There are countless ways to make a good first impression. Being greeted with fresh donuts is definitely one of them. Gwen Bertolami Lysons, GBL Materials’ founder, recounted this memory with a smile. She was invited to tour Premier Building Systems’ manufacturing facility in Puyallup, Washington. Of the plethora of green building products Premier offers, Gwen was most interested to see how structural insulated panels (SIPs) are created. Keep reading for highlights from the day that made Gwen come back to the office bursting at the seams with excitement (and donuts).

Overview of How a SIP is Made

When describing a SIP for the first time, a useful analogy is likening it to an ice cream sandwich. Expanded polystyrene (EPS) foam is glued in between two (7/16” thick) oriented-strand boards (OSB). Premier’s plant manager shared that material is not stockpiled on site, so when a project is submitted to the queue, accurate wood and foam quantities are procured from the raw material suppliers, so as not to over-order and create waste. Premier has their patented process down to a science, maximizing efficiency and minimizing environmental impact.

A hallmark of a structural insulated panel is the electrical chases cut out from the foam. Gwen learned that the first part of manufacturing a panel is using the shop drawings to precisely run the chases. This is done before the OSB panels are attached. With this sequence, if there is any mistake with the chases, the foam can simply be recycled and the wood remains untouched.

After the chases are run and double checked, the OSB is adhered to the foam using a structural glue. The raw panel size is 8’ by 24’. From there, the panels are cut to size as specified per the shop drawings. There is a cutting plan to minimize cuts, which saves Premier labor, and also minimizes unused material and waste.

People Putting on the Production

Gwen arrived at the factory early to allow more time for meetings later in the day, and not only was the factory manager ready to receive them, he actually spent more time with them than scheduled because everyone was so engaged. When a treasure trove of knowledge is unlocked, it naturally takes a while to explore.

Meeting the CNC operator was another highlight along the way. Gwen remarked that it was obvious, “he knew his business, had been doing it a long time, and was very comfortable with the process. He was very passionate about his job.” He makes precision cuts, with double checks on his work before and after the panels leave his station. Gwen reflected, “One of the things that struck me was that throughout the process of the fabrication, Premier checks and double checks everything that they are doing.” Gwen appreciated how eagerly every factory member shared their experiences. To put it simply, everyone was "all-in" and wanted to help.

From Gwen’s perspective, quality applies to every aspect of Premier’s business: the materials it sources, its business practices and procedures, and above all, its people. The majority of the people Gwen met have been working with Premier for decades. Team members expressed genuine passion about their work, and the wealth of information and experience ran deep. GBL Materials works with Premier SIPS to create fully supported buildings. Behind the product, the people are fully supporting each other as well.

The GBL Difference

GBL’s engineers understand how Premier’s manufacturing process works, so they can share design suggestions that would help minimize the number of panels needed. We work with designers and owners alike to understand their vision and offer strategic design choices that can help simplify construction, thus saving overall project costs by reducing labor and materials. With SIPS, vaulted ceilings, corner windows, dramatic overhangs, archways, and more are possible. We are fueled by creativity, an eye for saving everyone time and money, strict design standards, and of course, donuts. Our passion is sharing our knowledge to help bring others’ design dreams to life. GBL Materials is grateful for Premier’s support and eagerness to help create the best buildings possible for the client and planet.