PowerLags for Strength and Efficiency

By  Robert Knecht

Lake Geneva, Wisconsin is known for its scenic lake views and custom waterfront homes. The idyllic Midwest town boasts an abundance of recreation and entertainment choices and has attracted builders hoping to capture a piece of the luxury homebuilding market.

Among them is Lonergan Builders Inc., a residential builder based in Antioch, Illinois, that has specialized in custom home building and remodeling for over 25 years. As they continue to expand beyond northern Illinois and into southeast Wisconsin, building trust in and forging relationships with existing players is a priority.

On the shores of Lake Geneva, Wisconsin, Lonergan is building a massive custom residence spanning nearly 7,900 square feet, including a primary home, a pool and a pool house. With the project’s large footprint and tight timelines, the team faced challenges common to high-end builds in the region.

“If the quality isn’t there on a showcase project like this, you’re not going to get more work,” explains Lonergan. “On these large projects, we need every tool and fastener to work reliably and efficiently to get the job right the first time to keep our customers happy.”

Inside the Structural Fastening Decisions Behind a Large-Scale Lake Geneva Showcase Home

He notes that on a property and home that size, speed, structural integrity and efficiency required a fastening solution that is strong, reliable and easy to work with—and that will keep the job moving. Lonergan and Steve Albert, a veteran carpenter, both recognized early on that traditional lag screws could slow down the project and introduce variability that they just couldn’t afford on a project of this scale.

Framing a large custom home of this scale demands structural fastening that can withstand heavy loads, maintain tight tolerances and handle multi-ply LVL (laminated veneer lumber) and microlam (engineered wood) beams.

Supply Chain and Site Constraints

Coordinating the building schedule and material deliveries for a large custom home is inherently complex, but that was heightened by supply chain disruptions. The delivery of second-floor trusses was delayed by more than six weeks, interrupting what is typically a smooth progression from one phase of framing to the next. A relatively tight lot added more logistical pressure, since the staging space was limited and required a careful sequencing of work. Overall, the flow of the project wasn’t smooth for reasons that were out of the builder’s control.

Still, they had a timeline to meet. Lonergan says, “The work still has to get done, so you adjust.” He focused on aspects of the project that he could control, such as execution speed and minimizing rework, to make up time once the materials arrived.

Recovering Time

A key area where the team made up time is fastening. Homes of this scale rely heavily on a mix of standard building products and engineered lumber. While engineered products provide strength and predictability, they are not immune to basic construction challenges. Beams are not always perfectly straight, and assemblies must be drawn tightly together to maintain alignment and load transfer.

Albert added that quality begins with the tools and materials. “Lumber isn’t perfect; every piece is different, so having the best hardware and tools we can get makes a big difference in how we work with it,” he explains. “Quality is number one and if you start a project right, it’s going to end right.”

Lonergan Builders treated structural fastening as part of the framing system rather than as an afterthought. On this home, the SPAX PowerLags made a big difference for beam connections, wall tie-ins, and ledger attachments. Designed to boost performance, they feature a large-diameter T-STAR Washer Head that delivers strong clamping force while sitting flush against the lumber. The patented thread serrations eliminate the need for pre-drilling, which saves labor, time and provides a clean finish. For added durability, PowerLags are plated with HCR (High Corrosion Resistance) double-barrier coating to support long-term performance in demanding structural applications.

“They pull things tighter than other screws,” says Lonergan. “Anytime we’re putting multiple plies of LVL together, they’re not always straight. A few SPAX screws will literally suck them in tight. They start and drive fast, with very little effort.”

Because they require no pre-drilling and drive faster and easier than conventional lags and other structural lag screws, it was a choice that meant one less failure or delay to worry about.

Albert agreed, emphasizing PowerLags’ performance in challenging uses. “It’s a thicker, stronger screw,” he says. “The PowerLags pull them tight and true, and I haven’t had one break.” Performance on the jobsite ultimately determines whether a product becomes a standard.

Local code requirements in southeastern Wisconsin mandate either 6-inch truss screws or hurricane clips at rafters. Lonergan Builders consistently opts for truss screws for performance and labor efficiency.

“I can have one person install truss screws exponentially faster than using traditional clips,” Lonergan says.

On a project where the schedule has already been disrupted, that time adds up. Premium fastening solutions allowed the crew to move quickly through the framing phase while upholding the level of craftsmanship and quality that they’re known for.

“This is now our go-to for framing, especially when you have these massive lake homes,” says Lonergan. “You need quick, strong premium lags that don’t strip out. PowerLags are the best structural screws we’ve used for pulling together microlams, LVLs, 2x12s, and anything we need to tighten up.”

Winning Repeat Work

Lonergan Builders treats every project as if it were their own home, making premium fasteners an essential part of their process. “We use SPAX lags and screws almost daily, depending on the scope of work, and I’d never go against what they do for us,” says Lonergan. “Quality is our goal and we just can’t have breakage and difficult drives slowing us down.”

The custom Lake Geneva project achieved an outcome bigger than the expansive home: It validated Lonergan Builders’ approach with a new general contractor. The builder is now working with the same general contractor on another project.

“Things ended up going well,” says Lonergan. Despite challenges and fierce competition, the team delivered another mark of quality on the Lake Geneva market.”