CHERRY VALLEY, Ill. - Work recently wrapped up on the $40 million new marketing and production facility of Ingersoll Cutting Tools' U.S. division. The 30-acre corporate campus includes three buildings totaling close to 350,000 sq. ft.

Officials for Ingersoll, a supplier of metal removal tooling, had been looking for a new location since Israel-based Iscar Metalworking Cos. purchased the company from Ingersoll International Inc. in 2000. Iscar officials say the new location will offer easy freeway access and room to expand.

Installing the ductwork and hvac system for the production facility project was the Miller Engineering Co. of Rockford, Ill. The project required 28 air-handling units totaling 1,100 tons and capable of producing 350,000 cfm, 149,104 lbs. of ductwork, 26,200 sq. ft. of duct liner and 30 hours of crane time to set the rooftop units in place.

Work began in December 2001. From July 2002 until the project was completed last December, Miller had seven to 10 sheet metal workers on the project, under the supervision of general contractor Scandroli Construction.

Miller workers Jeremiah Tarbert (left), Shujun Wang, Earl Mosher, Todd Whitlock, Roger Feldman and job foreman Mark Shelly.

Work was intense

Work on the project was intense. After four months on the project, Miller employees had hung approximately 2,600 lineal ft. of spiral pipe. Miller worker and Sheet Metal Workers' International Association Local 219 member Earl Moser estimates that he and his partner put up about 225 ft. of pipe in two days, ranging from 36- to 68-in. in diameter.

"The hardest part was lining up the tapers with them being top-flat with one side straight," Moser says.

However, Miller officials say, the job was made easier by using the E-Z Flange and E-Z Flange with Barrel Clamp duct systems from Minneapolis-based Sheet Metal Connectors Inc.

The E-Z Flange is a self-sealing duct system with no exposed caulking. Because no screws or duct sealer protrude from the finished connection, SMC company officials say it results in a cleaner, more finished look than traditional coupling systems. Company officials add it reduces field-labor costs, since connecting pipe with the flange is as efficient as installing the gasket on one flange, sliding the two pieces of spiral pipe together and affixing the barrel clamp.

Mark Shelly, job foreman for Miller, says he figures the E-Z Flange system saved company about 40% on field installation costs, especially when threading the large-diameter spiral through the bar joist.

In addition to the marketing and production facility that Miller worked on, Ingersoll's new campus will also include a 60,000-sq.-ft. office building and a 177,410-sq.-ft. tool plant. Future plans call for a 100,000-sq.-ft. structure to house insert production operations.

(This article was supplied by Sheet Metal Connectors Inc.)

Ingersoll Cutting Tools production facility construction highlights

Cost: $40 million Project started: December 2001 Project completed: December 2002 General contractor: Scandroli Construction Sheet metal contractor: Miller Engineering Co. Ductwork installed: 149,104 lbs. Duct liner used: 26,200 sq. ft. Spiral pipe hung: 2,600 lineal sq. ft. Rooftop air-handling units: 28, totaling 1,100 tons and producing 350,000 cfm