This new Walmart distribution center needed a 1.8 million SF roof, which required a crew of 40-60 workers hitting an average of 50,000 SF a day.
On average the team received around 8 to 10 truckloads of material a day just to keep on with installation. Achieving the manpower needed to pull off this job was the first challenge. Luckily, we have our friends at the nearby Flynn Minneapolis branch and HR was able to recruit the rest needed. The next challenge was managing this many crews.
Flynn Midwest had not done a roofing project of this size and a lot of coordination at the jobsite was needed. A meeting was held with the Project Manager, Tammy Mauck, General Superintendents, Doug Sutton and Mike Mauck, the Job Superintendents, John Aeberhard, Charlie Holloway, Chris Zearley, and the Foreman, Zack Wisdom on what would be the best way to meet our labor goals for the project.
It was decided that our crews would be broken out into four teams. Two teams for each layer of insulation, one team for the layout of the crickets and detailing and one team for the installation of the TPO. Each team would have a leader and would be responsible for that crew and reporting to the job superintendents and foremen.
OPEX was also able to lend a hand when it came to the insulation installation. Instead of using sandbags to weigh down the insulation, Mike Shannon, Equipment Manager and Mike Pierce, Senior Advisor at OPEX suggested the use of weighted cones. Weighted cones are easier to pick up and are safer for our crews
to use.
The project was a massive undertaking and required skillful forethought and constant communication. On their best day the team hit more than 70,000 SF in one day!
Thank you to the entire team that made it happen.
