Manufacturing Excellence: Inside New Millennium's Steel Joist Plant
By Christy Lattin
On the outskirts of Fallon, New Millennium's steel joist manufacturing plant operates as a testament to modern industrial engineering and commitment to worker safety. Inside this 160,000 square foot facility, driven by 250 workers from the surrounding area, raw steel is transformed into custom-engineered building components that have shaped the region's skyline, from aircraft hangars at NAS Fallon to the Fox Peak Theater and warehouses at the Tahoe Reno Industrial Center. The joist plant, under the New Millennium flag since 2010, recently offered a tour to members of the Fallon Chamber of Commerce for an insider view of the plant.
Production Supervisor Jason Mathern said the facility receives 95% of its steel materials by rail, storing both massive coils and 60-foot lengths of merchant bar, metal formed into precise 90-degree angles. The transformation begins when overhead cranes transport these coils to sophisticated roll formers. The plant's innovative former gradually shapes the metal through eight precision rollers while a "flying shear" cuts pieces to exact specifications without stopping the production line.
Each steel joist is custom engineered and tailored to specific structural requirements. Engineers take things like seismic activity, snow load, and construction specifications into consideration when designing the joists. The manufacturing process involves assembling top cords, bottom cords, and specialized webbing patterns designed to handle varying structural demands. New Millennium has multiple production lines and movement in the main production building doesn’t stop. The main shop also reverberates with the sound of various alarms, banging metal and the buzz of welding torches.
"This company truly believes in safety, and it hasn't hampered productivity at all," Guy Gibson, District Sales Manager said. "I wouldn't have my kids working here if it wasn't safe." This philosophy permeates every aspect of operations, from the initial design of equipment to daily procedures.
The facility operates around the clock with three shifts—two day crews and one night shift—yet maintains an impressive safety record. Recognizing that 95% of injuries typically involve hands, Mathern said the company has implemented comprehensive safety measures throughout the estimated 400 manual "touches" each piece of metal receives from rail delivery to final storage. More than 100 employees are trained first responders who participate in monthly emergency response training, ensuring immediate medical assistance is always available.
Advanced safety systems include light curtains that can detect a worker’s presence and prevent equipment operation when personnel are too close. The welding shop has a robust ventilation system and they provide workers with personal respirator-equipped helmets. Workers always weld downward for safety, using an innovative "flipper" device to rotate joists as needed.
New Millennium has also embraced automation while still maintaining employment levels. Robots handle cutting, punching, welding, and material handling, each equipped with safety measures like light curtains and pressure-sensitive floor plates. In Building 2, an automatic wood nailer robot joins wood strips to joists, with a goal of automating 90% of this process.
The manufacturing process begins when customers submit initial designs. New Millennium's team estimates steel tonnage and labor requirements, then develop detailed plans through their engineering and detailing departments. This collaborative approach, involving 2-3 weeks of plan review and customer consultation, ensures each project meets exact specifications. After assembly, joists receive a quality analysis inspection before being dipped in primer and prepared for shipment.
Mathern and Safety Coordinator Jason Sibley both led tours for about 40 Chamber members, many of whom had never been inside New Millennium before. Attendees were treated to lunch from the MM Food Truck following the tour.
“We loved being involved in this tour,” said Danielle Lougheed, Branch Manager at Nevada State Bank. “I think everything was handled professionally. The directions were clear and seamless, the food was excellent, and the staff was knowledgeable and courteous. Definitely a once in a lifetime experience, thank you!"
New Millennium is a wholly-owned subsidiary of Steel Dynamics with headquarters in Indiana, six facilities in the U.S. and one in Mexico.
The facility's comprehensive approach—from custom engineering to final quality control—has established New Millennium as a trusted partner in regional construction projects, proving that safety and productivity can indeed go hand in hand.
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