Art Ackert”™s grandfather started his cement-block business in the town of Poughkeepsie during the Great Depression. “That was the way people built foundations and many still do,” said Ackert. “My grandfather made cement blocks by hand. I”™m glad to say we”™ve found a better, more efficient way of doing things.”
Ackert learned about Superior Walls of America, founded in 1981 by Lancaster, Pa., builder Mel Zimmerman. Disgusted with the time and delays that traditional cement block took when building, Zimmerman worked for several years to perfect a precast foundation system designed to streamline construction.
Ackert traveled to Pennsylvania to see Zimmerman”™s operation in action and bought into the idea, eventually deciding to convert his cement block-making plant into a precast concrete-wall manufacturing facility in 1989. Ackert”™s Superior Walls franchise ( HYPERLINK “http://www.swhv.com” www.swhv.com) just built its 10,000th home using the innovative precast wall system.
“You can”™t beat these walls for quality of construction and the fact that they are guaranteed waterproof and structurally sound,” said Ackert. “They are an invaluable tool for builders. More and more of our customers are turning to this construction method, and it”™s been a hit with customers all over our territory.”
Since it”™s not a poured foundation, the walls don”™t take days to cure. Instead, the precast walls are heated with infrared lights, cured and ready to be placed on the construction site within 48 hours. Because they are LEED-certified (Leadership in Energy and Environmental Design), they qualify for energy tax credits, which translate into savings for both builder and consumer.
“Because of the way these precast walls are constructed, there is little chance of mold and mildew developing,” said Ackert. “And rather than having to have someone come in and put up studs and then sheetrock and insulate traditional cement block after the house is built, the precast cement walls are already pre-insulated with R-5 material and pre-studded, ready for sheetrocking. It saves the builder time and affords an opportunity to offer customers a basement they can either finish themselves or have the builder do it for them.” The walls come with a 15-year guarantee.Â
Instead of waiting days for the foundation to be built, one typical 3,000-square-foot house can have its foundation up within a day. One innovative architect in eastern Long Island not only built his basement but constructed his entire two-story home with the cement walls. “He said he did it because the house was on the water and the precast concrete walls could withstand the weather better than a traditional stick-built house,” said Tami Ackert, who is the fourth generation of her family in the business. “While we haven”™t had anyone else use the walls to build an entire house, the result was fantastic.”
Art Ackert estimates that up to 22 percent of the heat lost in a home over a typical season is due to traditional cement-block foundations. “In today”™s market, with the high cost of heating a home, any way that a homeowner can save money and make their basement more comfortable and drier is a worthwhile investment.”
The Ackert family”™s Violet Avenue manufacturing plant in the town of Poughkeepsie turns out about five to six truckloads a day of the foundation walls. “When building was at a peak, we were doing five homes a day,” said the owners. “Now, we are doing about three a day. Building is still going on in the valley but we are seeing more condo and apartment-style homes going up.”
Superior Walls seem to be showing up everywhere in Ackerts”™ territory: Leyland Alliance, Ginsburg Development and many other large builders are turning to this method of foundation construction, said Ackert. While there”™s always someone trying to build a better mousetrap, he says the franchise he”™s invested into is a step ahead for his industry.
While no one has figured out how to create a precast concrete floor yet (floors still need to be poured after the walls are up), there”™s no doubt someone”™s out there working on a way to make it happen. And it”™s a pretty safe bet the Ackerts will be there to see if it”™s a worthwhile product to promote.
Right now, the family is hoping to enlarge its town of Poughkeepsie plant to keep up with the demand of builders in itsterritory, which includes Westchester and the entire Hudson Valley, Fairfield County, Conn., and all of Long Island. If their expansion plans are approved, the family predicts 35 additional employees will join the current staff of 50 at the 13-acre manufacturing site. “Like all things, getting through the process takes time. We are looking at other locations in Connecticut, but we really want to stay here in the town of Poughkeepsie, which has been our home for more than 70 years,” said Tami Ackert. “We really don”™t want to go out of state to expand ”¦ so we”™re hoping to get the go-ahead to expand and add more jobs to our local economy.” The company has had applications in for expansion with the town of Poughkeepsie Planning Board for months, according to Ackert Sr.
“We know we”™ve got a great product,” said Ackert Sr., pointing to walls filled with pictures of projects built all across the region. “We”™d just like and grow our business right here where we”™ve been all these years.”
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