Flexicore precast concrete slabs have been manufactured at Mid-States Concrete Products Co.'s South Beloit, Ill. production facility since the day it opened in May 1946 under the leadership of its founder, Charles V. Harker. At the time, the Flexicore process was only eight years old, but the 28-year-old Harker saw its potential as a practical, economical, and competitive product if marketed correctly and accepted by design professionals and construction companies.

Today, under the familial management team of Harker's son, Charles H. Harker, president, and grandson, C. Hagen Harker, vice president, Mid-States has grown in every way. Employing a staff of 100, the company manufactures Flexicore prestressed concrete slabs, precast concrete beams, columns, balconies, lintels and other specialty pieces as it serves a territory that includes Wisconsin (including Milwaukee and Madison), northern Illinois (including Chicago) and eastern Iowa. In 2000, to take advantage of state-of-the-art manufacturing technology, Mid-States commissioned a 42,000-sq.-ft. extruded hollowcore production operation, with an adjacent batch and materials plant. The facility brought the company into 4-ft.-wide prestressed plank, offering a companion to the 2-ft.-wide Flexicore product.

RIPE OPPORTUNITY

Mid-States' management team had been studying the possibility of expanding since 1997 to capitalize on improved technology and the growing construction business in the markets they served. “We were seeing people doing more with hollowcore,” says Hagen Harker. “And the building market was getting stronger thanks to lower mortgage rates. Before this time, our industry really hadn't had too much growth in terms of technology, and we were seeing a much greater acceptance of our products in the marketplace among contractors and designers in everything from single-family homes to multi-story office buildings.”

The new 4-ft. extruded hollowcore production facility was set up entirely with equipment and automation software supplied by PCE-Elematic Inc. With six, 4- ∞ 525-ft. beds in a new enclosure, the plant includes three EL 900E power units, two 8-in., two 10-in., and two 12-in. nozzle units; an EN886/12 lifting beam; two EL1300A saws; a system that oils and cleans the beds; and two overhead cranes, 12 and 20 tons. The range of floor plank products produced are 6, 8, 10 and 12 in. for the 2-ft.-wide product, and 8, 10 and 12 in. (standard) and 6, 16 and 20 in. (specialty) for the 4-ft.-wide product.

In 2000, Mid-States constructed a new batch and materials plant, supplied by Besser and featuring a 2.4-cu.-yd. Simen twin-shaft mixer, with room for a second if necessary. With an eye to the future, these two new structures were designed and built with the company's “master plan” in mind. “We've got room to expand next to the new plant,” says Hagen Harker.

When the new hollowcore plant was being constructed, the Mid-States' production staff became aware of PCE Elematic's ELi PLAN software. PCE custom designed the ELiPlan specifically for Flexicore production, which the company was involved with elsewhere on the property. Subsequently, the ELi-PLAN has been used in the Elematic plant. “The software is our primary database for production, delivery and product management,” Harker says. “We've been able to control our production and inventory since we started using the system. Right now, we're looking into using a bar code-based system to increase efficiency even more.” (See Concrete Products, July 2001 for more on Mid-States and ELi PLAN software.)

OLD SCHOOL

Mid-States maintains its original Flexicore business. The 10,000-sq.-ft. production facility was retooled in 1966 and remodeled in 1997 with a 60-ft. form length and product depths of 6, 8, 10 and 12 in. In the late 1990s, Mid-States' original batch plant was in need of an overhaul. According to Harker, “The bins and batching equipment are American Bin & Conveyor, and were refurbished in 1997. The setup includes a Besser ribbon mixer, which was completely rebuilt at the same time.”

In 2001, the company's 12,000-sq.-ft. beam and column production plant — one of the oldest structures on the property — was given a facelift as the building's skin was replaced and two new cranes were installed. The plant includes a 60-ft. prestressed inverted tee-beam form, a 190-ft. mild reinforced inverted tee-beam form; a panel bed for specialty columns, beams and balconies; four, 40-ft. column beds; and two, 30-ft. lintel forms. All columns, beams and balconies are self-compacting concrete.

As significant an investment as Mid-States has made in its equipment, Hagen Harker is quick to point out that its best investment is in its team of employees. “Their energy and unique abilities make it happen, and are of great value to our customers,” he says.

PROMOTION & PROFIT BUILDING

While Mid-States Concrete Products Co. acknowledges the influence that groups such as the Precast/Prestressed Concrete Institute and the local Precast/Prestressed Producers of Illinois & Wisconsin have on getting the word out on its products to architects, engineers and builders, it also realizes that the future growth of the company rests in providing a value for customers. “Our product is structural and not as flashy as what some architects are used to seeing,” says Mid-States Vice President C. Hagen Harker. “Our customers are builders, and they care about price and delivery times. We have greater access to our customers than any association can, and it's our job to help them gain a greater perspective on our products. We want them to be open to change and hopefully our company can steer things in that direction.”

One step toward that end is Mid-States' newly created Precast Profit Builder^™ program, a step-by-step set of business goals with a focus on helping customers streamline and simplify the building process. “Many builders have a great reputation and a thriving business, but may at times be overwhelmed by the complexity of their projects,” says Mid-States President Charles H. Harker. “Some clients find themselves lacking optimal organization and communication, being pressed for time or cash, without critical specifications, or uncertain about building design alternatives. These issues can quickly become costly obstacles for the builder and the entire project.”

The four-phase Precast Profit Builder^™ program includes a combination of workshops, strategy meetings and team building. Upon completion of the process, clients are armed with valuable tools that enable them to improve their bottom line and their business. “With this program, our work goes far beyond that of just being a precast manufacturer,” says Hagen Harker. “This is revolutionary in many ways.”

TM & ^© 2003 Mid-States Concrete Products Co. All rights reserved. Made in the United States, 2003. “The Precast Profit Builder^™” is a trademark of Mid-States Concrete Products Co. If you would like further information about the program or Mid-States' products or services, please phone 800/236-1072 or 608/364-1072, fax 815/389-2339, or e-mail at info@precastprofitbuilder.com