Post-Frame Technique Reaches New Heights
by Hanna Aronovich
Manufacturing Today

Whether it’s building a church or an office building, the basis of FBi’s construction method lies in post-frame building. “It’s a particular style of construction,” explains Joe Ely, director of quality, supply chain and logistics. “Rather than a continuous foundation that holds the building up, there are pre-engineered laminated wood columns spaced at specified distances that are part of the integrated framing system.”

Even though all of FBi’s buildings are designed with this method, - churches, office space, commercial and industrial - Ely emphasizes, “there are infinite varieties within a basic structure.” The building is designed by professional, licensed engineers to meet specific requirements and functions. He adds, “Our structures are also attractive and affordable [for our clients].”

FBi’s methods deliver solid buildings, designed with innovative techniques. “Years ago, post-frame buildings were known as agricultural ‘pole barns,’” says Jeff Neihouser, general manager, “and that’s pretty much what they were. However, post-frame construction is used in a variety of markets from agri-business, equine, retail, industrial, commercial and even residential. Improved technology, components and construction methods have dramatically improved these buildings and widened their appeal,” Neihouser says.

FBi has played a significant role in post-frame’s advancements. “We were one of the first to use square columns in place of round poles,” Neihouser remembers. A square column provides a flat surface for a wodden panel to be built against. Additionally, round poles are not as straight as square columns, also weakening the structure of the building. Neihouser says the rest of the industry now uses the square column support structure.

Another FBi innovation was introducing a stainless steel screw, which attaches the steel beams to the building. “Most industries used a galvanized screw, but we have a cap,” Ely explains. He says this innovation provides greater stability, durability, and corrosion resistance.

Stainless steel is not the only new material FBi has used to enhance its buildings. The company has also contracted exclusive, regional use of Perma-Column, which was developed in conjunction with one of its vendors. The Perma-Column is a pre-cast, high-load, concrete column system, which is rooted in the ground. Ely says using concrete – as opposed to treated lumber – prevents mechanical damage and is a more environmentally friendly option.

Customers are aware of FBi’s Perma-Column technology, and the company has seen the effect in its business. “We’ve been very positively affected,” Neihouser notes.

Safety Sites

Beyond structural innovations, FBi has propelled the issue of safety with new systems and a committed attitude. Although pre-engineered buildings are only one story, Ely notes that the roofs can be 14 to 25 feet off the ground. “Many in the post-frame industry have not had a strong emphasis on safety,” Ely continues, “but safety has been an area of intense focus for FBi.

To prevent injuries from falls, FBi pioneered a new safety harness. “We worked with suppliers to design a retractable rope system, similar to a seatbelt system on a car,” Ely explains. Employees are harnessed to the rope, which has give when they move slowly. However, an abrupt lean or pull will cause the rope to retract. “It will catch [employees] if they fall,” Ely adds. “A number of serious injuries are avoided.”

He adds that the company has seen a dramatic reduction in on-the-job injuries. “In the first quarter, we were down about 50 percent than from two years ago. It’s been striking,” he notes.

Built on Values

FBi, originally Farm Builders Inc., was founded in 1958 by Ed Bahler Sr. and served the agriculture and equine industries. “He saw a need for [post-frame] buildings,” Ely says. “And by paying attention to service and delivering a quality product, the company grew.”

“The company expanded from its rural focus to begin construction projects for small and midsize firms in various commercial, industrial and retail arenas,” according to company history.

Bahler has since retired and sold the company to his sons, who now own and operate FBi. Yet, Ely insists FBi’s culture has remained the same. “We focus on values that come from a high ethical perspective, that flow out of deep rooted, Christian convictions of owners and senior management,” Ely says. “FBi’s business management approach reflects these core values – and that’s fairly unique.”