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.

The post Concept to Certificate of Occupancy in Under a Year appeared first on PC Construction.

Wentworth integrates real work practice into our college experience through a co-op program, where students find jobs on their own and work in their major of interest. These opportunities are a big part of the curriculum because they allow students to learn what they do and don’t like about the workforce they are about to enter. This process also provides students with valuable exposure to the applicant process.

This opportunity at PC is so important for me because the classes I am taking span a myriad of potential career directions. This internship focuses on one piece – construction management. Every day on the jobsite with PC I can learn about the construction process and determine if this is the right direction for my future.

I am currently working as an office engineer intern at the Weidmann Electrical Technology Manufacturing Expansion project in St. Johnsbury, Vermont. I work with an extremely helpful team who keep me busy and spend the time to thoroughly explain their work and processes to me. Since I have been here, I’ve learned about submittals, RFIs, daily logs, punch lists, material orders and closeout. I even completed my OSHA 10 certification! I get to see the inside process of communication with engineers and supervisors to make sure every step of a plan is carried through safely and correctly.

The Weidmann project is progressing steadily across its three major construction areas: the Warehouse, BM2 Equipment Upgrades, and the Fab North Addition.

• Warehouse: A major milestone was achieved on June 2 when the Warehouse received its Certificate of Occupancy – a huge accomplishment! Construction began just five months ago, and the team successfully navigated numerous challenges, including material delays and harsh winter conditions. All structural steel, framing, roofing, siding, and miscellaneous specialties were installed by PC’s Special Projects Group, a testament to the versatility and skill of our self-perform team.
• BM2 Equipment Upgrades: The BM2 area also hit some exciting milestones, including the installation of a dump chest and a 70,000-pound, 1000Hp boiler. Preparations are underway for a significant facility shutdown in early October, which will last six weeks as work occurs seven days a week. This period will be critical for completing the bulk of the equipment upgrades and installations.
• Fab North Addition: Affectionately nicknamed “Big Foot” by the owner, the Fab North Addition began steel erection in mid-May and is moving at an impressive pace. Like the Warehouse, the structural steel, miscellaneous metals, siding, and framing are being handled by PC’s Special Projects Group.

Working alongside an active manufacturing site has been a unique and fascinating experience. I capture daily photos, and the transformation from when I first arrived to now is striking. It is inspiring to witness how fast, yet detailed construction can be—and how essential teamwork is at every stage of the process.

The post An Intern Experience: The Weidmann Electrical Technology Expansion Project appeared first on PC Construction.

South Burlington, VT

This facility, which was completed last year, included the construction of a new, 188,500-square-foot high-bay building located directly adjacent to the Patrick Leahy Burlington International Airport runways. The fully operating facility includes aircraft manufacture and assembly space, office and employee spaces and support areas. Work included substantial site preparation, blasting and excavation, a parking lot and utility road, and a 2.7-acre geothermal field, which is one of the largest in New England.

The CMAA National Project Achievement Awards recognize those construction projects that are pinnacles of excellence and innovation. In 2024, CMAA recognized 17 projects for their outstanding achievements in construction management, with the BETA project winning the top honor in the commercial, sports, entertainment or hospitality greater than $50 million category.

This large and complex project required PC to proactively support and address several key challenges for BETA – including incompatible zoning regulation impacts, supply chain disruption, and the proximity to an operating airport. In addition, evolving manufacturing requirements caused significant building scope and design changes midway through construction. Despite these challenges, the project was completed on a drastically accelerated timeline. PC poured the first placement of concrete in June 2022 and BETA started installing equipment on the manufacturing floor less than 12 months later. Recently, BETA rolled its first production-intent electric aircraft off the final assembly line at this facility — marking another major milestone, just another year later.

According to Alex Gagnon, a representative from BETA: “PC had the mental flexibility to align with BETA as a startup, not just as a company doing a construction project. Specifically, PC embraced scheduling the way we define it: not just getting something done by the deadline, but getting it done ASAP. The result, a net-zero building where we will build net-zero aircraft, is something we can all be proud of.”

Said PC President / CEO Matt Cooke, “I am so proud to have been a part of this important project for the State of Vermont, and for the incredible team who poured their heart and soul into the design and construction efforts. This was a truly collaborative project from the start, and the resulting success is testament to that team effort.”

The post PC Construction Accepts National CMAA Award for BETA Technologies Manufacturing and Assembly Facility appeared first on PC Construction.

The BETA Technologies Manufacturing and Assembly Facility project is Phase 1 of a two-phase master building plan on a 40-acre former brownfield site. The new, 188,500-square-foot high-bay facility, located directly adjacent to the Patrick Leahy Burlington International Airport runways, includes aircraft manufacture and assembly space, office and employee spaces and support areas. Work included substantial site preparation, blasting and excavation, a parking lot and utility road, and a 2.7-acre geothermal field, which is one of the largest in New England.

To successfully complete a project of this complexity, PC needed to proactively support and address several key challenges for BETA – incompatible zoning regulation impacts, supply chain disruption, and the proximity to an operating airport. In addition, the project required creative problem-solving to maximize efficiency during construction. Despite the challenges, PC completed this project on a drastically accelerated timeline, delivering a fully functioning state-of-the-art manufacturing facility just 2.5 years after project kickoff, which included six months for early design packages and six months for permitting delays. PC poured the first placement of concrete in June 2022, and the owner started landing equipment on the manufacturing floor less than 12 months later!

I am so proud to have been a part of this important project for the State of Vermont, and for the incredible team who poured their heart and soul into the design and construction efforts. This was a truly collaborative project from the start and the resulting success is testament to that team effort.

Check out this video to learn more about the BETA Technologies Manufacturing and Assembly Facility project.

The post BETA Technologies Project Recognized with National Award appeared first on PC Construction.

Hill-Engineers, Architects, Planners, and local officials to celebrate the groundbreaking for the approximately $44 million expansion at Weidmann’s St. Johnsbury, Vermont, facility.

The project, which will allow Weidmann to increase manufacturing capacity, includes three major components: the construction of a 10,000-square-foot free standing pre-engineered warehouse building, a 21,500-square-foot addition to their existing finished goods production space, and material production upgrades within the existing manufacturing plant.

PC completed an addition to Weidmann’s existing manufacturing facility 12 years ago with all the same key partners. We are excited to once again contribute to Weidmann’s expansion plans to support for their manufacturing operations well into the future.

The post Ground Broken for Weidmann Electrical Technology Expansion appeared first on PC Construction.

This project, which was completed last year, is Phase 1 of a two-phase master building plan on a 40-acre former brownfield site. The new, 188,500-square-foot high-bay facility, located directly adjacent to the Patrick Leahy Burlington International Airport runways, includes aircraft manufacture and assembly space, office and employee spaces and support areas. Work included substantial site preparation, blasting and excavation, a parking lot and utility road, and a 2.7-acre geothermal field, which is one of the largest in New England.

This large and complex project required PC to proactively support and address several key challenges for BETA – including incompatible zoning regulation impacts, supply chain disruption, and the proximity to an operating airport. In addition, evolving manufacturing requirements for ALIA caused significant building scope and design changes midway through construction. Despite these challenges, the project was completed on a drastically accelerated timeline. PC poured the first piece of concrete in June 2022 and BETA started installing equipment on the manufacturing floor less than 12 months later.

According to Art Klugo, a representative from BETA: “PC had the mental flexibility to align with BETA as a startup, not just as a company doing a construction project. Specifically, PC embraced scheduling the way we define it: not just getting something done by the deadline, but getting it done ASAP. The result, a net-zero building where we will build net-zero aircraft, is something we can all be proud of.”

Said PC President / CEO Matt Cooke, “I am so proud to have been a part of this important project for the State of Vermont, and for the incredible team who poured their heart and soul into the design and construction efforts. This was a truly collaborative project from the start, and the resulting success is testament to that team effort.”

The post PC Construction Receives CMAA New England Award for BETA Technologies Manufacturing Facility appeared first on PC Construction.

This project, which was completed last year, is the planned Phase 1 of a two-phase master building plan on a 40-acre former brownfield site. The new, 188,500-square-foot high-bay facility, located directly adjacent to the Patrick Leahy Burlington International Airport runways, includes aircraft manufacture and assembly space, office and employee spaces and support areas. Work included substantial site preparation, blasting and excavation, a parking lot and utility road, and a 2.7-acre geothermal field, which is one of the largest in New England.

To successfully complete a project of this complexity, PC needed to proactively support and address several key challenges for BETA – incompatible zoning regulation impacts, supply chain disruption, and the proximity to an operating airport. In addition, the project required creative problem-solving to maximize efficiency during construction. Despite the challenges, PC completed this project on a drastically accelerated timeline, delivering a fully functioning state-of-the-art manufacturing facility just 2.5 years after project kickoff, which included six months for early design packages and six months for permitting. PC poured the first piece of concrete in June 2022, and the owner started landing equipment on the manufacturing floor less than 12 months later!

I am so proud to have been a part of this important project for the State of Vermont, and for the incredible team who poured their heart and soul into the design and construction efforts. This was a truly collaborative project from the start and the resulting success is testament to that team effort.

Check out this video to learn more about the BETA Technologies S40 Aircraft Assembly Facility project.

The post CMAA New England Recognizes BETA Technologies Project appeared first on PC Construction.

The 188,500-square-foot facility will support the manufacture of up to 300 of the aerospace company’s first all-electric aircraft, ALIA, each year. It is also a net-zero emissions building, making it the most sustainable manufacturing facility east of the Mississippi River. Located directly adjacent to the Patrick Leahy Burlington International Airport runways, the facility utilizes a mix of renewable energy sources including a 2.2-acre solar array along with 257 geothermal wells to provide the primary heating and cooling for the building. No fossil fuels are used in the operation of the building, and it is estimated that it will consume half as much energy when compared to a typical building of its size that meets baseline ASHRAE standards.

Learn more about this project on pcconstruction.com.

Check out more about BETA Technologies and their new facility on Aviation Week Network.

LAINCO, the LAINCO logo, HIGHRIDGE SYSTEMS, and the group of each main truss and associated secondary beams are trademarks of Lainco Inc. used under license and constitutes an architectural work protected by copyright © 2011 Lainco Inc.

The post BETA Technologies’ Facility Opens for Production appeared first on PC Construction.

Extensive planning was required to meet the unique challenges associated with the work. The team developed comprehensive pick lift plans and coordinated with BETA, airport operations, the pilot, and our trade partners to ensure every detail was evaluated. Preparations were taken to perfectly align the steel to receive the beams while we worked with our trade partners ensure the site was battened down to protect from rotor wash.

This new, 188,500-square-foot high-bay facility includes aircraft manufacture and assembly space, office and employee spaces, and support areas. This first phase of BETA’s campus expansion project will support the manufacturing and assembly of the aerospace company’s first all-electric aircraft, ALIA.

The post Helicopter Pick Secures Skylight Ridge Beams appeared first on PC Construction.

Facility will turn food and beverage waste into renewable energy

South Burlington, VT – PC Construction joined PurposeEnergy on Friday to officially break ground on the Middlebury Resource Recovery Center (MRRC), which will convert residual materials from food and beverage manufacturing into renewable energy and cleaned effluent.

This innovative project will provide a lower-cost, local, greener alternative for food and beverage waste disposal. When fully operational, the MRRC will treat approximately 80,000 gallons per day of food waste and wastewater, converting over 90% of the organic content into renewable biogas that will be used to generate more than one megawatt of renewable electricity for Vermont homes and businesses.

Experts estimate that the facility will reduce greenhouse gas emissions by more than 2,000 tons of CO₂ equivalent every year, primarily by eliminating more than 270 truck trips each month. The project also protects Lake Champlain by preventing phosphorous runoff into the watershed and Otter Creek.

“We’re excited to start work on this project,” said PC President and CEO Matt Cooke. “PC has completed significant digester projects along the east coast for our clients in the water and wastewater industry. We’re proud to bring that knowledge and experience to the food and beverage industry, where there is so much potential for alternate power production and green energy.”

“This groundbreaking is the result of years of work by PurposeEnergy and our feedstock provider partners,” said Eric Fitch, Founder & CEO of PurposeEnergy. “The MRRC will serve Middlebury based food and beverage producers by a connected pipeline, and others within approximately 50 miles by road. It will improve economic opportunity in the area by providing a lower cost, greener alternative for disposing of food waste, while improving the environment.”

The MRRC will serve Middlebury-based food and beverage producers, including Vermont Cider Company, WhistlePig Distillery and Agri-Mark for Cabot Creamery.

The project is scheduled for completion in December 2023.

The post PC Construction Begins Work on Middlebury Resource Recovery Center appeared first on PC Construction.

A long-anticipated groundbreaking ceremony took place on Friday amidst Vermont’s first snow storm of the season. While more snow was likely shoveled than dirt, construction has officially kicked off for the Middlebury Resource Recovery Center (MRRC) in Middlebury, Vermont. The industrial organic waste treatment center will convert food and beverage residuals and wastewater into renewable energy and treated water to provide a lower cost, greener alternative for food and beverage waste disposal.

The project includes an anaerobic digester, a generator to produce renewable electricity from digester biogas, and a related building and piping. The facility will serve Middlebury based food and beverage producers – such as Cabot/Agri-Mark and Vermont Cider Company – by a connected pipeline, and others within approximately 50 miles by road. The heart of the facility is PurposeEnergy’s patented Tribrid-Bioreactor which converts organics in food and beverage waste into biogas, resulting in the generation of more than one megawatt of renewable electricity for Vermont homes and businesses.

The project will result in significant environmental benefits:

• The MRRC will treat approximately 80,000 gallons per day of food waste and wastewater, converting over 90% of the organic content into renewable biogas, which will directly offset fossil fuel use.
• The MRRC is estimated to reduce greenhouse gas emissions by >2,000 tons CO2e/year, primarily by the elimination of more than 270 truck trips each month.
• Over 60 tons per year of Phosphorus will be sequestered at the facility, removing the risk of run-off to Otter Creek and Lake Champlain.
• The process sequesters Phosphorous and other valuable nutrients into solid fertilizer that will be removed from the digester periodically. This solid fertilizer can be added to compost to increase its value or be directly applied to fields by local farms growing corn and bean crops – thereby reducing the use of chemical fertilizer.

PC’s partnership with PurposeEnergy began nearly 15 years ago to bring anaerobic digestion to South Burlington food and beverage producers. We are excited to now embark on a similar journey to help further this innovative and sustainable process in Vermont.

The post Construction Underway for Organic Waste Treatment Center appeared first on PC Construction.

The 187,000-square-foot high-bay facility, which is located directly adjacent to the Burlington International Airport runways, will include assembly space, office and employee spaces, and support areas. This first phase of BETA’s campus expansion project will support the development of the aerospace company’s first electric aircraft, the ALIA.

Mass excavation began onsite in October 2021 to prepare for the initial pouring of concrete, which began last month. The steel trusses, a proprietary product by Lainco Inc., are 10 feet tall and will provide a clear span of 170 feet at the center of the facility.

Partnering with BETA Technologies and PC Construction is the design team of Stantec, Studio 3 Architecture, Scott + Partners, Wagner Hodgson, Lainco, and RFS Engineering.

To read more about BETA’s exciting vision, click here.

LAINCO, the LAINCO logo, HIGHRIDGE SYSTEMS, and the group of each main truss and associated secondary beams are trademarks of Lainco Inc. used under license and constitutes an architectural work protected by copyright © 2011 Lainco Inc.

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