US Gypsum – Precision in Motion: Expanding a Working Mill

In May 2024, MJW was awarded a contract for a complex, multi-phase project to expand and modernize an active operating facility at the US Gypsum wallboard plant in Jacksonville Florida. From the start, this project called for creativity, precision, and careful coordination—especially since the mill had to remain fully operational throughout construction.

Phase One began with the removal of existing steel structures across five floors of the mill. Once that was complete, the team faced one of the project’s most demanding challenges: installing a brand-new Williams Mill weighing more than 50,000 pounds—and doing so 30 feet inside the existing building. To make this possible, MJW crews built a temporary roadway, 20 feet wide and 80 feet long, allowing heavy equipment from Sterett Crane and Rigging to safely enter the building and position the new mill onto the concrete foundations previously installed by MJW in early 2023.

With the mill successfully set in place, Phase Two moved forward with the installation of 58 tons of new structural steel throughout the facility. The work required careful sequencing and detailed planning to ensure both safety and productivity within the active manufacturing environment.

Now in Phase Three, the project continues with the construction of a new Mill Building, complete with upgraded equipment, piping, and structural systems. The foundation alone required 25 tons of reinforcing steel and 900 cubic yards of concrete, with the structural frame adding over 340 tons of steel when fully erected.

Slated for completion in late winter 2026, this project stands as a testament to the MJW team’s expertise in tackling complex industrial work—balancing innovation and efficiency while ensuring safety and precision every step of the way.