Automotive

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SSOE was selected by Continental AG to perform engineering, procurement, and construction management (EPCM) services for their new 215,000 SF state-of-the-art manufacturing facility located in New Braunfels, Texas. The plant manufactures products for Advanced Driver Assistance Systems (ADAS) that will help with assisted and automated driving. With ADAS in high demand by car manufacturers, this new facility positions Continental to expand its U.S. research and development footprint and manufacturing capabilities.

The new, future-oriented greenfield campus includes a production facility, office space, warehouse, guard shack, technical building, and cafeteria. The project also included campus infrastructure, integral roads, parking, truck docks, and other site requirements. The innovative, edgy design of the facility integrates with its environmental surroundings and fits the needs of a modern-world production environment.

A high priority for Continental, the facility was designed as a model for energy efficiency and sought LEED® Silver certification upon completion. To help the client meet this goal, SSOE capitalized on our extensive LEED certification experience and our vast network of LEED Accredited Professionals to help formulate a design strategy that fulfilled the client’s sustainability needs and expectations. This included an energy-efficient building shape and innovative solutions in building technologies. The project ultimately received LEED® Gold certification.

SSOE has extensive knowledge of Continental’s specifications and project execution preferences and has delivered successful facilities to them for over a decade. Our recent experience working together on Continental’s “Greenfield Plant of the Future” in Central Mexico was instrumental in leveraging lessons learned to drive efficiency into the facility design.

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SSOE’s design of vehicle and powertrain manufacturing facilities returned more than the total fee in construction savings when compared to the competition’s design for the same facility.

Toyota has utilized SSOE as their trusted A/E partner of choice since 1999. SSOE’s structural department has consistently designed facilities for Toyota that could be constructed for less than any of their competition in the market place, regularly designing much closer to the actual service factor. SSOE consistently delivers on schedule for Toyota, and the number of errors and omissions experiences is much lower than what they had seen with their previous engineering services providers.

With these factors in mind, it was an easy decision for Toyota to select SSOE to provide the design to double the size of their automobile manufacturing plant in Princeton, Indiana and for their greenfield facilities in San Antonio, Texas and Tupelo, Mississippi.

In Indiana, having gained an understanding of Toyota’s goals and needs from previous projects in France, SSOE provided architectural / engineering services for an addition to the existing factory space to double the assembly plant.

In Texas, SSOE provided the facility design for a greenfield truck assembly plant on a 2,000-acre site that included suppliers. SSOE also provided on-site engineering staff to Toyota’s Owner’s Representative Office (ORO) to support the construction efforts and coordinate the design documents during construction phases.

In Mississippi, SSOE performed the master planning and design of the plant, as well as provided on-site engineering staff to Toyota’s Owner’s Representative Office (ORO) to support the construction efforts and coordinate the design documents during construction phases.

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Ford, our oldest client and one of America’s top electric vehicle brands, recently awarded SSOE the design of a new assembly plant—named the Tennessee Electric Vehicle Center, part of Ford’s BlueOval City manufacturing complex—which resides on the West Tennessee Regional Megasite. This exciting new complex will become a vertically integrated ecosystem where Ford will assemble its next electric truck and batteries for future Ford and Lincoln vehicles.

Together with Walbridge as our construction partner, we’re executing the project under a design / build contract. In addition to the 4 million SF building design, we’ve been chosen as the engineer of record for the entire site design of the 4,000-acre mega campus. Our full scope of work includes preconstruction documents and detailed engineering as well as construction administration. Our team used the most innovative technology available to provide regular updates throughout the design process, with major deliverables scheduled out in advance for reviews and contractor use.

At its peak, SSOE assembled a dedicated team of more than 60 full-time employees to support the detailed design phase of the project. A project win for SSOE in several ways, this complex will also significantly support electric vehicle production in the Southeast U.S. and create close to 6,000 new jobs in Tennessee. Groundbreaking took place in May 2022 and Ford plans to begin production at BlueOval City in 2025.

On-Site and Full Circle
Our work on the West Tennessee Regional Megasite—formerly known as the Memphis Regional Megasite—actually dates back to 2007. SSOE worked with the State of Tennessee to develop the site and provided ongoing support as potential clients evaluated it. We were also involved with water and wastewater infrastructure projects specific to the site for over a decade. Worthy of note, SSOE provided the civil design of Ford’s BlueOval roundabout, an idea we presented to the client that makes Ford’s signature emblem shape—originally used to advertise Ford as the “hallmark for reliability and economy”—visible from the air.

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SSOE is proud to be Toyota’s engineering and design services provider for their BEV production facility on their 1,800-acre campus in Liberty, North Carolina. The new Toyota battery campus is currently in the design phase and will be constructed in phases over the next several years. This important investment for the Toyota Battery Manufacturing, North Carolina mega site further extends the 20+ year successful relationship between Toyota and SSOE.

SSOE is providing architecture, engineering, and on-site technical staff for the ambitious build, currently approximately 2.5 million SF of design is under construction. At full buildout, the project scope includes multiple BEV production lines with associated support buildings. In addition, Toyota continues to explore new energy savings opportunities for battery production at the campus in an effort to reach their long-term goal of carbon neutrality for its vehicles and operations by 2050.

Toyota’s robust campus vision includes the potential for a childcare facility, healthcare facility, and fitness center with associated outdoor sport courts. Adjacent to the team member amenities a park-like setting containing walking paths and green space is also under consideration.

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Through value engineering activities within the assembly and stamping areas, we provided more than $8 million in cost savings to Toyota.

SSOE provided design services for Toyota’s San Antonio plant, which spans more than 2 million SF, and continues to provide services for multiple projects as the facility grows. Our familiarity with the plant, on-site construction support services, and responsiveness make us a valuable asset to Toyota. Based on our intimate knowledge of this facility and our successful long-term working relationship with the client, Toyota selected SSOE as the A/E firm of choice for this program.

A number of factors drove this significant program. Changes to the Toyota Tundra model required a different assembly footprint to accommodate new options. Additionally, Toyota moved Sequoia production from their Indiana plant to San Antonio. This relocation called for alterations in multiple areas to house the new line. SSOE provided all architectural and engineering design services, including on-site representation and permitting for this program.

Our team leveraged technologies such as laser scanning, Cintoo, SharePoint, and Plangrid for file sharing and construction administration.

In total, the program affected eight plant areas including stamping, welding, Forma (an on-site supplier who shares space within the plant), Avanzar (an on-site supplier who feeds the assembly shop), Vuteq (a Tier 1 supplier), assembly shops, the east parking lot, and the dock area. Using a staggered approach with a significant focus on schedule, we coordinated the expansion of multiple areas simultaneously. Our team utilized non-production times to complete work without halting production.

SSOE coordinated a revised process layout for the assembly shop expansion, positioning noncritical spaces to the west and maintaining the roof pitch from the existing area to the new expansion. These value engineering measures eliminated the need for a step-up in the roof, new roof drains in the existing roof, new storm drainage piping, and existing structural member reinforcement to mitigate water ponding. These creative design concepts provided Toyota with savings of approximately $750,000.

For the stamping shop expansion, we began with a compressed air usage study. The results showed the existing system could support the new laser weld process with minor piping modifications. This discovery eliminated the need for a utility building expansion and associated equipment, providing a cost savings of $5 million. We continued value engineering within the stamping shop with our approach to the sheet receiving area. As sheet receiving is critical to the stamping process and cannot be shut down for an extended time, we developed a construction sequencing plan to reconfigure delivery to the area. This plan allowed the area to remain functional, saving Toyota approximately $2.5 million in lost production costs.

SSOE successfully executed this program though the strategic coordination of projects led by an experienced project manager and team with intimate knowledge of the entire facility. Our team collaborated with the client daily and leveraged on-site design reviews with the affected process groups to ensure our designs met their business needs and goals.

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SSOE was able to identify and suggest a 1/3 reduction in overall equipment costs for Phase II— translating to nearly $1.5 million in savings for the client.

To meet growing demand, a well-known electric vehicle manufacturer formed a strategic partnership with a leading battery manufacturer to construct a factory to manufacture electric motors and battery packs. The facility is being built in two phases, with the second phase involving the installation of additional battery production lines and associated utility system upgrades. SSOE was selected to provide engineering and design services for the second phase.

This project was uniquely challenging. Merging the battery manufacturing client’s improved technology with the vehicle manufacturer’s ongoing production capacity increase in one shared facility created a need for simultaneous site and equipment upgrades. SSOE’s cross-functional team assisted with planning all aspects of the expansion, virtually eliminating the risk of design gaps. Using this cross-functional team dramatically improved the holistic design and minimized issues in the field.

SSOE provided support for the following critical functions:

  • Utility Systems. Our team assessed system capacities, including compressed air, cooling water, dry room design alternatives, and production environment baselining. Once we understood these systems, we were able to determine which needed additions and/or modifications. Our focus then turned to the details around battery manufacturing. Beginning with raw material flow analysis, we then followed with space planning to ensure the production equipment would fit. The team confirmed that proper maintenance and utility spaces were incorporated into the design and that the equipment was in working order. SSOE also provided regeneration options for site HVAC systems and all water and water cooling systems.
  • Safety. With safety at the forefront of all projects we execute, our team provided chemical process analysis and confirmed proper permitting and certification for chemical usage in various manufacturing steps. We also ensured overhead clearances, aligned beam attachments to catwalks, and confirmed proper electrical, egress, and operational clearances. SSOE’s design assured both people and equipment could move safely throughout the facility.
  • Site Stability. SSOE’s structural team inspected site supports and analyzed how the equipment operated to ensure proper anchoring for safety and successful long-term production. Our team recognized that previous equipment installations had been insufficiently anchored, which caused damage to the slabs and cracked the foundation. We were able to mitigate these issues and provided suggestions for improvement. Additionally, SSOE partnered with both clients at the project onset to align on the optimal project approach. Through close collaboration during the construction and procurement stage and supporting the trade bid process, SSOE helped reduce overall equipment cost by about one-third of the project budget, translating to about $1.5 million in savings. With additional battery production lines slated for installation in the near future, SSOE’s practices will be replicated, with better documentation and a strong basis of information to copy, which will result in future operational savings.
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Nissan North America commissioned SSOE to provide the design of its new automotive assembly facility in Aguascalientes, Mexico. This 1.9 million SF facility is the first of three project phases planned for the greenfield site. SSOE delivered this fast-track project in partnership with Yates Construction, who served as the prime general contractor and provided at risk construction services for the manufacturing plant. The plant was designed, constructed, and placed in production within 22 months.

SSOE was responsible for the entire assembly plant layout and subsequent design of the automotive manufacturing campus. The project involved multiple buildings to be completed simultaneously, including more than 300 acres of developed land, a stamping facility, body assembly shop, paint shop, and final assembly area. Additional facilities were designed to support the manufacturing system, such as an electrical switchyard; water pretreatment, wastewater treatment, and stormwater systems; and a fire protection system, including storage tanks.

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SSOE worked with Nikola Corporation, a leading designer and manufacturer of heavy-duty commercial battery-electric vehicles (BEV), fuel-cell electric vehicles (FCEV), and energy infrastructure solutions, as a design partner for their new manufacturing facility in Coolidge, Arizona.

Now complete, the zero-emissions facility has the capacity to produce Class 8 commercial semi-trucks. The facility features in-house offices, conference rooms, and support facilities which showcase Nikola technology and culture.

As part of the initial facility master planning, SSOE provided a conceptual site layout and arrangements for the envisioned facility, including block diagram floor plans. Our team presented a conceptual artistic rendering for the exterior facility design in its surroundings to provide a realistic representation of the proposed facility, drawing from examples of desired building aesthetics provided by Nikola.

The SSOE / Walbridge team helped the Phase 1 master plan vision into a reality by providing design and construction management services.

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A well-known electric vehicle manufacturer sought to build a new greenfield facility to produce compact sedans, SUVs, and pickup trucks. Based on previous successes with this client, SSOE was selected as the structural Engineer of Record (EOR) for this project. We provided full structural engineering and design, in addition to fire protection code review and permitting for the 500,000 SF multi-level general assembly shop and paint shop areas of the new facility.

Our staff integrated with the client’s engineers and other consultants early in the project. The team executed the project using an owner-directed construction approach, involving a hybrid EPC delivery method with a hyper fast-track schedule. The schedule required the seamless hand-off of steel detailing packages among design, procurement, and construction teams. To maintain a constant and organized workflow, SSOE leveraged native Revit functions to code and communicate all activities. Our practice ensured each group was continually aware of what was being released to them, resulting in little to no rework, as we reviewed and released each coded piece for the next step in real-time. Proven effective, our method was shared with other design consultants and the client’s structural modeling team as a best practice.

In addition to the efficiencies gained through Revit tools, SSOE also committed to a 48-hour turnaround time on shop drawing reviews to meet the project schedule. This proved challenging, as some steel submittals consisted of more than 200 pages with multiple submittals per week. To meet this goal, we utilized SDS/2 (Structural Detailing Steel) software to enable 3D model-based shop drawing reviews. Leveraging the model gave the project team and stakeholders the ability to closely analyze the design, streamlining the review process.

This project’s intricate delivery approach and expedited schedule required innovation and agility in its execution. Our ability to drive efficiency through the use of technology and seamless collaboration with the project team was key to its successful delivery. Based on SSOE’s continued performance with this client, our structural team was selected to design the facility’s warehouse, while our architectural team was selected to design the cathode building.

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This well-known automotive client set an aggressive goal of producing mostly electric and autonomous vehicles by 2035. To achieve this, the client developed a plan that centers around converting multiple Internal Combustion Engine (ICE) manufacturing and assembly facilities to all-electric vehicle plants and spans several locations throughout North America.

Partnering with multiple general contractors, SSOE provided the engineering and design of substantial renovations and expansions for two facilities. To drive efficiency, the collaborative team leveraged Lean project delivery methods on every project.

The team and client stakeholders used the Big Room concept and remote collaboration to review the proposed facility additions, connections to existing buildings, concepts for new program elements, and stand-alone greenfield manufacturing construction. All sites employed a fast-track schedule, relying on innovation and technology to quickly move the projects from planning and design to construction.

The team’s first project focused on engine, body, paint, and general assembly shops, in addition to process buildings, a commercial kitchen, and an employee cafeteria. SSOE and its partners kicked off the project with an in-person Big Room collaboration meeting. However, three months later, all team members were forced to work remotely due to COVID-19. To keep the project on track, SSOE implemented an on-site construction administrator and daily virtual huddles.

At the second site, SSOE designed major plant additions, including new body and paint shops. The project included a nine-bay dock addition to the general assembly shop and a three-bay addition to the current body shop, with a connector trestle spanning over a road. Our team also designed the structural reinforcement of many existing buildings to accommodate the heavier electric vehicles. Additionally, we relocated the facility’s main access road to provide space for the paint shop addition and other utility tie-ins within the existing plant.

Throughout these projects, SSOE gained significant knowledge and insight into the process of converting ICE facilities to EV producing plants, which we will leverage as we continue to assist this client with its program.

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SSOE was selected to provide planning, design, and owner representative services to GEDIA Automotive Group for their new advanced manufacturing facility in Dalton, Georgia, with operations expected to begin in the third quarter of 2021.

In the Dalton plant, GEDIA will produce lightweight body-in-white automotive parts and assemblies, as well as chassis components using state-of-the-art press hardening, tempering, and automated welding processes, to produce parts for electric vehicles. The German company manufactures parts for Volkswagen, BMW, and Mercedes vehicles and currently has one operating U.S. plant in Michigan.

GEDIA selected design / build as the project delivery method for this 185,000 SF greenfield facility. SSOE’s scope includes providing an early grading package, master plan and comprehensive bridging documents, assistance to GEDIA in the design / build contractor selection, construction administration, and on-site owner’s representative services. SSOE disciplines involved in the project include project management, architectural, civil, electrical, fire protection, mechanical, and structural.

The construction timing was essential to the process equipment installation. Per an agreement between GEDIA and the general contractor, SSOE was selected to develop the final construction documents for the entire manufacturing facility project.

With GEDIA, SSOE is supporting yet another European-based client expansion in North America, specifically to the ever-growing Southeast region where SSOE has a local presence and expert resources.

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As a part of the agreement with Volkswagen, the State of Tennessee funded the $40 million dollar investment for the new Volkswagen Academy. The Academy sits on top of a hill, looking down at the actual plant, and is connected via an enclosed pedestrian bridge. The parking area at the Academy also serves as the main parking lot for the factory.

The Academy was designed to be a state-of-the-art training center for preparing workers for their jobs at the new factory in Chattanooga, Tennessee. The Academy is operated in conjunction with Chattanooga State Technical Community College with the support of other local universities and educational facilities. Most of the Academy is surrounded by windows, allowing natural lighting throughout the structure, and included the use of daylight sensors to maintain appropriate lighting levels.

Volkswagen Academy is approximately 153,000 SF, which includes a lean manufacturing center, a manufacturing and automation center for basic and advanced training, and an automotive training area. The training simulates all aspects of the manufacturing process, but on a smaller scale to allow for hands-on training. The facility includes 19 classrooms, a cafeteria, a gift shop, a coffee shop, and a conference center.

The conference center houses a large, open auditorium area that can be viewed from not only the first floor, but also the office area above. This area has movable partitions to allow for individual conference rooms to be created. The conference center also includes a board room with adjacent meeting rooms.

The Academy achieved LEED® Platinum certification.

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American Axle & Manufacturing (AAM) turned to their strategic global alliance partner, SSOE to develop the conceptual design for a new state-of-the-art European Headquarters and Technical Center (EHQ). The EHQ serves to consolidate two existing AAM facilities formerly located in Bad Homburg and Dieburg, both in Germany, so employees can freely interact with each other with the goal of facilitating intensified idea generation, innovation, and product development.

The new facility includes spaces for product development and testing, labs, product display, corporate and engineering offices, cafeteria, and office support—accommodating for future expansion with shell spaces within the technical center. SSOE’s conceptual design scope included site and architectural plans, sections, elevations, and 3D images for the new facility as well as flow diagrams and conceptual design narrative for the building engineering systems. SSOE collaboratively engaged with AAM during the programming phase to understand current and future needs for the space as well as considerations related to individual workspaces for adjacencies, access, and resource sharing. Incorporating AAM’s standards for interior selections, our team helped locate all furniture and fixtures within the building, providing photorealistic interior renderings to present AAM with a clear visualization of the space.

AAM’s new EHQ reflects the company’s brand while integrating European culture through furniture selections, material selection, and use of natural light. As a focal point, the lobby entrance for visitors will serve as the public introduction—an impressive expanse of curtain wall and metal panel with accents of precast concrete and an entry vestibule with a custom canopy—connecting the office wings and technical center.

SSOE is not only responsible for conceptual design but also provided the permit design package and re-zoning to take the site from agricultural to commercial use with in-country consultant, Scalaplan GmbH, as well as approval of final design and on-site construction management services.

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SSOE was chosen to provide architectural, structural, civil, mechanical, electrical, and plumbing (MEP) design services for the expansion of Kenworth Truck Company’s (Kenworth) paint facility located in Chillicothe, Ohio. This state-of-the-art 120,000 SF paint facility is an addition to Kenworth’s Class 8 truck assembly plant which produces their T680, T880, and W990 models.

The new addition, located adjacent to the current 502,000 SF plant, will create nearly a 50% increase to the current paint capacity and is expected to be fully operational in 2021. SSOE is partnering with construction manager Rudolph Libbe Group on this project. Together, SSOE and Rudolph Libbe have completed numerous expansion projects at this same Kenworth site including the Chassis Abatement RTO system, Painted Parts Automated Storage and Retrieval System Penthouse, and the Robotic Build Cell.

SSOE’s knowledge of paint processes and requirements allows for successful completion of complex facility design projects such as this one.

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After assisting BOCAR, a German-owned leading Tier 1 automotive parts supplier, with selecting the location of their first manufacturing facility in the U.S., SSOE was selected to start work on the full design and permitting. A $115 million investment, the new 350,000 SF facility sits on a 72-acre site just off Interstate 65 and will produce high-end structural aluminum parts for automakers operating in the U.S. once construction is complete.

The location, with its proximity to a nearby rail line and Huntsville International Airport, offered ideal logistical conditions for our client, who supplies parts to all major automotive OEMs. During the site selection process, SSOE assisted in the thorough and technically complex evaluation of 45 potential locations spanning the Southeast U.S. Ultimately, Huntsville was selected due to the skilled workforce availability, AIDT’s training programs and facilities, favorable quality of life, and room for future expansion of the facility in Phase 1.

SSOE was selected to perform complete design of the facility based on our extensive experience with automotive and manufacturing facilities worldwide and portfolio of work in the Southeast U.S., which includes the ACEC award-winning Volkswagen plant in Tennessee. The close partnership developed with BOCAR during the site selection process provided our design team with a clear vision and the ability to deliver the state-of-the-art facility for which BOCAR is known. The new plant will utilize advanced manufacturing techniques.

SSOE is also providing permitting and construction administration services for the project. The new Limestone County facility, which is expected to be completed in September 2019, will generate more than 300 jobs with room to grow.

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SSOE provided architectural, interior design, and engineering services to support construction of a new 15,000 SF Welcome and Training Center for Transportation Research Center (TRC), the largest independent vehicle test facility and proving grounds in the U.S.

As the gateway to the TRC campus, the facility is the main welcome and access control point to the campus. The center includes informal and formal collaboration areas, conference rooms, project lab space, and office space for three user groups: TRC security, the Regional Plan Commission, and the Ohio State University (OSU) distance learning program, which supports academic liaison efforts via teaching and research.

Designed to accommodate meetings of all sizes, the welcome center includes small gathering spaces, distance learning facilities, and, for seminars and presentations, a large meeting room featuring state-of-the-art AV technology and space for presentation vehicles. Within the OSU distance learning area, the space is flexible and reconfigurable for project and team needs. The design of the space allows for both team based work and lecture based presentations. Height adjustable tables with plug and play power allows for the space to be one level, verses a tiered layout. Interior design highlights include some areas with exposed ceilings with acoustical clouds, the lobby ceiling is designed with metal longboard, patterned with wood, to add warmth to the area, custom casework design, and sealed concrete flooring.

Budget, visual appeal, and functionality were top design concerns for this client. SSOE incorporated a strong graphical approach, both inside and out, for an attractive, modern, cost-conscious design. Exterior design resulted in a brick and metal façade with a welcoming entry and a strong daylight component.

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SSOE has a long and successful project history with BMW, including initial architectural / engineering services for previous expansions at BMW’s Spartanburg assembly plant. Because we also have extensive experience designing training and technical centers for automotive clients, BMW selected SSOE to provide design services for their new Southern Regional Technical Training Center. Our expertise in this area has proven invaluable throughout the design and construction phases of this project.

The new technical training center includes five training units, each consisting of a practical workshop and a theory classroom. SSOE worked closely with BMW to design the new facility to their unique specifications, which includes automotive equipment, furniture, ICS equipment, data network, and IT cabling routing and requirements. Additionally, design for all necessary special structural supports required for mounting of automotive equipment was included.

SSOE’s electrical engineers completed the lighting, power, emergency generation systems, fire alarm, security systems, network racks, patch panels, and cable for telephone / data networks. Parking layout, civil engineering, and landscape design also included the design of carports to utilize BMW-provided solar panels. SSOE’s structural engineers completed the design of the foundations (including soils and sub-slab specifications) and our Data / Fire / Security design team performed audio visual system design for the classrooms and public address systems.

SSOE also provided architectural, interior design, mechanical, and cost estimating services. Our partner, Alliance Consulting Engineers, provided civil engineering and landscape architecture services.

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Permit requests done in parallel to reduce project execution schedule and meet permitting needs. 30% savings in energy use.

When the Anniston Army Depot (ANAD) and the United States Army Corps of Engineers (USACE) embarked on a project to consolidate the transmission remanufacturing process for all tracked military vehicles it serviced into a new, world class manufacturing facility, they enlisted SSOE to provide full facility architectural and engineering design services, as well as equipment migration design for the new facility.

As one of the top ranked firms in automotive facility design, SSOE brought state-of-the-art technology into an open floor plan, while modernizing and consolidating ANAD’s transmission remanufacturing program. This enabled a more efficient process flow from transmission disassembly through the cleaning process, to reassembly and testing.

The scope included design to support the relocation, installation, and point-of-use connections for more than 170 existing pieces of equipment from 13 buildings on the site. Additionally, more than 70 cranes, up to 10 dynamometers, and more than 30 pieces of new process machinery, both government and contractor furnished, were integrated into the facility. This project also incorporated the expansion of an existing 15kv switch yard to support the facility.

SSOE considered potential site constraints including Anti-Terrorism Force Act (ATFA) requirements, existing boundaries and easements, environmental permitting, and a concurrent USACE Cold Water Creek Relocation project, as well as project specific permits required to move an additional tributary creek flowing through the site. SSOE recommended that permit requests be done in parallel to reduce overall project execution schedule.

The facility, which is LEED Silver certified, also supports all applicable energy sustainability standards, including a 30% decrease in existing energy use, sustainable solutions for grass and landscaping, and the incorporation of natural light and high reflectant materials to minimize heat gain.

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Input from programming phase was used to eliminate duplicate space requirements and reduce the building footprint by 15%. Additionally, developed method to capture and reuse energy generated during dynamometer testing process throughout the facility.

To meet the market demand for new products in China, GM built its first Chinese R&D facility in Shanghai. This facility, which is the most comprehensive and advanced automotive development center in China, included areas for advanced vehicle development, powertrain design, electrical and fuel cell design, chassis, HVAC, body, exterior and interior development, and telematics. SSOE applied its vast experience in designing automotive R&D facilities, and familiarity with the Chinese design and construction process to deliver this high caliber, sustainable project.

SSOE designed an interior hydrogen fuel cell garage space, along with an exterior hydrogen fueling station and garage space. Special considerations, including distance from nearby high rises, were made during design due to safety considerations. Fuel farms were also integrated to provide for blending and testing operations for hydrogen-based vehicles and hybrids.

A significant design feature was a central garage space that separated the building into two halves. The central garage space functions as a central spine and serves as a common use area for multiple groups. It potentially allows groups to share tooling.

Another feature was a visually secure, exterior patio for GM to view vehicles in natural sunlight. This requirement created an interesting challenge since the site was located within city limits and near a multiple story building. SSOE designed a visual screen to obstruct the view from the building while still allowing the natural sunlight to enter the space.

SSOE provided an innovative design which minimized environmental impact, while maximizing occupant safety, health, and comfort. Design criteria also emphasized the use of sustainable materials and other energy reduction features.

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3D object models of the facilities and their utility infrastructure were developed and shared with the contracting partners proving invaluable in the design of the intricate routing of utilities between components in the facilities.

SSOE provided facility engineering and architectural services for two new paint shop facilities. 3D object models of the facilities and their utility infrastructure were developed using Bentley Structural, and sharing them with the contracting partners in DWG format. The object models proved invaluable in designing the intricate routing of utilities between components in the facilities.

SSOE and equipment vendors were able to study facility and process components in relation to their true magnitude. Clip volumes, perspective drawing, and isometric detail extractions aided in studying these complex relationships. From the piping models developed, SSOE used Bentley Structural’s drawing extraction feature to create several evolutionary construction details to delineate the complex routing and transitions of utility systems. These details passed the advantages of BIM to fabrication and construction members of the team.

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Created a detailed RFP and negotiated with multiple vendors to reduce material and installation costs, saving the client nearly $150,000.

SSOE’s in-house Data/ Fire/ Security (DFS) team designed data, fire, CCTV, security systems, and voice systems for a  500,000 SF Research and Development (R&D) facility. Several state-of-the-art video conference and projection rooms were designed, as well as a 3,250 SF, Tier 4 data center and back-up power system to support all of the data and server needs.

The data distribution system was designed with in-floor data communication ports and wireless connectivity. The building communication infrastructure was designed to standards far exceeding TIA/EIA standards. More than 150 networked interior and exterior CCTV camera were installed to monitor and protect the owner’s intellectual property. Placement of the cameras and video storage needs were evaluated and determined by SSOE with 3D modeling views provided for reference.

The team designed a fire alarm system that was integrated into the campus style fiber optic fire alarm network, CCTV system, and access control system. The office building’s paging, sound masking, and other notification systems were integrated into the consolidated head-end, so each system took the appropriate action during an alarm condition. SSOE teams designed a complete premier detection system for the facility with several detection devices, including motion detection and glass break sensors.

SSOE integrated sustainable design features which led the main facility to achieve Gold Level LEED certification.

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Negotiated with vendors and integrators as well as created a design and installation guide. This reduced costly overruns and saved the client approximately $200,000.

Volkswagen selected SSOE to oversee architecture, engineering, and construction management for its new greenfield production facility in Chattanooga, Tennessee. SSOE was responsible for the campus’ data centers, fire alarm system, access control, and CCTV systems.

The data center was designed with multiple cooling systems, power systems, and data routes for redundancy. In addition, a primary and secondary command and response building was designed, each with video walls and several communication pathways.

The campus includes ten, multi-level buildings that were connected in a Style 7 fiber optic network to eliminate communications gaps. The fire alarm system also serves as a mass notification system to alert occupants of all emergency classifications, interfacing with production-based equipment and other internal automation systems. In addition to the fire alarm system, a complete access control system was designed for several of the buildings in the complex. The entire system was designed to be monitored from primary and back-up on-site control rooms.

Cameras and monitoring systems were installed around the site and consisted of both analog and Internet Practical (IP) cameras. The CCTV system was connected to the fire alarm annunciator to allow the camera to locate and view a specific area in the event of a fire. The alarm within the facility will automatically be displayed on the video wall.

The fire alarm, access control, and CCTV systems were integrated together to provide for a converged system. If a fire alarm occurred it would unlock the respective access control doors for emergency egress and point cameras to cover the area in question. All systems were designed such that a common reporting method could be used.

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Within 36 hours, SSOE arranged and obtained aerial photography of an alternate project site.

In addition to designing this greenfield truck assembly plant, SSOE also provided site evaluation services for the 2,000 acre site. The project required a high level of confidentiality throughout the entire site evaluation process and SSOE worked with state and local economic development authorities to locate the potential properties for analysis.

Site services included evaluating topography, climatic conditions, severe weather potential, transportation, soils, hydrological, electric service, gas service, water service, wastewater treatment service, and rail service at various locations in multiple states in the central and South Central United States. SSOE evaluated project sites ranging from 1,800 acres to 2,300 acres. Site observation visits were performed on the preferred geographic locations. A site report was prepared along with supporting documentation for each site. To provide a ranking of each location, a summary matrix of critical attributes was presented to Toyota electronically for use by top management.

Utilizing 3D MicroStation design platform, SSOE electronically produced the architectural rendering for ground breaking announcements, press releases, and public relations purposes. Toyota also requested an additional site evaluation in a neighboring state and within 36 hours, a helicopter was dispatched and obtained digital video of the site fully annotated showing key site features.

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Saved $20 million prior to design phase by avoiding approximately 5 million cubic yards of earthwork.

SSOE was commissioned to perform the master planning and design of the Toyota plant near Tupelo, Mississippi. The new plant was originally intended to produce the Highlander vehicle. With the turn in the economy, the plant will now produce the fuel efficient Prius, one of Toyota’s most sought after models.

The design of the facility and infrastructure is configured to allow for future expansion and the utility needs for the increased production capacity. The overall project has been issued in multiple packages for site work, foundations, structural steel, and general contract work. SSOE also provided on-site engineering staff to Toyota’s Owner’s Representative Office (ORO) to support the construction efforts and coordinate the design documents during construction phases.

The first phase of master planning efforts for this 1,700 acre site required more than 16 million cubic yards of earthwork. Site infrastructure was developed in conjunction with the State of Mississippi and the PUL Alliance which originally developed the area. Site utilities were not only required by the main plant, but also by the other onsite suppliers. SSOE coordinated  the overall utility requirements for Toyota Motor Manufacturing, Toyota Logistics Services, and Toyota Tsusho of America.

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Through design modifications, experience, and innovation, SSOE has saved the client nearly $5 million.

To meet their growing product demand in North America, renowned automotive parts supplier, ZF Friedrichshafen (ZF) chose to build a new transmission plant in Greenville, South Carolina. ZF selected an experienced team comprised of SSOE and other contractors to design and construct the 970,000 SF facility.

SSOE is currently providing architectural, mechanical, and electrical design and engineering for the entire facility, which will consist of manufacturing spaces, offices, laboratories, a data center and a cafeteria. The facility, which is ZF’s first passenger car transmission plant in North America, will produce fuel efficient, eight and nine-speed automatic transmissions.

As part of the original project scope, the facility was classified as an F-1 and S-1 use group (International Building Code). However, with SSOE’s vast experience with similar facilities it was realized the facility should actually be classified as an F-2 and S-2 use group. As a result, several unnecessary fire protection systems were eliminated, saving the client $575,000. This cost savings, combined with several other design innovations, has resulted in a project savings of more than $4 million.

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EPAct 2005 building related energy standards with 50% annual energy reduction.

When BMW needed additional production capacity at its most utilized campus in Spartanburg, South Carolina, they needed a firm known for their expertise in automotive facility design. Having completed a previous energy study for the automotive manufacturer and with recognized capabilities, SSOE was secured for the project. The expansion allowed BMW to increase their output from 160,000 to 240,000 automobiles annually.

SSOE provided the detailed architectural design as well as civil, structural, mechanical, electrical, and fire protection engineering services for the assembly plant built on an existing BMW site. With a multi-discipline team in place, SSOE’s scope for the new facility included design for parking areas, a central energy plant, conveyor enclosures, and all utilities required for the plant. Working against a compressed construction schedule, a comprehensive planning process allowed SSOE to meet an aggressive four-month design schedule. The results were plans for an energy efficient building, designed for future expandability.

SSOE also had to consider site challenges, including the property size, proximity to private residences, and mitigation of streams flowing across the corner of the property. The building’s design meets the Energy Policy Act of 2005 (EPAct 2005) standards for “Energy Efficient Commercial Buildings” and includes increases in insulation in the walls and roof, efficient lighting systems, high efficiency heating and cooling systems, and high efficiency hot water systems. The result is projected to produce a 50% total energy savings over the American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) recommended standards.

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Coordinating standards set by General Motors’ Global Facilities Group with the local design and construction standards of the actual plant in Silao, Mexico was a challenge that could have proved costly for General Motors. Without careful communication and teamwork, extensive redesign efforts could have been required to comply to all codes. SSOE’s understanding of General Motors’ Global Facilities Standards, as well as the local design and construction methods, provided a smooth incorporation of design into construction.

As a result of this close collaboration and understanding, this plant expansion project for a new, eight-speed transmission production line progressed on time and within budget through all three phases, while also meeting all client objectives. Serving as a liaison, communicating with both the Global Facilities Group and local plant officials, SSOE closely monitored the budget and schedule and quickly addressed concerns or nonconforming design elements. A 3D model was utilized throughout the program for integrated project delivery and interactive communication between teams. Representatives from SSOE’s León office attended construction meetings, facilitating the resolution of issues between design and construction.

In addition to project coordination and management, SSOE also provided the program’s Phase I bridging documents and bidding support. For Phase II of the project, SSOE partnered with a construction firm for a design / build delivery, further expediting the schedule. Phase II drawings were provided by SSOE for the transmission plant addition, office and cafeteria expansion, GSC warehouse building, and central utility complex building.

Due to the success of the first facility expansion, SSOE was requested by General Motors to design the project’s Phase III – a design / bid / build, five-bay addition incorporating as-built conditions into the 3D model. SSOE also provided construction administration services.

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Energy saving features with less than five year ROI.

To meet the market demand for new products in China, this automotive OEM built its first Chinese R&D facility in Guangzhou. SSOE’s relationship with this client extends more than 30 years and includes experience at no less than 10 of their facilities throughout the world. With robust expertise in R&D facilities and knowledge of China’s governmental standards for design and construction, SSOE was a clear choice for this project.

SSOE was selected to design an R&D facility that consolidated multiple facilities throughout Guangzhou, bringing the team together in a new location to foster more efficient internal collaboration. R&D areas included trial manufacturing, materials testing, body testing, aesthetic design, crash testing, and EMC chambers. Individual buildings were connected with access roadways separate from normal vehicle flow. The main site access was limited to one entry point in order to control entrance to the campus. The most notable design feature was an onsite high-speed test track for new product development. For the client, it was important to also build an onsite recreational facility reflective of its corporate culture. As part of the design process, SSOE interviewed individual client user groups to find out specific functions, demands, and cultural aspects.

The facility was constructed with an emphasis on use of recycled, renewable, and non-polluting materials. Though the campus had large power requirements, SSOE integrated features that provided the highest possible energy efficiency such as water conserving plumbing fixtures and strategies to reuse the power generated from processes, such as the engine dynamometers. A grey water system was incorporated to minimize overall water consumption and was used to provide the most cost effective method of supplying water for the testing processes on the test track. Such systems were designed to provide less than a five year return on the client’s investment.

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SSOE suggested incorporating high efficiency lighting saving the client approximately $300,000 annually in operation costs. SSOE also suggested using PVC roofing membrane and sandwich panel siding to minimize the installation time.

In order to provide R&D capabilities in India and to better supplement their existing fabrication plant, an automotive client set about to build a new technical center and office complex. Having completed several successful projects for the client’s U.S. facilities, as well as projects for other U.S.-based companies in Asia, SSOE was selected to provide full architecture and engineering for the project.

The center includes performance, structural, environmental, oil flow and lubrication, and metallurgical testing, as well as noise, vibration, and harshness (NVH) testing capabilities. SSOE worked closely with an Indian design firm to ensure the center met Indian regulations, while still providing the client with the international appeal that they were trying to achieve.

Comprised of two filled-in quarries with irregular soil makeup, the site posed a unique challenge. Special considerations had to be made in the facility’s structural design, specifically in the areas that house dynamometers and other large equipment. The site also lacked connections to public utilities, so city water storage tanks had to be designed.

The facility is state-of-the-art and places a high priority on features that maximize occupant safety, health, and comfort. As a result, air conditioning and fire protection systems were included in the center’s design, going above and beyond government requirements for R&D facilities.

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No reportable injuries despite maximum of 500 workers on-site at times.

Based on its long-term relationship with SSOE in the U.S., Ford China hired SSOE to coordinate development and construction of a Research and Engineering Center in China to improve product development. The facility included offices and testing laboratories on Ford’s Nanjing campus. Ford performed master planning and retained a local design firm for engineering services. SSOE coordinated the team so that all were working together toward cost control, quality, and safety. SSOE met the client’s expectations on every level, including challenges posed by an aggressive schedule.

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In addition to architecture, engineering, and construction management services for this new production facility, SSOE also performed a full-spectrum renewable energy survey to determine the most suitable and cost effective technology to utilize to meet Volkswagen’s energy production and system integration requirements.

The survey included all available renewable energy technologies such as solar electric, solar thermal / cooling, wind, biomass, and landfill gas to meet a 4 million kWh renewable energy production target. The study aimed at developing the most effective renewable energy systems to meet Volkswagen’s sustainability and economic objectives for the campus on a 1,500 acre site. A preliminary design of a 3 MW photovoltaic system and a 2 MW landfill gas generating system resulted from the study.

The photovoltaic segment of the project included a full technology comparison of ground based and building-integrated systems, multiple module technologies, and tracking system evaluations. This project resulted in preliminary design of an 800 kW and 3 MW building integrated photovoltaic system which included a CSI master specification-based bid package.

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Through innovative design concepts, benchmarking common practices, and scheduling, SSOE offered Volkswagen a savings of more than $44 million.

Having successfully performed design work for more than 50% of all greenfield automotive assembly plants built in the United States over the last 10 years, SSOE was well qualified to oversee architecture, engineering, and construction management services for Volkswagen’s new automotive production facility.

Volkswagen was also looking for a firm with a strong sustainability focus who would help the company execute its green initiatives.

Located on an 830-acre brownfield site, the production facility includes conventional steel framed buildings with concrete columns, roof structures with skylights, metal wall panels with windows, and a single-ply membrane roof. The plant has the capacity to produce 150,000 mid-sized vehicles annually. The primary manufacturing operations include weld, paint, and assembly. Other facilities on this site include outbound logistics, an extensive training center, media (utility) center, social hall with cafeteria, technical center, tank farm, recycling center, and fire station. SSOE provided environmental permitting, civil, architectural, structural, mechanical, fire protection, plumbing, electrical, fire alarm, access control, and security system design as well as construction management. SSOE’s expertise led to the first and only LEED® Platinum automotive assembly plant in the world. SSOE assisted with the preparation, submittal, and multiple agency approvals of the air permit in record time—2 weeks ahead of an aggressive 3-month schedule.

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