Welcome to the Breckenridge
FactoryTour
The Breckenridge 120,000-square-foot park trailer manufacturing
factory is located on 14 acres of beautiful countryside in the heart of Amish
country, Nappanee, Indiana. Our state-of-the-art facility combines sophisticated
equipment, and innovative manufacturing technologies to assure a high degree of
quality and structural integrity. We are currently making plans for our next
expansion which will almost double the size of the current facility and ensure
our ability to keep up with the ever-growing demand for innovative high quality
products.
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Facility Design
The advanced design and organization of our modern plant assures
that all of our park models will be manufactured quickly, efficiently and
safely. Our extremely high ceilings accommodate over a half million-dollar
investment in overhead bridge cranes and mechanical hoists that further increase
efficiency. And excellent lighting increases visibility and enhances the safety
of our skilled workers.
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Floor Construction
The strength and durability of each of our park models depends
on a strong foundation. Our floor gives each unit a rigid base for strength and
long-lasting performance and assures that there is a square foundation to build
on. Our process of building all of the major components, like the floor,
sidewalls and roof, on a table in one piece affords extraordinary control of the
manufacturing process. This process is extremely efficient and assures
structural integrity and high quality in all of our products.
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Floor Construction
Every Breckenridge product starts with a solidly built floor. A
double 2-inch x 6-inch perimeter beam frames in the other 2-inch x 6-inch floor
joists. Full width sheets of 5/8-inch plywood decking provide a sturdy
foundation for the rest of the unit. Our unique one-piece floor construction
lets us complete the insulation, plumbing and heat ducts efficiently and
skillfully.
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Floor Construction - Frame
Using our giant bridge cranes, the completed floor is carefully
hoisted off the construction table, then lowered onto the steel I-Beam frame.
Each frame is custom designed for a specific floor plan. This is an excellent
example of how the bridge cranes save time, assure smooth installation and help
to provide excellent structural integrity.
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Carpet Installation
Once the floor is bolted to the frame the next step is one you
get to participate in the selection of flooring. We offer several choices in
carpet and padding, including multi-shaded 26-oz. standard carpet or a 36-oz.
deluxe plush carpet. We also offer a durable Berber with a residential carpet
pad. In the kitchen, bath and in front of the rear entrance we recommend
linoleum or optional hardwood. The linoleum comes in two styles, a wood look and
the standard style, a stone tile pattern. Every Breckenridge is built
to a high standard.
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Sidewall Construction
Our sidewalls are built with all 2-inch x 4-inch studs on
16-inch center, we use double studs at all corners and around window and door
openings. These openings feature true laminated header beams ensuring strong
square openings. This is much heavier construction than the average travel
trailer. An important side benefit of the thicker sidewall is the added room for
insulation. As mentioned before, each wall is built on a construction table
allowing for more efficiency and control of the manufacturing
process.
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Sidewall Construction - Mounting
Our giant crane lifts the completed sidewall and positions it on
the finished floor with the help of one or two of our employees. Many
manufacturers still do this manually, using up to fifteen people to lift that
wall and get it mounted to the floor. Our advanced methods are much safer and
more efficient. Remember the 4-inch perimeter beam in the floor under the
5/8-inch plywood? Well, the sidewall is placed right on top of that beam and
secured. So it is a 4-inch sidewall mounted on a 4-inch beam, helping make it a
structurally sound product.
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Sidewall Construction - Insulation
After the sidewall is installed, all the electrical wiring is
run. Notice the metal plates covering the wiring at each stud— they protect it
from any siding nails that could cause a short in the electrical system. Each LE
sidewall has a minimum of four horizontal stringers fastened into the studs
adding extra strength and a solid surface on which to attach the siding. Glue is
sprayed on the sidewall and the insulation is fixed into place, this prevents
the insulation from gapping or sliding especially during transportation. These
small details play a big role in the overall performance of a Breckenridge
product.
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Sidewall Construction - Flexfoil®
Before siding is attached to the exterior of the park model
unit, premium Flexfoil® insulative wrap is installed. Flexfoil has a published
R-value of 6.2 when added to a sidewall, making the sidewall of our 12-foot wide
products R-17.2. It is standard in all 12-foot models and optional in all 8-and
8.5-foot wide models. It is also a great wind and water barrier in the sidewall.
It is installed in a full 7-foot tall sheet that is rolled out around the unit,
then the windows and door ways are cut out, causing minimal seams in the
process.
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Roof Construction
All Breckenridge roofs are built in a special custom-designed
roof jig to insure accuracy and structural integrity. The roof jig is positioned
at the right pitch and ceiling tiles are placed on it. Then the truss rafters
are secured in the jig every 16-inch and a spray foam adhesive is applied at
each rafter. This adhesive becomes like cement when dry, making for a very
strong roof. The fascia board is added to the outside edge and the roof is ready
to be placed on the park model.
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Roof Construction - Mounting
The roof is then manouvard and placed on top of the partially
constructed unit using a double-hoist motorized bridge crane. This unique
procedure assures that the roof remains square and true with a minimum amount of
flexing or stress during the installation process. As the roof is placed on the
unit it slips down over the top edges of the sidewalls (like putting a lid on a
box) this helps hold everything together, so nothing can shift, especially
during transportation.
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Roof Construction - Strengthening
After the roof has been installed and secured, the five step
roofing process begins. First, insulation is laid in the roof cavity. Then
9/16-inch Wheryhouser® Structurewood® sheathing is installed. The next step in
the process is placing Ice Guard Roof Edge Treatment around all vent and/or
skylight openings, any dormer area (which is a flatter area), which prevents
water leaks. Ice Guard is also optional along the edges of the roof. It
effectively keeps ice and water from backing up under shingles and damaging the
roof decking. Shingle paper is then placed over the entire roof. The final step
is the roofing material itself, and the choice is yours. We offer a standard 25
year 225-pound asphalt shingle in five different colours, or you can pick from
four colours of optional architectural look shingles. We also offer a 29-gauge
steel roof (pictured) in six colours.
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Roof Construction - Final Touches
We give special attention to the details of our roofing process.
Attics are properly vented ensuring long life for the roof structure, and 6-inch
wide maintenance free aluminium fascia finishes the edges. The roof is then
carefully inspected for quality workmanship, and the first several feet of the
roof is covered to prevent shingle damage during transportation. As the roofing
is being done there are several other Breckenridge employees working on the
siding and still others working on interior details, like cabinetry and
trim.
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Roof Construction - Final Touches
We give special attention to the details of our roofing process.
Attics are properly vented ensuring long life for the roof structure, and 6-inch
wide maintenance free aluminium fascia finishes the edges. The roof is then
carefully inspected for quality workmanship, and the first several feet of the
roof is covered to prevent shingle damage during transportation. As the roofing
is being done there are several other Breckenridge employees working on the
siding and still others working on interior details, like cabinetry and
trim.
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Siding Installation
Before the siding goes on, a weather-tight seal is installed
around the windows and other openings for maximum protection from the elements.
Vented soffit material is used under all overhangs to allow proper air flow
through the attic. Premium vinyl siding is now affixed. The standard siding on
our LE park model units is .046-inches thick for extra strength, durability and
low maintenance. It comes with a limited lifetime warranty. The standard siding
comes in six different colours in our LE series and three colours in our SE
series. We also offer real cedar log siding for a quaint rustic look, and if
that is not enough to choose from, take a look at our vinyl cedar shake siding.
See your dealer for details and samples.
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Interior Decorating
Each unit is thoroughly inspected as it approaches the final
stages of completion. At Breckenridge we realize that the two most important
assets we have are our customers and our employees who build our products. Many
of our employees have been with us since our early days. They have become
familiar with the expectations of our customers because of their long
experience. While we do not consider ourselves a custom builder, we offer such a
wide array of floor plans, options and colours that you will have the feeling of
creating your own custom coach. But without the high cost of a true custom
builder.
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Quality Inspection
Each unit is inspected in several different areas. First for
quality workmanship—checking fit and finish of things like trim and cabinetry.
We also double-check all options to ensure the unit was built to order
correctly. We also take it through a multi-point systems check, running gas
through the lines and lighting the range and furnace. The water system is also
checked by filling the sinks, tub and drain lines. All these checks help us find
any problem before it leaves our factory. Every unit must adhere to the ANSI
119.5 standard for recreational park trailers, which cover important details
like fire, life, safety and structural codes. These extreme measures mean you
will receive a quality product that will afford you and your loved ones years of
enjoyment.
Breckenridge’s pledge to you is that we will endeavour to do
what is right every time.
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Camping 
