Gearbox Express

Mukwonago, WI Commercial Industrial

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Clean, Crisp Heavy Manufacturing Facility

Precast products allow for no two facilities to be the same, products can be designed, constructed and installed based on the client’s individual needs to allow for complete design flexibility in today’s industrial and commercial marketplace. For this heavy industrial manufacturing facility, the owners needed large open, column less space to repair wind turbines. They also envisioned a clean, crisp design to mirror European wind turbine facilities. Gearbox Express is the only US based wind turbine repair company. All other wind turbines must be shipped overseas for repair. Gearbox Express wanted a truly impressive and one of a kind structure - that’s how precast became the ideal building method – strength and beauty all in one.

The 75,000 sq. foot facility is built on a 10-acre parcel which allows for future horizontal expansion as business needs grow, and precast panels will be removed and reused for seamless integration over time.

The facility was created with clean lines and open bays, reminiscent of current European architectural design. The speed of the precast components minimized onsite staging requirements and accelerated the building enclosure to allow for winter interior work to continue; given the delayed project start due to permitting and building site challenges. Gearbox Express was up and running faster than expected, production began sooner, and the return on the investment is better than the owner expected.

Wide open spaces and dually functional precast columns and beams

Gearbox Express needed wide open spaces to allow movement of heavy industrial equipment throughout the facility and using 60 ft. precast double tee beams and 70 ft. crane beams fulfilled the owner’s vision.

The precast beams were designed to have 2 overhead cranes with a 30 ton and 60 ton capacity to function and travel simultaneously at full capacity. Using precast columns served a dual function for both building structural needs and crane beam requirements; multiple JIB cranes were needed leading to additional structural design.

Gearbox Express provides down-tower, wind gearbox re manufacturing solutions. These large gearbox’s are used to propel wind turbines for renewable energy. Their current yearly capacity is 250 gearboxes, the sheer size and weight of these turbines is the driving force in the design of this structure.

This was not a one-size-fits-all solution, every industrial and commercial construction project is as unique as their business and owner’s dreams, leading to this building being total precast.

Architectural Wall Panels Thermal Efficiency along with style

Precast insulated wall panels allowed for maintenance-free, architectural finishes on the outside of the building while allowing the facility to be fully climate controlled on the inside, increasing the structures R-factor and thermal efficiency especially given the Midwest’s temperature variations.

The owners loved the design of their old facility so much, that Spancrete mimicked the design and features using precast architectural panels; including its trademark blue stripe. The structure was also designed for future expansion of both office and manufacturing spaces.


  • Total precast project
  • Wide open spaces to allow movement of heavy industrial equipment
  • Exposed aggregate lime stone finish


General Contractor: Harmony Construction Management, INC.

Engineer: Excel Engineering

Architect: Excel Engineering


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