Millar began his career as an apprentice electrician at Bergelectric before later joining one of the county’s largest building and infrastructure companies, Clark Construction in California, as a Senior MEP manager, where he helped lead critical infrastructure projects, including major military housing and healthcare facilities. Most recently, he served as project development director at Colorado-based multi-service construction company Hensel Phelps, where he was instrumental in securing key projects across their Southern Californian region and driving business growth.

“Nabholz is committed to delivering exceptional value to our clients, and Andrew’s experience and strategic approach to project development will be a tremendous asset to our team,” said Conway EVP of Operations Mark Solberg.

Millar is actively involved in industry organizations, including DBIA, CMAA, ASHE, ACA AAAE, ACI, as well as community initiatives that support workforce development and industry innovation, such as ACE Mentor Program.

The post Andrew Millar Joins Nabholz at Project Executive appeared first on Nabholz Construction Corporation.

As part of this acquisition, Bass Concrete’s more than 200 employees will continue to operate under the Bass Concrete name and leadership while being a Nabholz-owned company.

“We’re happy to welcome those at Bass to the Nabholz team,” Nabholz CEO Jake Nabholz said. “I am even more happy that Robby and the existing leadership team of Bass will be staying on board.  This acquisition significantly improves our self-perform capabilities and ability to meet our clients’ needs for expedited construction services. We share a culture of quality, integrity, and safety that is vital in our line of work.”

Like Nabholz, Bass Concrete performs work in a variety of industries, including industrial, K-12, higher education, commercial, multi-family, parking structures, healthcare, and religious.

“This acquisition gives us the capacity to better serve existing customers and expand into new markets as we combine our capabilities,” Bass Concrete President Robby Brosius said. “We’re excited to become part of the Nabholz family and we’re looking forward to what we can accomplish together.”

For any questions about the transition, please contact Jake Nabholz or Robby Brosius to discuss how Nabholz can continue to serve you.

Read the full articles for more details:

Arkansas Democrat-Gazette

Talk Business & Politics

Arkansas Business

Arkansas Money & Politics

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Today, Nabholz partners once again with the university to construct Anthony Timberlands Center for Design & Materials Innovation, a new cross-laminated timber facility made almost entirely of mass timber. Construction began in fall 2023 and is expected to be completed in summer 2025 in time for the fall semester.

What is cross-laminated timber?

Cross-laminated timber, or CLT, is a relatively new construction method in the U.S. Popularized in Europe, the method fabricates plywood paneling off site in in a mill shop, where it is glued, pressed, and cut to size according to a project’s design specifications.

CLT consists of perpendicular layers of plywood glued on top of each other, in odd groups of three, five, or seven. Once glued, the timber is pressed together with a vacuum press or hydraulic press to form a solid panel, then cut to form door openings, window openings, ductwork chases, utility piping chases, and more. The finished panels are then transported to the job site where they are installed more quickly than traditional methods.

Building a facility out of CLT, instead of concrete or steel, has its advantages and disadvantages. CLT can be produced quickly, leading to faster project schedules with minimal errors in production. It also has a high char rate, meaning that in the case of a fire, it would burn slower and fail later than a steel structure would.

On the other hand, CLT has yet to gain an expansive library of building codes to ensure the material is installed correctly. This, combined with the high technical entry point for contractors, reduces the number of available experts to implement CLT. Research is being conducted by the USDA and others to establish more codes and encourage the use of more environmentally friendly material.

You can learn more about CLT and how Nabholz trained to be an expert in the material in our blog about Adohi Hall.

CLT in Arkansas

Cross-laminated timber is continuing to gain popularity in the United States as a construction material. Arkansas-based businesses and organizations, in particular, have been interested in pursuing CLT to utilize the state’s natural resources. In the past few years, Nabholz has worked on a variety of CLT projects, including Adohi Hall, 5^th Street Offices in Bentonville, Nabholz’ own Rogers office, and more.

According to the Arkansas Economic Development Commission, Arkansas is covered by 19 million acres of forestland — that’s over half of the state’s total area. The timber industry has a huge impact on the state’s economy, with nearly 12% of its workforce employed in manufacturing and timber products sold to companies all over the world.

As CLT gains popularity, it can support Arkansas’ economy and other states with a large timber industry. More of Arkansas’ natural resources will be used, which will translate into more jobs to support the demand. It also means materials can be gathered locally instead of outsourcing and paying transportation costs to deliver them long distances.

Using CLT is also more environmentally friendly. Timber is a renewable resource that is replanted as it is cut down. Arkansas has a number of organizations dedicated to sustaining forests and ensuring trees are replanted after harvesting. In addition, the construction process for cross-laminated timber produces fewer carbon emissions than concrete or steel because fossil fuels are not burned during production.

Anthony Timberlands Center

The Anthony Timberlands Center is the University of Arkansas’ latest CLT project, with Nabholz on board as construction manager at-risk. The center is a $38 million project that will include a fabrication shop, studios, seminar and conference rooms, faculty offices, a small auditorium, and a public exhibition space for students of U of A’s timber and wood programs. The 44,800-square-foot building is designed by Dublin-based firm

Grafton Architects and local Fayetteville firm Modus Studio to be constructed (almost) entirely of mass timber.

This design choice makes Anthony Timberlands unique from the start. Typically, CLT projects utilize a

combination of CLT and structural steel. Anthony Timberlands has only a small portion constructed with steel beams and columns; the building’s elevator opening required structural steel to safely support the elevator’s load. The rest of the building is comprised of CLT and glued laminated timber — even the queen truss, which supports the load of an entire floor on its own.

The University of Arkansas selected southern yellow pine for approximately 60% of the project’s timber. The wood is native to Arkansas and was chosen as part of the university’s goal to utilize more of Arkansas’ natural resources in construction. Most of the pine was sourced from Arkansas, while 10% came from Washington. The remaining 40% of the project is constructed with spruce from Austria.

Nabholz has worked closely with contractors from all over the world to make the Anthony Timberlands Center a reality. Our team has coordinated with professionals from seven countries across six different time zones in order to construct the project’s complex design.

The project has already been recognized for its unique design by international publication The Architectural Review, which named the Anthony Timberlands Center overall winner of the magazine’s 2023 Future Project Awards, as well as winning first place in the new education category. The awards “celebrate excellence in unbuilt and incomplete projects, and the potential for positive contribution to communities, neighborhoods and urban landscapes around the world.” The center was the only North American project to be recognized.

The Future of CLT

Building codes are still catching up with what mass timber construction can do, informed by years of experience Europe already has with the material. Tests are also being conducted every day to update codes and help put cross-laminated timber into practice where it is most beneficial. In the coming years, CLT professionals expect to see the material used more often as owners turn to quicker and more environmentally friendly methods.

Nabholz continues to pursue CLT technology and projects to provide more tools for owners to choose from. Looking to learn more about CLT or work with Nabholz on your next project? Find out more here.

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We are pleased to announce that Nabholz has recently acquired Brother’s Construction of Van Buren, Arkansas. This acquisition marks a significant milestone for Nabholz, enabling us to expand our infrastructure construction services and better serve customers throughout Northwest Arkansas and the River Valley. 

As part of this acquisition, Nabholz will integrate the assets and operations of Brother’s Construction. Brother’s owners, Todd and Terry Mooney, along with their talented team will remain with the company. 

“The future has never been brighter,” says Terry Mooney. “We’re excited to see the vision of Nabholz unfold.” 

Nabholz is proud to welcome the highly skilled craft professionals from Brother’s Construction, who have decades of experience serving the region’s excavation industry. “They are now valued members of the Nabholz team,” says Chris Kauffman, President of Excavation Operations at Nabholz. “Bringing the Brother’s team into the Nabholz family provides growth opportunities for all and enables us to better serve our customers. We are excited and looking forward to what we can accomplish together.” 

This acquisition is about more than expanding our equipment, offices, and market share. It is about helping these craft professionals grow their careers at Nabholz by offering more resources, expanded benefits, and boundless opportunities. Additionally, we remain committed to continuing to serve Brother’s clients with our relentless dedication to quality and customer service, backed by an expansive range of services. 

We are excited to welcome the Brother’s team into ours and look forward to continuing the legacy of integrity and excellence that has been the cornerstone of both companies. For any questions about the transition, please contact Todd Mooney at (479) 883-2217 or Chris Kauffman at (479) 659-7855 to discuss how Nabholz can continue to serve you. 

We are grateful so many have shared this important development in Nabholz’ ongoing growth. 

Read the full articles for more details: 

Arkansas Money & Politics 

Arkansas Business 

Northwest Arkansas Democrat Gazette 

5 News Online 

Axios Northwest Arkansas 

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Nabholz’ 75th Anniversary was recently featured in Arkansas Money & Politics, the state’s only Forbes-like business magazine. Published monthly, the magazine features articles on health care, agriculture, energy, sports, entrepreneurship/innovation, finance, technology, and politics.

This year marks a huge milestone for Nabholz, and we’re taking the time to reflect while also reinforcing key values in our organization. What began as a small, family-owned construction company has grown into a large, multi-discipline, employee- and family-owned firm. We’re proud to say that, throughout the years, one thing has never changed: Integrity. The Nabholz name has been synonymous with integrity since Bob Nabholz founded the business 75 years ago in 1949.

We are committed to maintaining our integrity as we consistently look forward to the future by growing our people, serving our clients, and building our communities. These concepts are more than words on a page; they are the truths this company lives by — truths that have been proven time and again over our 75 years in operation.

Check out this snippet from the Arkansas Money & Politics story:

“Every time you have a milestone like this, everybody wants to celebrate the history,” Jake Nabholz said. “We’re doing that, but I think what we’re doing differently with our 75th anniversary is we’re honoring what Grandpa did and his forward-thinking attitude and how we’re still doing the same thing now, having that mentality that the decisions and the investments that we make today have got to set us up for the next 75 years. This anniversary is a good chance for us to reinforce that.”

Many thanks to Dwain Hebda and Arkansas Money & Politics for this amazing feature.

Read the full article here.

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Nashville, Tenn. — Nabholz Executive Vice President of Operations John Strack is pleased to announce the promotion of Blake Osteen to the role of Project Executive for construction operations in Middle Tennessee and surrounding areas. Osteen is a seasoned construction leader who will serve as an integral part of the team while striving to deliver the highest level of customer satisfaction possible.

Osteen holds a construction science & management degree from Middle Tennessee State University and is a Certified Healthcare Construction professional. Originally from Franklin, he brings a wealth of experience, specializing in healthcare and higher education construction. Blake played a pivotal role in shaping Nabholz’ Middle Tennessee construction operations and will continue to be a driving force for future growth. His dedication and expertise contributed to the success of projects across various sectors, including the Franklin Special School District, HCA Healthcare, Metro Nashville Public Schools, Lewis County Public Schools, and Shamrock Trading Corp.

“As one of the first employees in our Middle Tennessee construction operation, Blake has worked tirelessly to transform the office into what it has become today and will be a huge part of what it becomes in the future,” shared EVP of Operations John Strack.

In his new role, Blake will lead growth initiatives and drive operational excellence in Nabholz’ dynamic Middle Tennessee market. His objective is to expand the company’s presence while fostering relationships. Blake’s unwavering commitment to client service and community engagement makes him an invaluable asset for projects of all sizes.

“My main goal is to continue to help grow the Nabholz name around Middle Tennessee and beyond, but also maintain past and present relationships,” Osteen said. “People are recognizing us, which is exciting! We have made great progress within the last two years of opening this office, but this is just the beginning!”

Founded 75 years ago, Nabholz is now a multi-service contractor providing construction, industrial, excavation, specialty, environmental, and railroad services. Nabholz’ Nashville office was established in 2021 and is part of the company’s network of locations across Arkansas, Kansas, Oklahoma, Missouri, Mississippi, Tennessee, and Connecticut. For more information, visit www.nabholz.com.

Blake Osteen was recently featured by Nashville Business Journal in their People on the Move section. Click here to read their story. 

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The construction industry faces a significant challenge looking forward: a shortage of skilled labor. Since the beginning, Nabholz has worked to redefine what it means to be a construction company, and our purpose is clear: to grow our people, serve our clients, and build our communities. Guided by the philosophy of our founder Bob Nabholz, who led by example by reinvesting profits in his people and their training, we recognize that the construction business thrives on having the best people. In response to the pressing need for skilled professionals, we’ve developed strategies to promote our time-honored profession, support the growth of our team, and address the industry’s challenges head-on.

Fostering a Culture of Integrity

At Nabholz, our roots trace back to a small, family-owned construction company founded by Bob Nabholz in 1949. Over 75 years, our evolution into a large, multi-discipline, national firm has been marked by an unwavering commitment to integrity serving as the cornerstone of our purpose, guiding principles, and every project we undertake.

Integrity, for us, means valuing people. We do so by prioritizing the safety, wellness, and growth of our employees, their families, and everyone we encounter.  Valuing our clients involves a commitment to hard work, rapid response, and profound respect.

We work to deliver the highest possible quality in all our products and services. We aim to provide extraordinary service experiences for our clients. Ongoing innovation means we continually explore avenues to enhance our processes, services, products, and the experiences of our employees and customers.

Training and Development Initiatives

Nabholz University provides comprehensive tools for employees and students to build successful, fulfilling careers. Training programs cover essential topics such as safety, project management, and specialized areas like lean construction and building information modeling. Craft professionals can develop technical and leadership skills through our In-House Carpentry Apprenticeship, Millwright Apprenticeship, and Operator Training .

Clear paths for growth are also essential to retain our talented team members. Our programs include Craft Leadership Development, Superintendent Development, and Project Fast Start, which help develop technical and leadership skills for aspiring leaders. We also believe it’s crucial to arm our current leaders with skills that, once combined with their experience, prepare them to oversee large teams.

Workforce Development Strategies

Partnering with our local communities and building relationships with educational institutions are paramount to source skilled professionals from diverse talent pools. Through these partnerships, we have found great opportunities to collaborate with construction education institutions to enhance the skills of candidates and support recruitment efforts. We welcome opportunities to connect with our communities and encourage our team to get involved, especially in the programs that helped grow their own talent. We are fortunate to as members of advisory boards and love to participate in construction expos. We also offer continuing education programs to our area teachers as well as trade days at our locations. We actively support Career and Technical Education (CTE) programs at local schools and collaborate with community colleges to create construction training and education programs, preparing new trade professionals for the industry.

Our Initiatives

• Youth Apprenticeship Program: This flexible program was created in partnership with local school districts and allows young people who are 16-18 years of age to work directly for Nabholz in a learning capacity.
• College Internships: Open to students in construction management, engineering, or similar degree paths, our intern program gives participants the chance to work alongside the Nabholz team, learning the construction business from the inside out. We guarantee a 40-hour workweek, competitive wages, and an interview with our company upon graduation. Our interns develop a solid foundation for their future by learning skills in project management, preconstruction operations, and field operations.
• Carpentry Apprenticeship Program: Developed in 1973, this was our first developmental program created to serve our people and community. This four-year track is open to both employees and members of the public looking to develop carpentry skills. Upon completion, participants are recognized by the U.S. Department of Labor as journeyman carpenters.

Giving Back to Our Communities

Our commitment to building communities extends beyond construction projects – it includes a deep, personal commitment to improving the cities and towns where we live and work. This idea goes back to our founder whose tireless dedication to serving others exemplified the spirit of generosity that lives on at Nabholz today. Bob established the Nabholz Charitable Foundation in 1987 to ensure support for charity and community organizations, hospitals, schools, and universities. And though financial contributions are an important part of giving back, we also believe it is the time and talent our employees give that truly make the difference. Each year, Nabholz employees generously donate thousands of hours of their own time to volunteer for the causes and organizations they choose.

Competitive Benefits

At Nabholz, we believe in providing not only outstanding career opportunities but also enhancing the overall well-being of our employees and their families. Our benefits package, including comprehensive health insurance provided at no cost to the employee, is complemented by optional Health Savings Account (HSA) and Flexible Spending Account (FSA) choices for personalized healthcare management. We also offer a group life insurance policy, robust 401(k) retirement contribution and matching program, and a generous paid time off package. Further, our award-winning Health & Wellness Program actively invests in our team’s well-being through healthcare assessments, monthly incentives, and annual reimbursement allowances for wellness-related items. With a consulting physician, a full-time physician assistant on-site in our Conway office, and a partnership with Premise Health Clinics in other locations, we ensure accessible healthcare with no deductible and reduced waiting times.

Team Collaboration

Our leadership team leads by example, demonstrating accessibility, openness to ideas, and a willingness to collaborate. Whether manning the grill at a cookout or leading a site walk to improve quality measures – our leaders are involved in all aspects of our culture. We value the input of our team members, encouraging active participation in the company’s development. The company crowdsources ideas from employees in an annual innovation challenge and works hard to implement the practical solutions suggested by its team members to reinforce a culture of safety, quality, and integrity.

Looking Forward

Our proactive and holistic approach to workforce development and industry challenges positions us to offer a strong culture, prioritizing training, and engaging with communities and educational institutions. We aim to build a skilled and productive construction workforce armed with the tools for sustained success in the evolving industry landscape. As we continue to elevate our people, Nabholz looks forward to fulfilling its purpose for the next 75 years: Grow our people. Serve our clients. Build our communities.

About the author: Greg Fogle joined Nabholz in 2004 as Vice President of Project Management, later advancing to Executive Vice President of Operations and Regional President. In 2018, he became Nabholz’ Chief Operating Officer. Committed to community service, Fogle has been active in several organizations like Fellowship NWA church, Bentonville Chamber of Commerce, and the West Ark Area Council of the Boy Scouts, serving as Chairman of the Board of Directors for both organizations. Fogle currently volunteers as a mission pilot with Angel Flight, a non-profit service providing medical transportation to people facing medical challenges. He prioritizes nurturing talent within Nabholz, fostering an environment where individuals can thrive. Currently, he leads several development and leadership programs for Nabholz.

The post Building the Future: Nabholz’ Approach to Tackling the Labor Shortage appeared first on Nabholz Construction Corporation.

Now, we’re witnessing a new evolution in computing power. Artificial intelligence enables rapid data searches, predictive analysis, and machine automation. What once seemed possible only in comic strips now appears to be right around the corner. As exciting as this tech might be in consumer electronics, what does it mean for the construction industry?

Construction is a noble and time-honored profession that celebrates hard work. But as projects become more complex, documentation requirements grow, schedules compress, supply chains stumble, and our labor pools shrink, hard workers need more complex solutions than many of our conventional tools can provide. Our traditional management methods need a boost. As AI-enabled technology develops, here are some ways we think AI will support our projects and teams, providing interesting solutions to these challenges.

• Of the low-hanging fruit, virtual assistants may be the tools to socialize artificial intelligence among a demographic that will be skeptical. Large language models can retrieve specific information on demand, generate draft documents, and manage meeting minutes. Relief from these tasks should allow a construction manager to invest more focus on strategy and risk management.
• One of AI’s special powers is data management. We produce valuable data in the construction industry, but we often don’t know what to do with the sheer volume. AI will enable us to organize, retrieve, trend, and analyze data volumes now sitting idly in the cloud. An enterprise understanding of our performance will undoubtedly lead to better individual project outcomes.
• Risk management is an ancient art form, but what if we could layer AI’s predictive analytics with our human instincts? What would we learn? AI-enabled applications can quickly consider alternative work sequences, spotlight risky contractual provisions, or surface best practices for the right worker at the right time.
• Image-recognition technology is a remarkable advancement. These tools can scan progress photos for safety concerns or installed materials, scrub drawings to help an estimator identify scope items, and stitch together drone imagery to create ortho-mosaic maps and 3D models.
• Vision-enabled technology is paving the way for autonomous operation of vehicles, and the same technology is being applied to heavy construction equipment on active job sites. If there aren’t enough skilled operators to meet the demand of a booming infrastructure backlog, autonomous equipment might fill that gap.
• Speaking of autonomous machines, AI-driven robotic applications can help our teams with tedious tasks like progress photos or delivering materials around a job site. Some robots even perform high-hazard tasks that would otherwise put human life at risk.

We think artificial intelligence and machine automation will develop in concert with our need for highly skilled construction professionals, not as an alternative. We’re dedicated to our professional craft and want to empower them with the best tools. We’ll continue to watch AI-enabled tools with keen interest and apply them where they can best serve the people who execute Nabholz projects with pride and skill.

About the author: Jon Pahl is the Corporate Innovation Director at Nabholz. JP started as an intern in 1997 and is now our innovation champion. He leads the charge to stay on top of the latest innovations in our industry, implementing them thoughtfully and intentionally. He also encourages and empowers Nabholz employees to share their own innovative ideas and bring them to life.

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In 1949, my grandfather, Bob Nabholz embarked on a journey to build a house for himself and his bride, setting in motion the start of a construction legacy that has thrived for 75 years. Today, as we celebrate this remarkable milestone, we reflect on the vision that propelled us forward. We’re celebrating this incredible milestone all year, and what better way to kick things off than with a look back at the man and vision that drove us forward through the years.

Companies tend to adopt the personality and values of their founders, and Nabholz is no exception. My grandfather was a wonderful man — fun, honest, hardworking, and deeply committed to his community and the people who worked at Nabholz. While so much has changed over the past 75 years, his vision and values have always been our foundation, and I’m proud to see them reflected in who we are today.

All these years later, these values — working with integrity, elevating our people, building communities, and serving clients, among others — are as important as ever. They’ve been the driving force behind our success, and they will continue to guide us moving forward.

“Construction is a people business, and the contractors with the best people always survive.” –Bob Nabholz

He used to say, “Construction is a people business, and the contractors with the best people always survive.” He knew that the people in the company mattered — watching the early employees of Nabholz, those who didn’t share our last name but still poured sweat and blood into launching the company, made him realize that without quality people, we’d be nothing. People build. And good people build with quality, build safely, build relationships, build trust, build integrity, and build for a lifetime. They build on the success of the past and then hand the reins over to more good people to build the success of the future.

He recognized the value of our craft professionals and their talents. A big believer in leading by example, he dedicated himself to elevating construction to a respected profession, correcting misconceptions about construction workers by showcasing their professionalism and skill.

He always promoted construction as an ancient and honorable profession, never as a last resort. And rightfully so — the highly skilled work our team does is truly amazing, and it deserves to be respected and admired.

That’s why he worked so hard to grow the talents of our people by recruiting the best in all fields. His introduction of the Nabholz Carpentry Apprenticeship Program in 1973 led to the creation of Nabholz University, which in turn lead to the many training programs we offer today.

As we celebrate our 75th year, we honor the legacy of those who got us here. Our success isn’t just about what we build, but about the exceptional people who make it happen. We continue to grow, innovate, and serve our clients with dedication because “good enough” will never be good enough for us.

We often wonder what my grandfather would think about his company today. I like to think he would be amazed at what we have grown into and proud of all the talented people who work here. I know I am.

– Jake

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The Federal Emergency Management Agency (FEMA) describes a safe room as a hardened structure that meets FEMA criteria and provides near-absolute protection in extreme wind events, including tornadoes and hurricanes, based on our current knowledge. A safe room is officially FEMA rated and follows FEMA 361 guidelines, meanwhile a storm shelter does not have the official FEMA rating. Most people will use the terms interchangeably, but keep in mind that your shelter can only qualify as a safe room if it is FEMA rated.

Pre-cast concrete, CMU block, and cast-in-place are three methods to consider when constructing a safe room. These methods, combined with the right design specifications, will help you meet FEMA guidelines – and offer the chance to be FEMA rated – while also choosing the best fit for your project.

Pre-cast concrete

Pre-cast concrete storm shelters are built by a caster using a casting mold and then shipped to the construction site ready to go. This means that construction can avoid most material or weather delays on the front end because the safe room is constructed in a controlled environment. It can also speed up construction because it requires less time to install.

Pre-casting also allows for taller or longer structures, but there is a limit based on the cast sizing available at the local pre-caster. In that case, the request would have to be fulfilled by an out-of-state pre-caster with the required equipment.

A downside of this method is potentially increased shipping costs. Since the structure is cast off-site, it has to be delivered to the job site – and so the size and location of the safe room can add more to shipping costs.

Another downside is that the pre-caster could have a queue of several projects to get through before constructing your shelter. It’s important to plan accordingly to ensure your project can be completed on time with that potential delay.

CMU block

Concrete Masonry Unit (CMU) block, also known as block for short, is built on the job site using individual concrete blocks.

Block can be beneficial with a tight budget because there are little to no shipping costs like with pre-cast. All the work is done on-site, so workers can assemble and place the structure without waiting for the caster or shipping.

However, this type of storm shelter can take longer to construct if there are material or longer weather delays. If the job site is compromised, the construction workers have to wait until the all-clear is given to resume work on the block.

If the shelter is intended as a multi-purpose space, like a gymnasium with basketball hoops or volleyball nets, block is most likely not the best choice. The concrete block walls are not able to support the roof structure’s weight in a taller building. A potential solution to this is to use thicker or double block to adequately support it. However, it’s recommended to use another method like pre-cast concrete to support that type of structure.

Cast-in-place

Cast-in-place combines the method of pre-casting with the location of block – allowing workers to cast concrete into a mold on-site. Like block, on-site cast in place opens up the possibility of material or longer weather delays. However, it removes the shipping costs that come with pre-casting.

A subset of this method is tilt-up, where the concrete is cast horizontally on-site and then “tilted,” or lifted, vertically with a crane to assume the final position in the building.

Choosing the right fit for your project

Each construction method has its own pros and cons. There is no best way to construct a storm shelter – it all depends on what is best for your project’s needs, schedule, and budget. When in doubt, consult your construction team, architect, or FEMA resources.

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“The majority of our education clients decide to somehow incorporate the shelter into another functional space. It’s the most common type of storm shelter I’ve encountered in the past 15 years,” Nabholz Project Manager Jodi Phillips said. “I recommend proposing multi-purpose spaces to clients instead of just a hardened structure so they can get their money’s worth.”

Since 2015, Nabholz has worked with Greenbrier Public Schools in Arkansas to build six shelters that double as other facilities. Greenbrier High School’s newest storm shelter was completed in 2022. The shelter serves students daily as physical education, athletic, and flex spaces. In fact, it held a 5A school state volleyball tournament shortly after its completion. It is also FEMA rated – meaning the structure is qualified as a safe room that can withstand an EF5 tornado – and can house approximately 1,625 occupants during a storm. While structures are not always FEMA rated, Phillips recommends building the shelter to meet FEMA 361 guidelines regardless of if you plan to pursue the official rating.

“Your general contractor should work closely with you to guide you through your different options and make the best decision for your school,” he said. “That can include what you’ll need to make your shelter safe, how you can transform the space into a multi-purpose facility, and how you can qualify and apply for funding.”

In addition, schools can apply for FEMA safe room funding to get up to 75% of the structure’s eligible cost refunded. Eligible cost includes materials for the shelter’s structural integrity and practical use, such as walls, doors, electricity, plumbing, and fixtures. It’s important to note that FEMA will not reimburse additions that don’t add to the structure’s safety. Schools utilizing the space as a multi-purpose facility will take the cost of aesthetics, like paint and flooring, and sports equipment.

“The cost of the safe room will vary depending on what you’re turning the shelter into. For example, adding in a basketball or volleyball court means your shelter needs to be taller to accommodate that, which will cause the price to increase for that extra height,” Phillips said. “The biggest thing that drives the design, and therefore cost, is the function of the multi-purpose space, and design is always evolving with what you can do and how you can get the most out of your shelter for less.”

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Nabholz’ Millshop has become one of the region’s premier fabricators of custom cabinets, solid-surface countertops, and architectural millwork. To allow them to increase production, the crew there has focused on lean practices and efficient workflows. When they moved into a new fabrication facility in Conway earlier this year, manager Jonathan Davis and production manager Hunter Martin spent time with their team planning the shop floor layout and workstations.

Their improvements to workflow began with investing in a state-of-the-art CNC router to work in tandem with their existing machine. This innovative equipment includes a cutting head capable of swapping between ten router bits without stopping work and can process 70% more sheets of material daily, significantly increasing output potential.

From there, solid surface projects flow to the south end of the shop, and architectural millwork flows to the north for production. Parts that come off the CNC routers are labeled and loaded onto wheeled carts, streamlining the transportation of materials between the cutting table and workstations. In addition, the labels on the parts correspond to digital shop drawings, so cabinetmakers always have current and accurate information.

Of course, when your employees build custom cabinets for a living, designing and constructing personalized workstations is the obvious choice. Working with free reign, the team members created a workstation for solid surface backsplashes that virtually eliminates the need for time-consuming clamps while shaping, sanding, and gluing pieces. Our cabinetmakers also custom-built workstations for architectural millwork designed so tools, electricity, and compressed air are at their fingertips. Furthermore, with the workstations on wheels, crews can reconfigure the production floor very quickly to meet the specific needs of any project that comes through the door.

The team also decided that the shop would need to be kept incredibly clean and organized to run at peak efficiency. Thanks to built-in vacuum systems and trash containers on wheels, they can more easily collect debris and keep the floor clear of trash while eliminating time and extra cleaning materials. The millshop employees also intentionally organized tools and materials to ensure they are visible and within easy reach, eliminating wasted motion on tasks such as walking around to find clamps and time spent inventorying.

Davis and Martin promote continuous improvement, and their teams constantly look for better ways to build. The results are paying off, and not just in increased efficiency. They’ve also been able to up prefabrication processes. For example, they’ve now prefabricated patient headwall units for many Nabholz hospital projects in the new shop, as it offers a safer, more controlled environment than the job site.

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