Donaldson Warehouse Project
2020 Award of Excellence in Construction | Pre-Engineered Metal Building | 169,000 SF | 18-Month Timeline
Project
Overview
To meet growing demand for air filter products, Donaldson Company required a significant expansion to its Frankfort manufacturing facility. Steinberger Construction was awarded a design-build contract based on the owner’s outline specifications and a tailored concept developed in partnership with KJG Architecture. The 169,000 square foot addition addressed critical needs in traffic flow, warehousing, production, and office space.
The expansion included a new two-story office addition, additional breakrooms, and new workspace within the warehouse. These additions created a modernized, cohesive environment for Donaldson’s growing workforce. A complete HVAC system upgrade was implemented to maintain product quality and comfort in the existing production areas.
Meeting stringent Factory Mutual insurance requirements, the project was designed and built without disrupting existing production and shipping logistics. Key efforts included the installation of a temporary INDOT entrance, implementation of advanced drainage systems, and drive stone staging for uninterrupted site access. Rammed aggregate piers and soil stabilization measures were critical in overcoming soft soil conditions across the site.
Location:
Frankort, IN
Awards:
2020 Award of Excellence in Construction
Manhours:
60+ workers on site daily
Completed:
18-month design-build timeline
Square
Footage:
169,000 square foot warehouse and office addition
Highlights:
Pre-engineered metal building system with modern office space
30 new dock positions and expanded production space
Upgraded HVAC systems and traffic flow improvements
Coordination with INDOT, FAA, and adjacent airport
Safety
First
A project of this size introduced multiple safety concerns, especially regarding site fill and traffic crossing patterns. With between four and six feet of fill required across the site, intersecting with active semi-truck traffic, safety was our first priority.
Donaldson’s original single access point on State Road 28 had previously experienced a fatal accident, increasing the urgency for a new entrance. Working directly with INDOT and Donaldson, we developed and executed a traffic flow plan that improved safety for all personnel and vehicles. Coordination with the FAA and adjacent airport was also required for crane erection activities.
On average, 60 personnel were on site daily across several trades. Despite the inherent risks, our team managed the job with exceptional focus. The project saw only one OSHA recordable—a restricted days case for a twisted knee—an outstanding record for a job of this scale.
Built For
Performance
Phased turnover was prioritized to enable early occupancy of the warehouse and office areas. As construction progressed, the temporary INDOT access was converted to a permanent entrance, separating semi-truck and automobile traffic for long-term operational efficiency.
Special attention was given to the design and finish of the two-story front office, which visually connects the new construction to the existing facility. The finishes were selected through a collaborative process involving KJG’s interior design team and Donaldson’s corporate input to create a unified, branded environment.
Despite challenges ranging from soil conditions to supply coordination, Steinberger Construction successfully delivered a facility that improved product workflow, enhanced worker safety, and modernized the company’s operational capacity.
Partnership
In Action
The Donaldson Warehouse Expansion is a prime example of Steinberger Construction’s dedication to partnership, precision, and performance. We worked hand-in-hand with the client, designers, and governing agencies to deliver a seamless expansion that empowers Donaldson’s continued growth. Our intentional planning, proactive safety measures, and commitment to quality made this project a success both in outcome and in lasting relationship.