Laying the Groundwork
Merlo Construction at Alro Steel’s New Facility
When members of ABC SEMI visited Merlo Construction’s active job site in Mt. Clemens, they were welcomed by Bryan Baker, who led a tour of one of southeast Michigan’s most significant industrial developments currently underway—the new Alro Steel distribution facility.
Marlena Booth (left) and Bryan Baker (right) on the job site.
Situated near the former Gibraltar Trade Center site off I-94, the project represents a major investment in the community and in the region’s manufacturing supply chain. The Jackson-based steel and plastics distributor plans for the 250,000-square-foot plant to serve as a warehouse for metals, as well as a hub for value-added processing and distribution.
Construction began in late 2024, and the company expects to be fully operational in 2026. For Merlo Construction, breaking ground at the high-profile location came with both opportunity and challenges. The first step was clearing and leveling the site, a process complicated by poor soil conditions that required removing and replacing tons of dirt.
Crews then began installing footings for the massive plant. During this phase, workers had to navigate 7,500 concrete inclusions 20 feet below ground and set every five feet across the property. These were installed earlier in the project to help hold the new building up.
The pit inside the Alro Steel facility.
“This site really required us to think creatively,” Baker explained during the tour. “The ground itself posed challenges, and with the structural pieces under ground, it meant extra precision at every step.”
One of the most unique feats of the project so far has been the construction of a 10-foot pit that had to be poured and reinforced before any ground-level work could move forward. Designed to support the massive steel racks that will store product moving in and out of the facility, the pit required extensive reinforcement and presented one of the toughest engineering challenges of the project.
Another highlight for ABC SEMI members was seeing how multiple member companies are working side by side to bring the project to life. Lee Industrial, for example, set the cast in place for foundation walls for the pit and facility’s drive-thru lanes on both the north and south ends of the building—demonstrating how the strength of ABC membership often extends into the field.
The Merlo team finished the concrete on the east side of the building.
But the toughest adversary on this job wasn’t hidden underground or in engineering documents—it was the weather. From bitter cold and snow to summer heat, humidity, and sudden rain, the open site made concrete pours particularly difficult.
“Without a roof overhead yet, we were exposed to everything Michigan weather threw at us,” said Baker. “Pouring concrete in those conditions takes extra planning and a lot of patience.”
Despite these hurdles, Merlo Construction has kept the project moving forward and anticipates wrapping up its scope of work by the end of this year. When complete, the new Alro Steel facility will not only transform the long-vacant site but also strengthen the industrial backbone of the region, supporting jobs, growth, and investment well into the future.
For ABC SEMI members, the site visit was more than just a tour of concrete and steel—it was a chance to see how collaboration, expertise, and perseverance are shaping the future of construction in southeast Michigan.
