Truss worthy
A-1 Industries’ state-of-the-art 175,00-square-foot manufacturing facility in Fort Pierce. A-1 INDUSTRIES PHOTOS
A-1 Industries raises the roof with state-of-the-art tech
BY KERRY FIRTH
A-1 Industries is using technology to help fuel its rapid growth.
Nearly half a century after its founding, A-1 Industries has emerged as one of the nation’s most progressive manufacturers of pre-engineered roof and floor trusses. Rising from its humble beginnings in 1977, A-1’s integration of modern technology has fueled its 100% growth in the past several years. For decades, the company has stayed true to its mission of “Using Technology to Change the Way America Builds Homes.”
The company has expanded its footprint to 120 acres — with eight acres under roof — and tripled employment to more than 460 people. A-1 operates from its headquarters and manufacturing plant on 4451 St. Lucie Boulevard in Fort Pierce. A second state-of-the-art facility in Bainbridge, Georgia, helps the company meet growing regional demand.
Cutting-edge technology is driving exponential growth. The company is an affiliate of Whole House Engineering, which utilizes Building Information Modeling software to streamline workflows, reduce project timelines and ensure all necessary information is accessible throughout the project. While they are currently shipping about 50 units a day, the new technology should enable its fleet of trucks to load up to 200 units daily in just 15 minutes.
High-speed truss production ensures quality and timely delivery for every project.
AUTOMATED SYSTEM
Part of A-1’s philosophy is to empower employees and make sure women are provided the same opportunities as men.
A-1 is one of the first manufacturers using robotic machinery to embed plates on trusses. The fully automated system reduces the process by 20%, while improving quality, increasing production and streamlining manufacturing steps. Soon to come is a customized “go-bot” machine, designed to improve the daily activity in the plant by reducing the number of people needed to move lumber from one station to another. It will increase speed and efficiency, and improve safety for all, by eliminating the need for manual labor to push heavy loads.
“Another thing that differentiates A-1 from other truss companies is we ensure quality from start to finish, and deliver it when it’s actually needed — not too soon or too late,” said Michael Fagan, director of marketing. “We fuel and load trucks in advance, ensuring they’re on the road by 6 a.m. Our fleet averages 2.5 loads a day, and by owning our trucks, we control scheduling and delivery. With 21 trucks, 25 trailers, ASE-certified technicians, cutting-edge software, and drivers equipped with the best tools, we consistently deliver on our promise: on time, every time.”
Citing A-1 Industries’ status as a privately held company, Fagan declined to disclose annual sales.
The 180,000,00-square-foot A-1 Industries plant in Bainbridge, Georgia is also a state-of-the-art facility.
EMPLOYEE FOCUS
Women, supported by the cutting-edge technology at A-1, thrive in roles traditionally dominated by men.
A-1’s growth isn’t only about technology and logistics. It’s also about its people. In a world where the focus is production, A-1 focuses on its employees and is committed to their success. Many who start with entry-level positions go on to become skilled technicians, estimators, and designers. The company’s in-house, truss-design educational programs, enable them to earn upwards of six figures without a college degree.
Employees have the opportunity to become stock owners, after completing one year on the job. A-1 recently celebrated its second year as an Employee Stock Ownership Plan company. As of last March, 235 employees — nearly half of the entire company workforce — became vested as partial owners. A-1 fosters an ownership culture, where every employee shares in the company’s success.
“John Herring, the chairman and CEO of Global Holdings, Inc., the parent company of A-1 Industries, founded the company in 1977 and has always viewed it as very family-centric,” said Jan S. Beck, president of A-1 Global Holdings Inc. “We recognize that our employees want to enjoy what they are doing and feel they are being treated properly in a safe environment.
“One of our core values is ownership. By that, we mean owning the projects you are working on and being proud of your contribution. We felt that sharing company ownership with employees would enable them to grow with us. Each year, eligible shares are allocated based on their W2 income. They can’t buy shares; the company gives them shares.”
A-1 is an equal-opportunity employer, where women have the same opportunities as men. “Women at A-1 thrive in roles traditionally dominated by men, from operating saws to managing machinery,” said Fagan, “We’ve invested in the newest automated equipment that enables women to do more. We also allow employees a bit of flexibility in schedules, when required, so that they can take care of sick children, etc. This is particularly helpful for single parents.”
WASTE NOT
Traditionally, there is a lot of waste in the construction industry, but A-1 has instituted technology to maximize every inch of wood purchased. Usable defective pieces or scraps are salvaged for other capacities. Smaller, unusable pieces are ground up for horse shavings, landscape mulch and paper. The discarded materials are automatically collected and transported through a tunnel system beneath the milling stations and deposited into a truck in the lumber yard. This practice recovers three truckloads monthly, saving the company approximately $100,000.
A-1 is now transforming home building in the same manner they’ve transformed truss building with their proprietary EZWALL® Innovative Framing Solution™. Their precision-cut, pre-labeled wall framing kits have revolutionized home construction by ensuring faster builds with minimal waste.
A-1 designers work with their clients, all the way. The process starts with fully dimensioned wall placement plans, including shop drawings with framer-friendly markings. A-1’s state-of-the-art saws cut each piece accurately and labels it with easy-to-understand markings. The wall bundles are packaged in the order they will be used, shipped on flatbed trailers to the construction site, and offloaded for the builder’s framing crew to assemble. A-1’s pre-cut EZWALL® Innovative Framing Solution™ kits reduce weather-related delays and human error, which minimize sawing injuries in the field.
A-1 has invested in its own fleet of delivery trucks and an on-site maintenance shop with ASE-certified professionals.
COMMUNITY INVOLVEMENT
A-1’s dedication extends to the community, exemplified by its long-standing partnership with the Treasure Coast Food Bank. As presenting sponsor for the second consecutive year, A-1 will again support the food bank’s Pack the House event on October 25-26, aiming to provide 80,000 meals to people in need. With over 40 A-1 volunteers participating, this initiative highlights A-1’s commitment to giving back.
“Our involvement shows our deep connection to the community,” said Robert Chance, vice president of human resources.
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