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Brinnon Fire Hall Press Release \| Local Firm takes on Big Steel Metal Building Manufacturer Upgrades Manufacturing Equipment By Krista Hovis Associate Editor Founded in Alaska in 1981, HCI Steel Building Systems Inc., a pre-engineered steel building and metal panel manufacturer, was initially an affiliate of an established steel building contractor. Its first customers were large companies such as Arco, British Petroleum, Sohio, U.S. Corps Of Engineers and the U.S. Navy. "These customers demanded a high level of quality and conformance to their specifications," stated Lee McDaniel, HCI’s general manager. "Most metal building manufacturers have their origins in the agricultural markets, which are very simple when compared to the institutional and industrial construction markets which are highly technical and very demanding of quality and adherence to strict specifications," he continued. "This initial demand worked to the long-term advantage of the company by keeping it on the leading edge of technology, innovation and quality control." In 1986, when the oil industry and the Alaskan economy declined, HCI decided to purchase 8-1/2 acres of industrial land in Arlington, WA. It was from this location that the company first established itself in the lower 48 states. It was also on this property that HCI decided to expand its operations in 1996 and build a new facility. The 81,000 sq. ft. plant and 9,600 sq. ft. office building were designed to incorporate an extensive material handling system which was laid out for ease of material flow. Overseeing the entire operation are co-founders Joe Holden, president; and Lee McDaniel, vice president/general manager. Aiding them in assuring that HCI runs smoothly are: Bill Holden, customer service manager who has been with HCI for 22 years; 15-year veteran Jason McDaniel, chief estimator; Stacey Gunn, detailing manager with 13 years of service; and plant manager Jim Cline, who has served HCI for 12 years. This management team, along with nearly 80 employees, markets HCI’s products to the western U.S. and Canada, the Canadian Arctic, Alaska, and the Pacific Rim. The Special Projects Division of the company markets products worldwide. HCI’s existing equipment was moved into the new plant when it was built. Last year, the company decided it was time to update that equipment. With this upgrade, HCI now manufactures five metal panel profiles, including two standing seam roof systems; one concealed fastener wall panel; and two thru-fastened roof and wall panels; all in a variety of colors, finishes, and gauges. In addition to traditional pre-engineered metal buildings, the company can also manufacture hybrid and multi-story buildings. It specializes in clear span buildings and can fabricate them in over 500’ widths. McDaniel added, "Heavy industrial buildings with complex crane systems and mezzanines are welcome work." HCI also now has the ability to fabricate beams 84" deep, and can process structural shapes such as beams, channels and angles. To further detail the new equipment HCI purchased, as well as provide some insight on the company’s future plans, Metal Construction News conducted an interview with Joe Holden. Following are his responses. Metal Construction News: Within the last year, your company decided to upgrade much of its manufacturing equipment. Why? Joe Holden, president, HCI Steel Building Systems: Actually, the decision to upgrade was made in 1996 and the planning and research took time. Factors included a desire for expanded design flexibility and efficiency and lower cost per ton of steel. We believe that today we have the highest quality with the lowest cost per ton in North America. We also wanted to expand our component line. MCN: Why wasn’t the upgrade done when the new plant was built? Holden: Simple--money. HCI is a closely held corporation with two stockholders who waited for what they thought was the right time to invest in the new production systems. We did add a new processing system when we built the new plant. The system accurately punches and saws to length wide flange beams, angles, channels and flats. We use this system to fabricate our chord and web members for trusses used in long span building systems. MCN: What pieces were recently replaced? Holden: We replaced our beam welding line, our cee and zee mill, our web processing system and our flange processing system. MCN: How old were these machines and what were their capabilities? Holden: Our beam welding line was built in 1967 and did a good job, but was limited to 6’ webs and 1" x 14" flanges. Our purlin mill was built in 1981 and was limited to 6" through 12" sections and only 3" flanges. It also had limited punching capabilities. MCN: Please describe your new machines. Holden: We look at our new beam welding line as a system. The new system is very comprehensive starting with automated raw material sorting and handling to sub-components processing of the parts, then conveying the parts to the beam welding line. There are 856’ of powered roller conveyors, two gantry material handlers, two cross conveyors, four seam weld stations and a fit up station. Our welder is a pull through type with submerged arc welding machines. The maximum web size is 7’ and the maximum flange size is 1-1/2" x 16". Our web processing is done in a continuous strip of 8’-wide plate on a 63’-long slat conveyor. The cutting is done with a computer controlled plasma torch. Flanges are processed in a continuous strip technique; also punching and shearing of the flanges is performed with a computer controlled triple gag shuttle punch and a 425 ton shear. Flanges are then conveyed directly to the beam welder or cross conveyed for secondary welding at the step flange assembly station. Our new purlin mill processes cee, zee and gee (eave strut) shapes. Sizes range from 3-1/2" to 14" webs and 2" through 4" flanges with virtually limitless hole sizes and locations. Piece marks are automatically stenciled on all parts for ease of field identification. Set-up time is now done in a matter of minutes, allowing HCI to respond faster to our customers’ needs. MCN: There are a variety of equipment manufacturers. How did you decide which machines to purchase? Holden: The primary motivation behind our decision was product through-put and finished product quality. Quite frankly, we would not settle for second best or second rate. MCN: Did your building need to be enlarged to accommodate the new equipment? Holden: An accessory warehouse was added and the trim department was relocated. Other modifications were necessary but the upgrade was anticipated at the time the new facility was built. MCN: How do your expect the new equipment to impact your business? Holden: We plan to increase sales with the more aggressive lead times and prices that we can now offer our customers. The new equipment also enables us to design and fabricate a much larger range of buildings efficiently, particularly the large wide span buildings in excess of 500’. The new purlin mill gives us the ability to produce wider bays and significantly broadens the secondary framing products available to our engineers and component customers. We can now offer our customers even better delivery times and pricing which will increase our sales. We are very pleased with our new equipment. MCN: In a previous conversation, you mentioned that the new equipment also provided a smoke-free shop environment. How? Holden: We installed a positive air assisted vacuum system for the plasma cutter that collects any smoke, scrubs it and sends it back into the shop as absolutely clean air. MCN: HCI is also currently trying to develop its builder network. How many builders do you have at this time? Holden: HCI currently has 31 authorized builders but will more than double that this year. A commitment "written in stone" has been made to market buildings primarily through our authorized builders. MCN: What is involved in becoming an HCI builder? Holden: We partner up with competent contractors of high integrity with a good reputation. MCN: Where do you see the metal construction industry in the next five years and what will be HCI’s role in it? Holden: The metal construction industry will make tremendous gains in the industrial and institutional markets. Quality and a higher degree of competence will take our industry there, aided by consumer confidence driven by certification programs such as AISC-MB. HCI will be there by staying focused. End TOP

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