony Terry worked closely with APi and Munger’s estimating team of Steve Mansfield and Jeff Brown to find cost effective ways to make a technological “splash” with the new building.

APi owners wanted an aesthetically pleasing aeronautical look similar to the Porsche Stuttgart facility that they visited, so Munger recommended galvalume roof and side panels. Munger was able to meet their desire for a single slope classic looking roof in front but helped them to understand the need for a sloped roof away from the production tower to prevent future water damage. Also, Munger showed initiative by assuming the role of process engineer for the unique and challenging seamless integration of metal building, equipment platform steel fabrication and production equipment.

Results

The new facility will accommodate growing demand and enable significant business efficiencies from the consolidation of production, storage and administrative functions that had been located in multiple sites.

• Doubled production capacity accommodates business growth.
• Consolidated operations saves time and money from process efficiencies.
• High employee morale is further enhanced by this new state of the art work environment.
• Aesthetics and process environment enhance credibility with customers.
• Differentiates APi from competitors by minimizing the amount of untreated outdoor air infiltrating the building.
• Exceeding state energy efficiency building code by 30% earned a $90,000 rebate from Eversource.

Teamwork Essential For Success 

“Munger people have a great grasp of what they are doing,” said Victor Cassella, APi President. “Weekly status review meetings with project manager, Joe Pierandi and site supervisor, Sven Uljens kept everything on track with great follow through on action items.”

Architect, Anthony Terry, specified details for skilled Munger craftsmen to produce fine custom trim and product display cases, along with door and glass wall system installation.

Terry Architecture- architectural design, Cubic Designs- built and installed production tower, First Choice Builders- building and tower erection, Empire Drywall- interior framing and sheet rocking, Controlled Air- HVAC and mfg equipment process piping, Finelli Electric- switchgear, control wiring and electrical, Marino Mechanical- plumbing, North Haven Ceramic Tile- carpet and ceramic tile, RA Torre- painting, Massey Glass- storefront glass systems

 

The management team of American Polyfilm, Inc. met with 3 builders before choosing Pat Munger Construction to build our unique building.

We could not be more pleased that we chose Munger Construction as our builder with Varco Pruden as the engineers and manufacturer, and Terry Architecture as our designer.

David DeMaio and the Munger team and Terry Architecture worked closely with the American Polyfilm team every step of the way.  Our building required some unusual features, such as a 55′ raised section in the center.  Varco Pruden’s building components and Munger’s execution were flawless throughout. The end product suits our requirements and exceeds our expectations in functionality and appearance.

Victor J. Cassella President/Member American Polyfilm, Inc.

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