Investing Through Uncertainty: Boise Cascade's Capability Bet Pays Off for Builders

Sky-high borrowing costs, policy whiplash, shrinking margins, declining consumer sentiment, and waning spring sales momentum ... American homebuilders face some of the most punishing conditions in recent memory.

Boise Cascade Company is doing something that cuts against the grain: doubling down on long-term capability.

In an era of uncertainty, it’s a bet that could make the difference between operational fragility and future-proofed resilience for homebuilders.

In a new TBD Player videocast, Boise Cascade Senior Vice President of Engineered Wood Products Sales and Marketing Robert Johnson breaks down what the company’s $140 million investment in engineered wood manufacturing capacity means not just for Boise Cascade — but for builders across the country fighting to stay efficient, predictable, and profitable.

Watch the full interview with Robert Johnson on TBD Player: "Investing in Capability: What Builders Need to Know About Boise Cascade's Strategic Mill Improvements."

What Builders Need to Know Now

If you consider the billion dollars invested over the last three years in engineered wood capability and capacity improvements," Johnson says, "it goes back to our long-term commitment to ensuring veneer supply, reliability in our plants, and the ability to serve customers when and where they need it most."

The company’s strategic investments at its Oakdale, Louisiana and Thorsby, Alabama facilities are just the latest phase of a broader, multi-year effort. These initiatives follow Boise Cascade’s acquisition of Coastal Plywood—a move designed to secure self-sustaining veneer production and reduce risk across the system.

The word Johnson emphasizes is reliability. That means investing upstream in raw material security, downstream in delivery capabilities, and directly into new technology like precision manufacturing and value-added EWP solutions.

Capability, Not Just Capacity

It’s essential to note Johnson's distinction: This is not simply about more volume. The company carefully frames these moves as capability improvements rather than expansion projects. Why? Because the priority isn’t just to increase output—it’s to make output more dependable, more efficient, and more aligned with how builders work today.

The Thorsby plant, for example, will soon be home to the first new I-joist production line installed in the U.S. in decades. The Oakdale mill, one of the country's oldest continuously operating plywood facilities, is undergoing full-scale modernization, with new log-handling systems, dryers, presses, and layup lines.

We've refurbished the green end. We’re bumping motors on new dryers and firing up new presses," Johnson explains. "This isn’t just about adding machines. It’s about ensuring the highest-quality EWP comes out of the best-performing mills in the system."

Strategic Geography, Nationwide Impact

Some might assume that these Southern plant investments only benefit Southeastern builders. That would be a mistake.

Boise Cascade’s manufacturing footprint is national, stretching from the Southeast to the Pacific Northwest and up into Canada. And thanks to supply chain integration and fungible product specs, increased reliability at Oakdale and Thorsby means greater delivery stability as far west as Colorado, Utah, and California.

These improvements allow our mills in the East to reach further West," Johnson notes. "That, in turn, frees up capacity in Oregon and Idaho to support other Western markets."

What Builders Can Expect

The timing is just as strategic as the geography.

Oakdale’s modernization is nearing completion. Within weeks, the facility will begin ramping up production, with the first wave of veneer feeding into Boise Cascade’s Alexandria EWP mill for the 2025 building season.

Thorsby’s new I-joist line is scheduled to go live in early 2026. Once online, it will diversify production risk, increase resilience, and make more I-joists available to high-growth East Coast and Southeast markets that have experienced recurring supply challenges.

A Broader Business Commitment

Johnson brings more than technical insight to the conversation. With a background that spans operations, finance, sales, and multi-site management, he sees the big picture.

Boise Cascade is not just an EWP manufacturer. We're a distributor with 40 owned branches and a vast third-party network. We’re a solutions partner with SawTek precision tools, pre-cut systems, and optimization software. Our goal is to take waste off job sites, reduce cycle time, and increase quality."

Builders are battling for margin everywhere: absorbing costs to keep buyers in the market, subsidizing mortgage rates, and juggling delayed starts due to labor shortages and permit bottlenecks. Boise Cascade’s approach—making structural systems more predictable, automated, and reliable—adds real-world value.

Why This Matters Now

The broader economic context underscores the urgency. The University of Michigan’s latest Consumer Sentiment Index hit 50.8 in early May—the second-lowest reading ever recorded. Inflation expectations have surged to 7.3%. Tariffs are adding upward pressure to material costs. First-time buyers are aging out. Builders offer discounts and rate buydowns that now exceed 8% of the average home price.

In this environment, there is no room for inefficiency. Every misstep, job site delay, out-of-spec joist, or missed delivery threatens a builder’s ability to close a deal.

That’s why the kind of investment Boise Cascade is making matters more now than it would in a bull market. As Johnson puts it,

It’s our job to help builders take dollars out of the dumpster and put them back into the house."

This isn't just manufacturing. It’s risk management, operational insurance, and strategic alignment with the builders Boise Cascade serves. Builders who align with partners making these bets on capability are more likely to weather the present storm—and come out stronger on the other side.