Due to increased production demands, MTD Products needed to expand its existing manufacturing plant in Martin, Tennessee. Operations in the lean manufacturing facility include stamping, welding, assembly, coating, and logistics for the outdoor power equipment provider.

As part of a design/build team, A2H designed this 130,000 sf expansion to the lawn equipment company’s facility. The expansion was designed and constructed on a fast-track schedule which dictated that the building and plant process be designed simultaneously; this required close coordination between MTD’s engineering staff and A2H’s in-house A/E design team. Careful consideration had to be given to the entire volume of space and the impact of column layouts and beam depths given the new space was proposed to be tightly packed in all three dimensions.

The project also included extensive site modifications to accommodate a new access road for distribution operations. A major drainage conveyance bounded the site to the north and east creating a need for an odd-shaped building footprint and design had to accommodate drastic grade changes over the length of the largely linear building. A wastewater treatment system was also included in the design.

Because of the need to continue operations as long as possible, the building had to be constructed from the farthest end of the existing building and infilled adjacent to the existing building as the last step. This created challenges in the design and layout as well. Most of the building allowed for high-density and flexibility of hanging process equipment loads. A2H also had to strengthen joists on the existing building adjacent to the new buildings to accommodate increased snow loading per FM Global design requirements. A laser table foundation was also designed to meet tight vibration and deflection criteria set forth by the equipment manufacturer.

This expansion helped bring over 200 new jobs to the local community.