Principle Construction Corp. has completed a 38,956-square-foot warehouse expansion and renovation for POLI FILM America, Inc. at One Elgiloy Drive in Hampshire, Illinois, delivering a redesigned manufacturing facility that increases operational efficiency and production capacity.
The project transformed an inefficient L-shaped warehouse into a streamlined rectangular layout through an innovative structural modification that maximized the existing building footprint instead of requiring a relocation.
Structural Redesign Maximizes Existing Facility
The most technically demanding aspect of the project involved relocating 12 precast concrete wall panels from an existing 133-foot wall.
Principle Construction repositioned the panels and integrated new precast sections to enclose the open section of the former L-shaped warehouse. The redesign created a single contiguous warehouse space that improves material flow and supports high-volume manufacturing operations.
The structural solution allowed POLI FILM America to expand production while avoiding the cost and disruption associated with constructing a new facility or relocating operations.
Mark Augustyn, Chief Operating Officer at Principle Construction, said the project delivered a practical expansion strategy for the manufacturer.
“Completing this project on schedule allows POLI FILM to scale their operations without the overhead of a total relocation. By literally moving the walls, we provided a cost-effective expansion that maximizes every square foot of their existing footprint.”
Expansion Adds Manufacturing and Logistics Capacity
In addition to the warehouse reconfiguration, Principle Construction completed several infrastructure improvements designed to strengthen logistics and operational efficiency.
The project included:
- A 38,956-square-foot facility expansion
- Relocation of 12 precast concrete wall panels
- Two new loading dock positions
- Expansion of the west-side dock apron
- A new entry door and drive-in door
These upgrades improve truck access, loading operations and internal warehouse circulation while supporting higher production volumes.
Mechanical and Site Improvements Support Operations
The construction team also completed several building system upgrades to improve long-term facility performance.
New building features include a gas-fired make-up air unit, a ballasted roofing system, upgraded lighting and an infiltrationpit that increases on-site stormwater management capacity.
Together, these improvements enhance environmental performance, building functionality and day-to-day manufacturing operations.
Adaptive Reuse Delivers Cost-Effective Industrial Expansion
Rather than demolishing and rebuilding existing structures, Principle Construction applied adaptive construction techniques to reconfigure the warehouse within its existing footprint.
Relocating precast concrete wall panels required detailed structural planning, careful sequencing and precise installation to maintain building integrity while creating a more efficient layout.
This approach reflects a growing trend across the industrial construction sector, where manufacturers seek to modernize facilities through targeted renovations that reduce capital costs, minimize operational disruption and accelerate project delivery.
Project Team Completes Facility for Production Growth
Andrew Mackintosh managed the project on behalf of Principle Construction, while Harris Architects provided architectural design services.
The completed facility now supports POLI FILM America’s growing production requirements with improved warehouse efficiency, expanded loading capacity and optimized manufacturing space.
As manufacturers continue investing in domestic production and supply chain resilience, warehouse modernization projects like this one demonstrate how strategic facility upgrades can increase capacity while extending the value of existing industrial assets.
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