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Oldcastle Precast, Inc

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Oldcastle Precast Supplies Precast Structure for 1st Pepsi/Muller U.S. Yogurt-Producing Facility

Oldcastle Precast lands large manufacturing plant project under Haskell Construction to deliver the structural precast concrete for construction of a new yogurt facility in the Genesee Valley Agri-Business Park, Batavia, NY.

Batavia, NY, May 11, 2013 --( Oldcastle Precast lands large manufacturing plant project under Haskell Construction to deliver the structural precast concrete for construction of a new yogurt facility in the Genesee Valley Agri-Business Park, Batavia, NY.

The facility, a new $206 million, 363,000-square-foot manufacturing plant, owned by Wave Holding, LLC, a company formed by two giant multinational companies, PepsiCo and the Theo Muller Group, is Pepsi/Muller ‘s first U.S. yogurt-producing facility and the biggest yogurt plant in the United States.

“Being a new product line in the highly competitive yogurt market, the owner knew that they needed to bring their product to market quickly. The Owner’s schedule required Haskell to complete the entire design-build project within 8 months. The Haskell Company chose Oldcastle Precast Building Systems as their precast fabricator and erector,” said Joe Navarro, General Manger of Field Operations, Oldcastle Precast.

Aaron Fink, Regional Sales Engineer, Oldcastle Precast said “Due to the tight schedule on the project, they needed to feel comfortable that the company providing the precast was large enough to handle the project’s size and scope.”

“This offered a unique challenge to Oldcastle Precast. It left us a very small window to complete our portion of the project,” said Navarro. “Product designed, manufactured, delivered and installed in a 5-month time frame.”

Oldcastle Precast supplied 134,103 total square feet of structural precast for the state-of-the-art dairy and yogurt production facility. In order to meet the demanding project requirements, Oldcastle Precast used their Selkirk, NY and Edgewood, MD plants and partnered with LC Whitford to manufacture the precast double T’s.

The structural precast list included:
68 pcs of 3” x 7’-6” wide Filigree style components (13,800 sf) – Oldcastle Precast-Selkirk
76 pcs of 33”D & 25”D Double Tees x 16’-0” wide 55,000 sf) – L.C. Whitford
78 pcs of 24”x24” and 20”x20” precast columns – Oldcastle Precast-Selkirk
52 pcs of 8”thk x 10’-0” wide precast solid walls – Oldcastle Precast-Edgewood
199 pcs of 12”thk x 12’-0” wide precast carboncast insulated walls – Oldcastle Precast-Edgewood

To meet the required schedule, Oldcastle Precast’s timeline was as follows: Jan 14 – received project go ahead; Feb 14 –submitted shop drawings; Apr 14 – started fabrication; May 1 –started erection; June 1 – added second crane on site; June 25– completed erection.

“Besides meeting an aggressive schedule, precast enabled wide open manufacturing spaces, met aggressive snow loading requirements, presented easily cleaned and very low maintenance wall surfaces, and helped meet modern energy saving needs,” said David Wan P.E., Chief Engineer, Oldcastle Precast Building Systems.

The yogurt facility initially includes three production lines, which will be increased to five, and ultimately to 16 in the future. It includes a refrigerated warehouse with an initial height of 45ft. The facility also includes 20 tanks. Two tanks are 77ft high, two are 65ft high and the remaining 16 will be 50ft high. The goal of Project Wave’s partners is to start making yogurt by July or August of 2013.

PepsiCo is the world’s 2nd largest snack maker. Theo Muller Gmbh is Germany’s largest privately-owned dairy business. Haskell Architects and Engineers, a Jacksonville, FL based firm, is the general contractor for this project.

About Oldcastle Precast.:
Oldcastle Precast is the leading manufacturer of precast and polymer concrete products in the U.S. Providing engineered product solutions nationwide to a number of market sectors including: Water - Transportation - Power & Energy - Communications - Engineering Services - Construction Services - Government/Military.

Oldcastle Precast is part of Oldcastle Building Products. For more information please visit
Contact Information
Oldcastle Precast, Inc
Barbara Bogo

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