At CT Darnell, we build solutions. Not only do we carry the leading line of storage systems and design and install metal buildings for the LBM industry, but we are also the industry’s leading general contractor. CT Darnell has designed and built solutions for more lumber and building material retailers than any other company in North America. Our experience encompasses designing and constructing retail spaces, warehouses, and production facilities for hundreds of hardware stores, lumberyards, and building material wholesalers.
Our projects range from greenfield sites to expansions and remodels to integrated rack-supported building systems. We can oversee your project from start to finish, providing unmatched value and expertise. For one of our latest projects, we delivered a state-of-the-art dual-purpose facility in St. Mary’s, Georgia. [For all photos, See PDF or View in Full Issue.]
Doubling Down in St. Mary’s
When Griffin Lumber and its Specialty Structural division began planning its newest location in St. Mary’s, Georgia, the objective went beyond expanding into a new market. The company needed a purpose-built facility that could support both a full-service lumberyard and a dedicated truss manufacturing operation, while maintaining efficiency, safety, and room for future growth.
The project presented a unique opportunity. Built on a greenfield site, the new location allowed the design team to start with a blank slate and plan both operations intentionally, rather than forcing production into an existing footprint.
“We had the land, the demand, and the opportunity to design the facility the right way from the start,” said Griffin Lumber President Jason Settles. “The goal was to create a location that could operate efficiently today and still support growth well into the future.”
Planning for Two Distinct Yet Connected Operations
While the lumberyard and truss plant would operate independently, it was critical that they function cohesively as part of a single distribution hub. Early planning focused on understanding Griffin’s current SKU mix, inventory turnover, production requirements, and anticipated growth across South Georgia and North Florida.
The truss operation for Specialty Structural required dedicated space for dimensional lumber and finished truss handling, while the retail yard operation needed clear access and safe traffic flow. The resulting design balances separation and connectivity, minimizing congestion while allowing shared efficiencies where appropriate.
“It was important that neither operation interfered with the other,” said Settles. “At the same time, we wanted a layout that made material movement and access as efficient as possible.”
A Purpose-Built Truss Manufacturing Facility
The truss manufacturing operation occupies a 54,400-square-foot building, supported by a 3,400-square-foot office, designed to accommodate current production demands while allowing room to scale. It is purpose-built for all the roof and floor truss manufacturing equipment and support saws, and outside it has planned storage for finished components.
The building footprint was carefully planned to support:
- Efficient raw material intake and staging
- Optimized equipment layout working in conjunction with the equipment supplier
- Clear movement paths for partially assembled and finished roof and floor trusses
- Safe access for equipment and personnel.
By designing the facility from the ground up, the team was able to optimize workflow from material delivery through production and load-out, reducing unnecessary handling and supporting consistent throughput.
The decision to consolidate operations into a purpose-built facility, with material flow planned from the outset, established a strong operational foundation for future expansion.
Designing for Growth
For Griffin Lumber and Specialty Structural, the St. Mary’s location represents more than a new facility, it’s a strategic investment in long-term growth.
“It was important for us to be able to service South Georgia as well as newer territory in North Florida,” said Settles. “The growth in that area is significant, and this facility positions us to support that demand.”
The ability to scale production, manage inventory effectively, and maintain safe, efficient workflows was built into the facility from day one—allowing Griffin Lumber and Specialty Structural to grow without compromising operational performance.
Key Takeaways for Truss Operators
- Greenfield projects offer the opportunity to design truss operations for optimal flow and efficiency.
- Separating truss manufacturing from retail operations reduces congestion and improves safety.
- Purpose-built layouts support scalability as production demands increase.
- Early planning around material movement and workflow pays long-term dividends.
As truss manufacturers face increasing demand, facility design remains a critical driver of operational success. Griffin Lumber and Specialty Structural’s project in St. Mary’s demonstrates how intentional planning and purpose-built design can support both current production needs and future growth. Contact CT Darnell when you’re ready to expand your business.