Just one year ago, the PC Construction team, led by Senior Project Manager Anne Minor, sat at the company’s Vermont office dissecting Weidmann Electrical Technology’s ambitious project. Shortly after, the PC Construction team mobilized in St. Johnsbury, Vermont, to construct three projects supporting Weidmann’s operational needs. First, a new 10,000-square-foot warehouse. Second, significant equipment upgrades to their board making machine. And lastly, a 25,000-square-foot addition to the Fabrication North building, affectionately nicknamed “Big Foot”. And now, we are celebrating an exciting milestone – going from a shovel in the ground to the owner making product in under a year! This was no small feat.
Due to the tight schedule, the team jumped right into construction of the warehouse upon approval of the permits. Despite the harsh weather of the Northeast Kingdom, the foundation was completed in just one month. PC Construction’s Special Projects Group showed up in force to erect the pre-engineered Butler Building, including steel erection, siding, and roofing. Despite the weather trying its best to impact our progress, the Warehouse received Certificate of Occupancy on June 2, 2025.
When it came to the board machine upgrades, our past work installing the two-million-pound machine in 2011 allowed us to quickly jump into action. PC worked closely with trade partner, Engineered Construction Services, to add a Kraft chest, a cleaner system, and a new 400hp, 4,000-pound electric motor. ECS found ways to complete nearly 60 percent of the work ahead of the planned six-week shutdown, which was huge to the success of the project. The upgrade also required rigging a 1,000hp, 70,000-pound boiler on the second story of the building, utilizing two cranes to complete the pick with just inches of clearance.
Finally, the 25,000-square-foot Fabrication North building addition broke ground on February 6, 2025. The building was designed with an expansive free-span to accommodate approximately 125 fabrication tools. One of the most critical and complex sequences associated with this work involved tying the addition into the existing building. Weidmann had to relocate their entire shipping operation as the design called for the roof to be raised by more than 10 feet. This required column and footing upgrades and shoring the existing structure. PC worked tirelessly with the Weidman team and our trade partners to enhance the schedule, successfully turning over this portion of the work to Weidmann a month early, decreasing the duration of planned impact to their operations.
Bernie Brochu, Manager of Engineering & Maintenance for Weidmann reflected on the achievement: “We met a huge milestone in Project Bigfoot today – we actually made board! This milestone could not have happened without all the hard work and dedication everyone placed on this portion of the project. We capitalized on every opportunity to beat the schedule, and it made a significant impact. The collaboration we all shared is by far some of the best I have seen in the many years of working on projects.”
With Certificate of Occupancy for the addition obtained on November 24, the team shifted swiftly to the final phase: tool moves. This phase will require the relocation of all machines – including four walk-in ovens, a 30,000-pound CNC machine requiring a special foundation with extreme tolerances, and seven bridge cranes, to name a few – all while maintaining Weidmann’s production schedule. This final phase of the project is scheduled for completion in April 2026.
This project has been a fantastic opportunity for PC to once again work with this highly collaborative client. Constructing in and around a 24/7 fully operational facility requires extensive coordination from both sides and the success can largely be credited to Weidmann’s “Can Do” attitude.
Thank you to the design engineers – Hill-Engineers, Architects, Planners / Dubois & King / Bowman – our talented trade partners, and all the vendors for your commitment to excellence. Your efforts were instrumental to bringing this concept to reality.