Productivity through Innovation: P1 Brings Improved Methods of Manufacturing, Adding Two New Shops to Meet Demand

Once upon a time…

P1’s 220,000 sq. ft. off-site construction and in-house fabrication facilities located in Lawrence, KS, had room to spare. Today, that has changed as demand for P1’s fabrication capabilities calls for additional dedicated space. This expansion supports our continued growth in client-awarded projects and strengthens P1’s ability to deliver at scale. As a result, P1 has added two new physical locations – also in Lawrence, KS – focusing specifically on advancing polypropylene and millwright manufacturing.

Polypropylene Resin

Known informally as the “poly” shop, the 90,000 sq. ft. polypropylene resin (PPR) shop at 910 E. 29th St. in Lawrence, KS, focuses on reforming the way P1 manufactures and streamlines PPR production systems. The shop is in addition to the full carbon, plumbing, and specialty pipe shops at P1’s main Lawrence location.

Pipe Shop Production Manager Jeremy Price said the new facility is dedicated to polypropylene manufacturing, specifically allowing for greater efficiency, precision, and scalability.

“We’ve been doing so much production for both the Aquatherm and Niron products, it required us to invest in more space to handle the capacity of work,” Jeremy said.

He notes the actual demand comes through large customers who use Aquatherm and Niron.

“We are currently shipping throughout North America, as well as internationally, with these two partners,” he said. “These relationships have grown over time due to P1’s outstanding reputation, capacity, capabilities, and commitment to quality.”

The PPR shop is designed specifically to maximize the storage and dynamics of producing polypropylene pipe and parts, with features like vendor-managed inventory, fitting production, production lines, and conveyors and trolleys to move product faster.

Trolley systems move pieces through the polypropylene resin shop faster

“The shop has been systematically designed for speed and efficiency to ensure consistent quality in mass production,” Jeremy added.

“Everything is stored inside the facility,” Process Controls Supervisor Nathan Peters said.

“That includes indoor receiving and shipping, meaning the trucks can back directly into the shop, and not be affected by weather, so nothing holds us up on schedule.”

For Nathan, the most critical part of the job is organization, which is no small feat.

“We have to stay on top of coordinating material and trucks coming in and out, checking availability, and putting the right product out on the floor, and making sure the process flow stays organized so everyone knows what is where and can get right to the job,” he said.

“We set up production lines to make us more linear in our manufacturing process,” Jeremy added. “Instead of jacks, we now have conveyors and trolleys to move the product faster.”

With the help of Stratus Technician Haydan Walker, the shop also uses Stratus fabrication management software.

“Stratus creates efficiency by integrating Building Information Modeling (BIM) software with manufacturing tools to streamline workflows from design to installation,” Haydan said.

“It increases efficiency by digitizing processes, enabling real-time tracking of parts, and providing automated labeling and analytics to improve project execution.”

Shop Coordinator Heidi Wittman notes this facility improves business development as well.

“We can bring customers and prospects here to see our facility, see what we have, and see how we can do it all in-house, and it’s very impressive,” she said.

In fact, following a recent prospect tour of the shop, the team is in talks with a potential new customer that could bring in a significant amount of work.

Quality Control Supervisor Brennan Walker ensures parts are built correctly and to spec for the customer.

“Each day, I’m keeping track of what’s being built, making sure it’s exactly right, and documenting all of it so everyone has access to that information and can communicate status to customers,” he said.

Equipment like the Ritmo bandsaw and Alpha 400 expedite finishing by moving - and then joining - pieces together.

“Then we have to make sure it’s crated and put on the truck properly, often to meet very meticulous, specific customer guidelines.”

We look forward to seeing what the shop can do in the future!

The shop has the team to make sure process and quality are top-notch, from left: Quality Control Supervisor Brennan Walker; Process Control Supervisor Nathan Peters; Stratus Technician Haydan Walker; Pipe Shop Production Manager Jeremy Price; and Shop Coordinator Heidi Wittman.

In the new poly shop location, P1 can now offer a fast, in-house turnaround process:

• Indoor receiving and shipping bays for all-weather operations
• Vendor-managed inventory systems
• Assembly line manufacturing
• Systematic inventory flow
• Belt-driven conveyor distribution
• Wholesale fitting manufacturing of 12”-18” 45’s, 90’s and Tee’s

Millwright Laser Shop

The new North Lawrence Millwright shop at 1723 E 1500 Road, Lawrence, KS, is home to the TRUMPF T7000 tube laser. The shop is in addition to the full Millwright shop at P1’s main Lawrence location.

The laser eliminates the need for sawing, drilling, deburring, and tapping.

Compared with conventional tube cutting, the laser replaces several work steps. It can cut very precise complex contours in materials such as mild steel, stainless steel, aluminum or nonferrous metal.

“P1 Construction is invested in high precision material production,” Fabrication Manager Kevin Norris said.

“The new laser gives us more speed, precision, and shortens the distance between design and finished product.”

“The tube laser allows us to cut and machine tubing and structural components faster, more accurately, and directly from the designs,” Kevin added.

The TRUMPF tube laser allows for faster, more efficient cutting and tubing of structural components.

Kevin notes that because of their diverse shapes and materials, tubes and profiles are in high demand in many applications, including data centers, industrial framing construction, custom platform construction, and multi-trade rack construction.

“For P1, it has increased our accuracy and productivity, and encouraged creativity,” Kevin noted. “For clients, they appreciate the accuracy and cost savings.”

“With bending frames, for example, you will need fewer parts. Positioning aids facilitate error-free assembly, the amount of work required for downstream work steps, like welding, is noticeably reduced, and it’s all done with just one machine.”

Since beginning laser operations, Millwright Team Leader Jim Nisely notes the shop has successfully landed significant projects, contributing hundreds of thousands toward the investment in just the first year.

Customer Benefits:

• In-house design capability
• Nearly unlimited design option
• Less effort between design and construction
• Product cost reduction
• Process simplification
• Lower organizational effort
• Efficient response times

 Interested in P1's off-site construction capabilities? Learn more here.