At ATMI Precast, sustainability is more than a commitment. It’s a core principle that guides every aspect of our operations. As a PCI Certified and Design Leadership in Energy and Environmental (LEED) certified organization, we’re dedicated to helping our clients achieve their sustainability objectives through innovative practices and cutting-edge technologies while achieving our own.

Proactive Carbon Footprint Forecasting

Understanding the environmental impact of a project before it begins is crucial. That’s why ATMI utilizes advanced software to provide carbon footprint forecasts during the planning stages. By inputting supplier data, including logistics, distances between locations, energy consumption for panel production, and material composition, we can estimate the project’s carbon footprint accurately. This proactive approach allows clients to make informed decisions and set realistic sustainability goals.

Sustainable Material Management

Efficient use of materials is a cornerstone of our sustainability efforts. We prioritize the recyclability of excess materials to minimize waste. Insulation scraps and unusable steel are returned to suppliers for recycling, ensuring they re-enter the production cycle. Any surplus concrete is repurposed for other projects, exemplifying our commitment to resource conservation.

Innovations in Precast Concrete

Enhancing the sustainability of our precast products begins with optimizing our concrete mixes. Recognizing that cement production significantly impacts Environmental Product Declarations (EPDs), our Quality Control Team is dedicated to reducing cement content in our mixes.

By incorporating Supplemental Cementitious Materials (SCMs) such as slag, a byproduct of pig iron production, and fly ash from coal combustion, we not only decrease greenhouse gas emissions but also improve the durability of our precast concrete. The use of fly ash enhances workability, cohesiveness, and finishing. Its fine particles help reduce bleeding and segregation, making it especially beneficial in lean mixes. Additionally, because fly ash is finer than Portland cement, it fills even smaller voids in the concrete matrix—spaces that would typically be occupied by water. This results in stronger, less permeable concrete with improved long-term performance.

At ATMI Precast, our dedication to sustainability is reflected in every project we undertake. Through innovative technologies, responsible material management, and a commitment to transparency, we empower our clients to meet and exceed their sustainability goals. If you’d like to learn more about our sustainability initiatives or check out our EPDs, visit here.

In 1983 Automatic Teller Modules, Inc. was formed by two Aurora families. One family, a second-generation family architectural firm specializing in financial institutions, and the other a third-generation family in concrete products and construction. The company was initially formed to fabricate and install modular buildings housing ATM machines – hence the name “Automatic Teller Modules, Inc.” The modular ATM buildings were precast concrete.

By 1985 the original firm had progressed to modular branch banks using precast concrete construction and full design build services for suburban branch banks also using precast concrete. The company began doing business as ATMI Design + Build. In 1987 ATMI Design + Build secured a multi-year contract with a large national financial institution to design and build a prototype branch bank and multiple replications each year for many years to come. The architectural piece was with the existing family firm, ATMI Design + Build brought the construction piece and the structure was precast, which closed the branch in rapidly for other trades to start.

The precast was a specialty architectural product and was being produced by a small, unrelated fabricator in Aurora, Illinois.  At the beginning of 1989 the small specialty precast fabricator was showing signs of distress in the midst of trying to produce multiple branch banks. ATMI Design + Build found itself in a situation of a key supplier for all of these banks in jeopardy.

By the summer of 1989, the principles of ATMI Design + Build and another member of the concrete products family (who had recently sold the family concrete products business) formed a new entity to produce the precast structures for the branch banks under a multi-year commitment. Since Automated Teller Modules, Inc. has been shortened to ATMI, the new entity formed to fabricate precast was named ATMI Precast, Inc. – which remains today.

In 1991, the national financial institution was itself distressed and the multi-year branch bank program was cancelled due to all capital expenditures being stopped on a national basis. The architectural firm had a contract for a new casino and parking deck and it was to be designed with precast. This order provided a life line in the absence of the branch bank orders for ATMI Precast.

By 1993, ATMI Precast re-focused on the industrial building market and built core relationships with the developers and builders in this market. Two years later, the industrial building market was driven by large public REIT’s. In addition, technology was allowing 30-foot clear height buildings and wider panels to accommodate dock doors. The market expanded beyond capacity for all of the key players including production capacity at ATMI Precast. As a result, ATMI Precast went from less than 500,000 square feet of walls fabricated in 1995 and 40 employees to over eight million square feet of walls, two million square feet of hollow core plank, over 500 employees, and the addition of two other fabrication facilities by 2006.

Today the ATMI Companies, consisting of ATMI Precast and ATMI Indy, LLC., fabricate approximately 19,000 pieces, nine million square feet of product, and 16,000 outbound over width, overweight, permitted truckloads to approximately 150 buildings per year. The ATMI Companies, service the industrial building market, the parking deck market, the urban multi-story retail market, and multi-story residential markets.

As one of the leading independent precast concrete manufacturers in the Midwest, ATMI Precast employs approximately 200 plant employees. Back in 2013 we were facing some workers’ compensation obstacles we wanted to overcome. The goal was to create a culture of safety to minimize risk in the workplace that would ultimately improve internal claims management practices. To do this, we turned to our business partner, Assurance, for guidance and together, we formulated a strategy that would meet all of our objectives.

“We recognized we needed to implement new protocols and initiatives in order to manage our rising workers’ compensation challenges,” said Mike Pelz, Vice President Operations, ATMI Operations.

To start, ATMI created a Safety Director position to review and develop an annual employee safety training schedule. We also aligned with a new insurance carrier that would better meet our needs, including ongoing claim reviews and ad hoc follow-ups.

ATMI Precast’s Keys to Success

The key to our success was total buy-in from the top down to create a culture of safety. Taking immediate action was also important. We implemented a safety training process with new hire orientation videos that uses our own employees.

ATMI Precast implemented additional safety practices including:

» Daily inspection forms and equipment checks for all foremen

» Monthly facility safety inspections with a focus on OSHA compliance

» New accident investigation guidelines and amended job descriptions

» New surveillance system to prevent fraudulent claims and ensure employee safety

» Significant improvements to their facility to increase efficiency

To improve employee involvement in the new safety program, the Safety, Excellence, Accountability, Leadership (S.E.A.L.) Team was created. Members of the S.E.A.L. Team must submit safety suggestions, demonstrate safe behavior, report unsafe acts/conditions, inspect equipment and tools, follow best housekeeping practices and demonstrate leadership. Additionally, to promote an ongoing safety culture, if certain employee safety parameters are achieved, a company-wide celebration lunch is provided.

ATMI Precast Results

ATMI Precast exceeded industry standards through our focus on safety, claims and risk management. Between 2013-2018, we successfully improved our loss ratio by 93%. From 2017 to 2018, our Experience Modification Rating (a number that influences a company’s workers’ compensation costs) was improved by 37 Points. ATMI Precast also decreased average claim costs by 79% in the last year and enjoyed a $300,000 premium reduction in 2018.

As a result, ATMI Precast was awarded the 2019 Minimizing Risk, Maximizing Health (MRMH) Award by Assurance.

“This award represents our dedicated efforts to our employee’s safety, as well as accomplishing lower claim costs,” Pelz said.

The Precast/Prestressed Concrete Institute (PCI) represents the summation of the precast/prestress concrete industry’s innovation, design, inspection, and process improvements gained since 1954. As an ISO 9001;2015 recognized and IAS (International Accreditation Service) Accredited Quality Program, PCI’s plant certification serves as the industry’s benchmark in quality system standards worldwide. ATMI Precast is proud to be PCI-certified.

What Does PCI Certification Mean for ATMI Precast?

To earn and maintain PCI certification, plants must demonstrate their commitment to quality through:

• The development of a comprehensive Quality System Manual
• The utilization of an established Multi-step Inspection Process for all products
• The successful completion and response to Unannounced Bi-annual Quality Audits through a third-party auditor
• The completion and documentation of Annual Internal Audits
• The completion and documentation of Continuous Root Cause Analysis and Process Improvements
• Plant Personnel Training Certification through PCI
• Regularly Maintained Calibration Intervals for all necessary Quality and Production Department equipment
• The completion and documentation of Approved Vendors for all materials

ATMI Precast is proud to be a PCI Certified plant for nearly 20 years!

What Does PCI Certification Include at ATMI Precast?

Our current product certifications through PCI include:

• Category A1 Architectural Products
  • Includes exterior cladding, loadbearing, and non-load-bearing wall panels, spandrels, beams, columns, and et al.
  • These products typically have more stringent requirements for dimensional tolerances, finish variations, and color consistency.
• Category C3A Commercial (Structural) Products
  • Precast concrete structural members that are Prestressed with straight, pretensioning, or post-tensioning. Includes stemmed members for roofs, floors, and walls, as well as beams, columns, spandrels, joists, and similar products.
  • These products may have a special architectural finish and/or suitable for painting if specified.

We strive to not only exceed industry standards, but rather our customer’s standards. The proven consistent quality of ATMI Precast products, demonstrates our commitment to quality on all phases of your project.

Are you familiar with the phrase: Hindsight is 2020? As we’re nearing the end of the year, this phrase has never been more relevant. It’s been a hard year for a lot of people, for a lot of reasons. But instead of looking at what we’ve all had to overcome this year, ATMI Precast has decided to look at our triumphs.

We kicked off 2020 with a full industrial backlog and hit the ground running in January. Of course, by mid-March the spread of COVID-19 had impacted life as we know it. For ATMI Precast, that translated to an immediate loss of 25% of our backlog.

How ATMI Precast Handled COVID this Year

Right away we reduced our plant capacity with about 200 employees. Our management worked diligently with plant personnel to establish social distancing and minimize touchpoints. We are very proud that we have been able to provide a safe environment for all of our employees through these safety protocols.

Safety for our ATMI Precast team during this year has always been our first priority. A close second was a concerted and continuous sales effort to get us back to a full backlog by June 1. A large part of this push includes the design and construction of 6 precast concrete parking garages. Two of these parking structures will be delivered by the end of this year, and 4 more will be completed in 2021.

Despite the impact COVID-19 had on our business this year, ATMI Precast expects to sell revenue levels that match 2019. We couldn’t have accomplished this without our excellent employees and our loyal customers.

New Projects & Initiatives

As a result of our amazing ATMI Precast team’s efforts this year, we have been able to participate in a variety of new projects and initiatives. For instance, we’ve continued to follow our general contractor customer base as they construct multiple Amazon projects within Illinois, Indiana and Wisconsin. Check out Project Tarpon and Project W to see what we’ve been up to!

Additionally, this year we implemented a new PCI Certification process for architectural precast. PCI’s plant certification serves as the industry’s benchmark in quality system standards worldwide. ATMI Precast is proud to be PCI-certified.

Our dedication to improvement doesn’t just center around our manufacturing plants. We continue to strive to improve efficiencies in technology across all departments, for example. This year we started ongoing implementation projects in CRM, Tekla and ROI. Of course, we are always looking to further strengthen our relationships with existing customers as well. To do this, we are constantly looking at how we can improve our quality, service and reliability.

Awards & Recognition

It’s always nice to be recognized for our work and fortunately, 2020 was no exception in this category. We are pleased to announce our award for the Facebook Data Center in DeKalb, Illinois. We look forward to working with Mortenson Construction on this exceptional project. ATMI Precast also applied for a PCI Design Award for our work on the Division & Clybourn project in Chicago. We are hoping to hear the results in 2021.

Last, but certainly not least, ATMI Precast is thrilled to have been honored with the MRMH Award. The Assurance Minimizing Risk Maximizing Health Award spotlights companies that have made a significant measurable impact on not only insurance costs, but also employees and their families.

Expansion & World Domination

Maybe not world domination – but certainly expansion! We are excited to have completed expansion of our ATMI Indy facility this year. This plant has nearly doubled capacity to serve the Indiana, Ohio and Kentucky markets and we are proud of their work. We also added 5 engineers to our team this year.

This year has taught us many lessons and one of them is that time is precious, our relationships with people are invaluable and we can overcome just about anything.

If you’re considering using precast concrete for your construction project, it’s important to understand how the process works.

1. 1. Concrete is poured onto a wooden or steel table utilizing wire mesh, rebar, and prestressed cable. This first step is done in a controlled inside environment like our ATMI Precast plant in Aurora, Illinois.

1. Once the precast concrete is cured, the pieces are transported to a construction site and erected into place.

But, that’s not quite as easy as it sounds! Most precast manufacturers have to call in an erector to get that last part completed. They may work with several different erectors depending on the location and the scope of the project. At ATMI Precast, we are fortunate to be the only precast manufacturer in the Chicagoland area to have our own controlled erector – Waubonsee Development.

What is a Controlled Erector?

Waubonsee Development is ATMI Precast’s controlled erector, meaning that the company is wholly owned by ATMI. In essence, this means that Waubonsee erects only for ATMI and is not beholden to other project schedules.

What is the Advantage of a Controlled Erector?

There are many advantages the customer benefits from when working with a team like ATMI Precast and Waubonsee Development.

1. 1. Accurate Sales & Estimating: ATMI Precast is able to accurately forecast from the erection side since both manufacturing and erection are under the same company.

1. 1. Consistent Crews: Waubonsee operates up to 4 crews at a time. This means that workers are able to stay on Waubonsee crews for longer periods of times and receive daily training on safety and erection protocols.

1. 1. Access to Cranes: Waubonsee Development owns its own conventional cranes for the warehouse market, which can streamline the construction process.

1. 1. Competitive Prices: Waubonsee is in a position to be very competitive when it comes to pricing since it only services ATMI Precast.

1. Advanced Scheduling: Erection scheduling is planned well in advance and matches our production schedule.

Sometimes coordinating outside subcontractors and their schedules can be a hassle. Working with a team like ATMI Precast and Waubonsee Development takes that potential out of the mix.

About Waubonsee Development

Since opening its doors in 1980, Waubonsee Development has grown to employ over 70 employees. Every year Waubonsee erects more than 75 precast building systems and that number continues to grow. Skilled in a variety of projects, from construction of precast parking garages and warehouses to retail, multi-story residential buildings, and field finishing and caulking, Waubonsee Development has the talent to take on any task.

There’s no other sporting event that’s as synonymous with its home state than the Indianapolis 500. Dubbed the “Greatest Spectacle in Racing” by a radio copywriter in 1955, the Hoosier state collectively celebrates the Indy 500. It’s a big deal – even if you aren’t a racing fan. With the 2021 race scheduled for May 30, we’re just days away from the world tuning in to what’s happening in Indianapolis. That’s why we thought it befitting to shine a light on ATMI Indy this month.

Start Your Engines: About ATMI Indy

About 30 miles due east from the Indianapolis Motor Speedway is a town called Greenfield. ATMI Indy calls Greenfield – approximate population 23,000 – its home. Strategically located along Interstate I-70, Greenfield is considered a prime location for businesses. This advantageous location allows ATMI Indy to serve a geographic market of approximately 250 miles from Indianapolis.

The Indy plant specializes in precast concrete wall panel construction – providing manufacturing, delivery, and installation of premium wall panels that offer a variety of insulation and exterior finish options. Demand for product exceeds 2.5 million square feet each year as customers continue to recognize the advantages of building with precast concrete panels.

While the plant began making panels in 2000, it wasn’t until 2003 that it became part of the ATMI Companies and was named ATMI Indy. As part of the ATMI Companies, ATMI Indy contributes to total fabrication of approximately 19,000 pieces and nine million square feet of product each year. ATMI Indy is dually certified as a PCI and NPCA manufacturer.

The Indy Team: A Winning Strategy

Drivers who qualify to race in the Indy 500 have an entire racing team behind them formulating a winning strategy. For example, because the Indianapolis Motor Speedway is 2.5 miles long with 4 distinct turns and straightaways, there’s a significant advantage for drivers who get out ahead of the pack early. Making less stops and saving as much fuel as possible is also part of that plan.

Similarly, ATMI Indy has a team behind them and a strategy in place in order to continue serving developers, contractors and designers with high-quality products and exceptional customer service. In fact, in the past few years the plant has undergone a slew of improvements.

The timeline below shows a significant number of new developments and how these enhancements strategically support increased demand, volume, and capacity.

• Fall 2018: We removed 3 of the original casting tables from the main facility and replaced them with one 14’ casting table and one 15’ wide casting table to allow for production of a wider product. At this time our company thickness standards had evolved to 9.5”, 10.5” and 12”.

• Winter 2018-19: We added an additional 12’ wide casting table outdoors with heat to sustain production during the winter months. This increased ATMI Indy capacity by 25%.

• Summer 2019: We started the foundations for a new state-of-the art Batch plant to further support increased capacity.

• Winter 2019: As capacity increases, so does need for storage. We purchased additional acreage from the Indianapolis Airport Authority, our neighbor to the south.

• Winter 2019-20: The new Batch plant came on line to meet demand.

• Spring 2020: We started work on our yard expansion.

• Summer 2020: The yard expansion is completed and we have no problem filling it up.

• Summer 2020: We take delivery of new MJ80 Mi-Jack Travel Lift to handle our new volume.

The Finish Line: Always Moving Forward

At the finish of the Indy 500 you’ll see the winner kissing the yard of bricks, chugging milk, and wearing a rather large wreath around their neck. And while that moment is no doubt a legendary experience for the driver, it’s not the end of the road. We feel the same way at ATMI Indy.

The past few years has brought progress and improvements that only help us build long-term and satisfying relationships with our customers. But we’re not done. Our race will never be over. While we certainly take the time to enjoy the accomplishments, our ATMI Indy team has a driver’s mentality that is always looking ahead to the next challenge.

ATMI Indy is hiring! Whether you are looking for an internship, have recently graduated, or have precast experience, we would like to hear from you. We have entry-level plant positions available. Learn more.

In the construction industry precast concrete has a well-known reputation as a structurally-sound and extremely durable material, but that’s not all precast concrete offers. For decades, architects and designers have purposefully selected precast concrete for its beauty as well. And because beauty is in the eye of the beholder, the possibility of any shape, style, color, and texture building with precast concrete offers is very attractive.

It’s in this vein that ATMI Precast is excited to announce we are on track to receive the Precast/Prestressed Concrete Institute (PCI) Architectural Certification in October of this year.

What is the PCI Architectural Certification Program?

The PCI Architectural Certification Program is the first of its kind. This new and improved certification criteria differentiates PCI producers in the marketplace and more accurately categorizes products in better alignment with the markets we serve. The program now includes four new categories of certification: AA, AB, AC, and AD and continues to include AT requirements. This five-category platform enables architects and other industry specifiers to define a category of certification that aligns with their project finish requirements such as tolerance, finish-type, and level of architectural complexity.

ATMI Precast will be certified in the AC category. This category covers the certification of plants producing products with architectural finishes like cladding and wall panels with plant-applied finishes like brick veneers and form liners. To ensure production capability for the types of products covered within this category, plant requirements for different cement types and colored mixtures are being implemented.

As part of the certification process, ATMI Precast was required to manufacture three mockup panels to demonstrate our ability to meet the specific category criteria for color consistency, finish quality, and forming capabilities.

Combined with our PCI-plant certification, our new architectural certification further provides architects, designers, and owners the peace of mind they need to know that the precast concrete products they are using are of the highest quality.

What Are the AC Category Requirements?

In order to earn PCI Architectural Certification in the AC category, ATMI Precast had to prove it could meet certain criteria.

AC category requirements include:

• Manufacture one colored mixture and texture per panel
• Manufacture thin brick
• Produce flat panels
• Produce flat panels with single-pour returns
• Create 3-D form surface (reveals and liners)
• Undergo key feature evaluation during plant audit cycle
• Undergo two plant audits per year
• MNL 135 (current MNL 117)
• MNL 135 erection tolerances (current MNL 117 with modification for maximum jog)
• PCI-certified erector

PCI precast concrete producers, like ATMI Precast, are embracing technology and applying it to the plant-cast concrete delivery system. Classifying PCI precast concrete producers based on our demonstrated capabilities to produce products of varying complexity shows our industry’s commitment to improve and collaborate.

What Does this Certification Mean for ATMI Precast Customers?

By definition, a certification represents third-party validation. Anybody can say they are the best at what they do, and they manufacture the highest-quality products. But a certification means the plant is taking great lengths to prove those claims.

From production to installation and completion, ATMI Precast’s PCI Plant Certification along with this new PCI Architectural Certification provides our partners and customers the confidence they require to work with us on current and future projects.