SITE DEVELOPMENT
LARGE-SCALE SITE DEVELOPMENT BUILT FOR COMPLEX, HIGH-IMPACT PROJECTS
Thalle Construction Company delivers full-scale site development services for the nation’s most complex and demanding projects. From airport expansions and industrial megasites to large commercial campuses and transportation corridors, we prepare the ground for successful construction with the power, precision, and reliability these massive undertakings require. Our teams integrate large-volume earthwork, deep excavation, mass grading, stormwater systems, utilities, and structural site preparation into a cohesive, high-performance workflow—executed safely, efficiently, and with tight schedule control. We excel in challenging environments where large footprints, aggressive timelines, and multi-discipline coordination demand disciplined execution and seamless communication.
Backed by strong quality programs, experienced crews, and a substantial heavy equipment fleet, Thalle delivers predictable results that allow owners and contractors to move quickly into vertical construction. Whether stabilizing subgrades, preparing aviation pads, building roadway networks, or installing major utility corridors, we bring the heavy civil capabilities and dependable project leadership needed to transform raw land into fully build-ready sites. Our site development work strengthens community infrastructure, supports economic growth, and sets the foundation for long-term project success.
GALLERY OF PROJECTS
CASE STUDY
CERTAINTEED FACILITY
EARLY SITE DEVELOPMENT PACKAGE
Thalle Construction delivered the full early-work civil package for the new CertainTeed Roxboro Wallboard Facility, preparing the large industrial site for vertical construction and long-term manufacturing operations. As one of the first contractors on the ground, Thalle was responsible for transforming an undeveloped tract into a fully engineered building platform capable of supporting heavy industrial loads, high-volume material handling, and continuous plant operations.
The project required more than 850,000 cubic yards of mass excavation, including 250,000 cubic yards of rock removal to achieve precise subgrade elevations across the expansive facility footprint. Working in Piedmont geology, Thalle deployed large-scale excavation fleets and advanced grading control systems to maintain production rates while operating within tight tolerances. Rock generated on site was processed through 90,000 cubic yards of crushing operations, allowing material to be recovered and reused as engineered fill—reducing import needs and strengthening the overall foundation system.
To support the deep cuts and elevation changes across the site, Thalle installed earth-retention systems designed to stabilize slopes, protect workers, and maintain long-term grade integrity. Comprehensive erosion and sediment control measures were implemented from day one, ensuring compliance with state environmental regulations and protecting downstream waterways during high-volume earthwork operations.
The early-work scope also included construction of new access roads, enabling efficient haul routes for mass excavation and providing long-term connectivity for plant operations and future construction phases. Through careful sequencing, haul-route planning, and stormwater management, Thalle maintained safe, continuous production even as earthwork operations advanced across multiple work fronts.
This large-scale site development package laid the groundwork for CertainTeed’s new manufacturing facility, ensuring a stable, well-engineered platform ready for major industrial construction. The project showcases Thalle Construction’s ability to manage high-volume excavation, complex geotechnical conditions, and aggressive production goals—delivering the precision, reliability, and coordination required for today’s industrial megasite developments.
