After all the work to fill, compact, and level the site, it might seem strange to be digging back into the dirt again. But this time, the digging has a purpose: we’re preparing to pour the footers and pylon bases that will carry the entire weight of the new facility. The process begins with carefully carved trenches and enormous pylon cavities. Into these, crews will place rebar and then pour 8 inches of solid concrete. These massive bases will anchor the structure, distributing the load and ensuring long-term stability. If you look closely at the size of the pylon cuts, […]

One of the less glamorous but absolutely critical parts of building a facility like ours is dealing with stormwater runoff. Local building codes require that new construction capture and control a certain volume of rainwater on site rather than simply letting it rush into the city’s storm sewers. The idea is to prevent downstream flooding and to filter out sediment and pollutants before the water leaves the property. To meet those standards, our plans include a carefully engineered detention basin system that looks simple at first glance but is actually quite sophisticated. Instead of just digging a large hole, the […]

The big hole is no more. After 207 truckloads of soil, countless passes of the roller, and precision grading, the site has been filled, compacted, and rolled flat. Using a laser and receiver mounted on the dozer, crews ensured the surface is level to the inch — a crucial step in getting everything just right before the next phase. Building codes also required the addition of a compacted fire lane around the entire perimeter of the site. This ensures emergency access and adds another layer of stability to the build. With this step complete, the site is ready for what […]

Digging the big hole was only half the job — now comes the task of filling it back in. To build up a strong, stable base for the new facility, we brought in 207 truckloads of clean, high-quality soil from just eight miles south of the site. For two days straight a fleet of diesel drinking wagons of steel hauled fresh fill back to the boardsort.com site. Truck after truck rolled in, each one dumping its load before crews spread the soil evenly across the footprint. Once the soil was down, the compaction began. A massive vibrating roller — tipping […]

Here it is: the giant hole where our 18,000+ square foot building will soon stand. To create this space, we removed more than 54,000 cubic feet of topsoil and clay — a staggering amount when you stop and think about it. That huge hauler parked in the middle of the site gives you a sense of scale; this isn’t just a foundation, it’s the start of something massive. But none of that material went to waste. Instead of hauling it away, we put it to work right here on the property. The soil and clay will be shaped into natural […]

Every construction site has a story to tell, and sometimes the ground itself speaks the loudest. As we stripped away the topsoil on our lot, we started noticing odd, perfectly straight dark lines embedded deep in the earth. At first glance they looked like nothing more than stains in the clay, but digging further revealed something fascinating: scattered pieces of terracotta irrigation tile. These tiles weren’t modern utilities or abandoned pipes — they were part of a drainage system laid more than a century ago. Based on known history of the area, they likely date back to the late 1800s, […]

Before a single wall can go up, the ground has to prove itself. After drilling five deep core samples — each reaching about 50 feet down — the geotechnical team delivered their verdict: our site can support the new facility, but not without some serious preparation first. The top layer turned out to be less than ideal. Beneath the surface, engineers found poor-quality topsoil and pockets of saturated clay, some areas up to 2–3 feet deep. This material isn’t strong enough to hold the weight of a large building, so it will all need to be excavated and removed before […]

After months of design work, revisions, and back-and-forth with regulators, the architectural and engineering plans for our new facility are finally complete. What you’re looking at here isn’t a technical blueprint — it’s an artist’s rendition that brings those plans to life. For the first time, we can all see what the finished building will actually look like. To help visualize it all, we’re also including a cutaway view of the building’s interior. This peek inside shows the mezzanine offices, balcony overlooking operations, and the spacious floor where truckloads of material will be processed and organized. It’s a glimpse into […]

What a difference a few weeks can make. This aerial view shows our lot after most of the trees were cleared, cut, and hauled into neat piles. The larger logs are being harvested for lumber, while the branches and smaller debris have been chipped down and carried off. What was once a wooded patch is now an open space, taking its first real steps toward transformation. With the all but the last few trees gone, the site feels completely different — open, wide, and full of possibility. Now comes the shift from clearing to planning. Survey crews will mark and […]