Battery

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$100 million documented project savings to date with additional savings anticipated.

A well-known electric vehicle (EV) manufacturer has partnered with a leading non-domestic battery producer to develop an advanced battery chemistry aimed at enhancing EV performance. The goal of this collaboration is to offer customers improved battery value, durability, and fast-charging capabilities. To realize this vision, SSOE—a seasoned design firm with extensive experience in the EV and battery manufacturing sector—was selected to lead the engineering design and execution of the groundbreaking $1.5 billion investment.

SSOE partnered with construction firm Walbridge to implement a design / build delivery method. Since the project’s inception, all stakeholders worked closely to ensure unified project recommendations aligned with schedules and budgets. SSOE’s responsibilities encompassed the entire facility design, programming, and engineering.

The nearly 2 million SF facility includes production space and ancillary buildings supporting the main manufacturing area. Drawing on insights from the client’s existing battery manufacturing facilities, SSOE adapted their foreign manufacturing processes, building design, equipment, and layout to meet U.S. codes and standards throughout all design phases.

This greenfield battery plant marks the first U.S. location for the foreign client and will serve as their flagship facility in North America. Leveraging SSOE’s expertise in foreign direct investment, we’ve ensured a seamless transition for this global manufacturer as they establish operations in the U.S. Once operational, the plant is expected to add more than 18 GWh of battery capacity and employ over 2,500 workers, contributing to the local economy and advancing sustainable transportation.

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A pioneering battery manufacturer known for its high-density silicon-anode batteries is embarking on an ambitious expansion project. The company is converting a former Kmart distribution center into a state-of-the-art production plant. This move represents a significant leap from R&D to pilot manufacturing, to scaling up the production of their cutting-edge batteries used in phones, drones, military applications, and electric vertical takeoff and landing (EVTL) vehicles.

SSOE Group, with its recognized architectural and engineering design expertise in the battery manufacturing market, has partnered with Turner Construction to develop and construct the 775,000 SF facility, which is part of a more extensive 1.2 million SF multi-tenant complex. Phase 1 is engineered to have a production capacity of 500 megawatt-hours of battery power once in production.

Turner took the helm with site selection, evaluating potential sites across the U.S. Ultimately, a site in the west was selected offering an optimal climate, suitable humidity levels, and a robust utility infrastructure, complete with existing substations and the possibility for future expansions.

A rezoning effort was necessary to transition from a warehouse-only designation to one that includes manufacturing capabilities. SSOE and Turner provided expert support to a subsequent community engagement campaign, which was launched to dispel misconceptions and provide transparent information about the facility’s operations and processes. Despite facing initial resistance and a legal challenge
against the city, the rezoning efforts were successful, allowing the project to move forward.

Addressing the challenges presented by the brownfield site, SSOE’s team had to overcome layout limitations, which led to the design of an additional structure and modifications to the ceilings to create a suitable cleanroom environment. Moreover, relocating the process line from China to the U.S. required a detailed plan to comply with the diverse standards and regulations concerning electrical systems, utilities,
and piping, ensuring a seamless transition.

This company’s commitment to innovation and overcoming challenges, while harnessing the advantages of the environment and topography, position them to help transform the battery industry with its high-quality, dense power solutions.

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After the successful launch of their pilot line to produce batteries, this battery manufacturer selected the partnership of Turner Construction and SSOE Group to design and construct their new greenfield production battery campus. Spanning 1.25 million SF on a 125-acre site in the Southwest U.S., the campus will feature a two-story battery production facility, administrative and engineering offices, a cathode production building, lithium processing and storage buildings, and a hazardous scrap storage facility.

The SSOE team brings a full spectrum of architectural and engineering expertise to this multi-phased project, guiding the project from the foundational Basis of Design to the final Issue for Construction packages. The project employs a Construction Management at Risk delivery method, chosen for its ability to ensure timely and budget-conscious project completion while maintaining cost certainty and quality control.

Navigating through the complexities of site evaluation, seismic zoning adaptations, utility access, and hazardous chemical planning, SSOE’s multidisciplinary team has adeptly addressed and overcome each obstacle to ensure this complex project continues to progress toward completion.

At the forefront of battery technology, this manufacturer is working to scale these batteries industrially and commercially. The development of the batteries promises lighter, more efficient, and cost-effective solutions for electric vehicles and other applications that require high-energy density storage—and potentially revolutionizing the industry.

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During the development of plans for a new brownfield manufacturing facility, Ascend Elements engaged SSOE to provide engineering and design services. The focus was on renovating an existing 150,000 SF industrial building, which they had leased and equipped for recycling lithium ion batteries. The project unfolded through several key phases: front-end loading (FEL 2 and 3), detailed design, procurement, construction, and commissioning.

As a start-up, Ascend Elements faced the challenge of designing each production line component to achieve their ultimate goal: producing “black mass.” This valuable powder contains critical materials like nickel, cobalt, lithium, and graphite. SSOE played a pivotal role in refining Ascend Elements’ patented Hydro-to-Cathode™ process, which drastically reduces the carbon footprint of new battery cathode materials by up to 90%. The process involves discharging scrap batteries fully, crushing battery cases, and providing efficient dust collection. The recycling plant achieves an impressive 98% recovery rate for critical battery metals used in electric vehicle (EV) batteries and gigafactory manufacturing scrap. By contributing to a closed-loop battery materials supply chain, Ascend Elements supports a cleaner and more sustainable EV industry.

Beyond the initial ribbon-cutting and production start-up, Ascend Elements continued to leverage SSOE’s expertise. Together, we optimized and debottlenecked their cutting-edge process, implementing new unit operations within the production factory. SSOE’s understanding of day-today manufacturing criticality facilitated seamless integration of process improvements.

Today, SSOE remains a trusted project delivery partner for Ascend Elements. Our collaboration extends to designing a state-of-the-art, first-of-its-kind EV battery materials manufacturing facility in Hopkinsville, Kentucky. Situated on a sprawling 140-acre megasite, this complex includes over 800,000 SF of manufacturing space, reinforcing Ascend Elements’ commitment to innovation and sustainability.

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Ascend Elements, a leading provider of sustainable battery material solutions, began construction on its new EV battery recycling and engineered materials manufacturing facility. Known as Apex 1, this 140-acre campus in Hopkinsville will produce sustainable EV battery precursor (pCAM) and battery-ready cathode active materials (CAM) for up to 250,000 EVs annually.

SSOE initially conducted site and utility evaluations for Ascend Elements’ new flagship facility. SSOE supported the evaluation of potential sites for the new campus and provided a comprehensive evaluation that aided the client in selecting a site. During Front End Loading (FEL), SSOE developed a site layout to include process, packaging, warehousing, office buildings, a preliminary project schedule, and an execution plan. Our comprehensive team for this phase included architectural, civil, structural, process, mechanical (HVAC / plumbing), piping, electrical, instrumentation and controls, and estimating.

Throughout the design phase, SSOE worked with Ascend Elements and their process technology provider to create an efficient overall process design while exploring engineering alternatives to enhance project value. With Ascend Elements’ foreign OEM / technology provider, SSOE conducted evaluations of equipment and design specifications to ensure compliance with all U.S. codes and standards. This involved regular meetings and continuous BIM / CAD coordination.

SSOE collaborated with the Turner Construction Company / Kokosing Industrial joint venture to create the detailed design for this groundbreaking facility. Based on a design / build contract arrangement, the project benefited Ascend Elements by optimizing contractor-assisted design and Lean deliverables tailored precisely to the contractor’s requirements. This accelerated megasite project engaged 13 firms and more than 250 users across multiple countries. Lean leadership and real-time information reduced rework through a suite of tools, including Autodesk Construction Cloud, that virtually replicated co-location for an environment of collective efficiency.

This further enhanced the project’s success by streamlining information sharing across all parties, earning SSOE the Autodesk Design & Make AEC Best Construction Project Award in 2023. As a new player in the battery market, Ascend Elements trusted SSOE because of our established resources to deliver a project of this sheer magnitude, solidified by our agility in adapting to project execution throughout a dynamic, fast-track schedule.

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SSOE was selected to design a new, state-of-the-art training center for the Electric Vehicle (EV) market. The center, a collaboration between Hyundai Motor Group (Hyundai), The Technical College System of Georgia (TSCG), and Georgia Quick Start, is located adjacent to the Hyundai Motor Group Metaplant America (HMGMA) facility and is poised to train the next generation of EV experts and innovators. Helping to solidify Georgia’s position as a national leader in EV manufacturing, the facility will support Hyundai’s first dedicated Electric Vehicle mass-production plant in the U.S. and promote Hyundai’s vision of becoming a global smart mobility solution provider.

Quick Start, a division of the Technical College System of Georgia (TCSG) is Georgia’s internationally acclaimed workforce training program. SSOE and its partners designed the innovative 90,000 SF training center to further Quick Start’s mission by providing spaces that are highly functional, adaptable, and supportive of a dynamic organization, built on 50 years of experience, with a nurturing team-oriented culture.

The training center will feature technologies such as CAD, BIM, and virtual reality as well as classrooms, technical labs, and high-bay spaces. The space will contain manufacturing-scale training simulations incorporating robotics, mechatronics, welding, motors, and other advanced manufacturing technologies to simulate the EV production environment and prepare the trainees for success.

SSOE applied its expertise and experience in the EV market to deliver a cost-effective, high-quality solution for the client. The building is anchored by respecting the site’s geometry and the HMGMA factory context. Transitioning between the landscape architecture and the building are two courtyards of two distinct characters. The north courtyard serves as the main entrance to the facility and is active, welcoming, and dynamic, with trellis and colonnades as contemporary interpretations of the Southeast Georgia coastal vernacular. The south courtyard is intended to provide a quieter area of respite where staff and trainees can recharge and prepare for the day’s assignments.

Project completion is slated for late 2025 and will support the creation of more than 8,000 jobs in the EV industry.

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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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When Panasonic Energy Co., Ltd., a Panasonic Group company, sought to build its first standalone lithium-ion battery production facility in the U.S., they knew they needed a partner with cleanroom, battery, and manufacturing experience. With SSOE’s reputation as an industry leader in the design of battery manufacturing facilities, greenfield site development expertise, and experience working with Panasonic on previous projects, they knew we could deliver their vision. SSOE was selected to provide primary engineering design and architectural design oversight.

SSOE’s involvement began at the earliest stage of the project when the firm became engaged in site evaluation efforts with Panasonic’s site selection team. We pulled together a team of architects and engineers to guide Panasonic through defining and ranking site criteria, assisting in the evaluation of multiple campus locations. In July 2022, Panasonic ultimately landed on Astra Enterprise Park (formerly the Sunflower Army Ammunition Plant), originally constructed in World War II and vacant for a quarter of a century—with 300 acres and hundreds of millions of dollars in incentive packages to go with it. A win for Kansas, this is the first economic development project exceeding a billion dollars for the state and will make the location a key economic driver for the region.

In parallel with site evaluation efforts, SSOE worked with Panasonic to generate a preliminary Basis of Design with enough detail to allow the construction manager to forecast a construction estimate in a post-COVID market. From there, we’ve continued to lead the project through the preliminary design phase. To mitigate labor market and supply chain challenges, the cutting-edge nature of lithium-ion battery manufacturing requires our design team to adapt to process and usage changes driven by Panasonic’s refinement to their battery technology. SSOE continues to suggest solutions that are adaptable to future process refinements.

Designing a facility that aligns with Panasonic’s employee-centric culture is to be top of mind. The site plan limits interaction between vehicles and pedestrians through a thoughtfully designed parking layout, one-way traffic, separate truck entrance, and site-specific traffic study. Architectural design is still in progress but promises the intelligent integration of the production process into the building design and spaces throughout to specifically support employees. The U-shaped design of the production facility will frame various support structures and utility buildings that will reside behind it. The fact that Panasonic and SSOE’s cultures naturally align has streamlined the ability to communicate and deliver what they’re looking for in this facility.

With a nearly 100-year history of innovation in batteries spanning both battery cell technology and battery business operations, Panasonic continues to strengthen its lineup of automotive lithium-ion batteries and expand its production capacity. The De Soto facility, the company’s first standalone EV battery facility in the U.S., will help do just that. The Japanese-based company’s expansion in Kansas is expected to bring in a projected $2.5 billion in yearly economic activity to make it the largest economic development undertaking in the state’s history. It will also allow Panasonic to ramp up production to meet surging demand and lead the evolution of the EV industry in the U.S.

Due to the complexity of the design and size of the facility, the City of De Soto will approve its development plan one phase at a time. Panasonic broke ground on the new plant in November 2022, with production slated to begin in 2025.

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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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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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SSOE provided architectural and engineering design services for KORE Power’s greenfield battery cell production facility, KOREPlex. KORE Power, a U.S.-based developer of battery cell technology for the energy storage and electric transportation industries, collaborated with Yates Construction and SSOE as the Design / Build team. SSOE advanced the design package to 60% completion at which point the client halted further design and construction.

The KOREPlex design included automated cell assembly lines, automated material movement and handling, an automated packaging line, and a pandemic-ready design to allow for safe workspaces.

The facility’s many cleanrooms were designed to maintain very low humidity requirements throughout the space, some targeting a temperature / humidity set point within the -45°C dew point range. The design used dedicated desiccant chilled water dehumidification units to dry the air, while providing space-level cooling. The rooms also utilized recirculating air handling units to allow for HEPA-level filtration and overall cleanroom pressurization requirements.

The SSOE team drew upon our unique expertise in the battery manufacturing sector to develop the KOREPlex designs—combining our understanding of large-scale manufacturing facilities with a technical mastery of controlled environments and process engineering.

The KOREPlex facility was designed to support up to 14 gigawatt hours (GWh) of battery cell production, producing nearly 60 million battery cells annually. The new facility would have production capacity to provide power for 3.2 million homes per year.

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Viridi Parente is a developer of innovative battery technology that can be safely installed and operated in nearly any environment or location. The project increases the space on their 42-acre green tech campus to meet robust demand for its safe battery technology solutions. The company is working with Alberici Constructors to add 60,000 SF, expanding its total research lab, assembly, office, and production space to 180,000 SF. The expansion also integrates automation features, such as robotic welding technology and a vertical lift management system throughout the manufacturing space.

Located in a plant that was originally built by General Motors in 1923, Viridi Parente bought the plant in 2008 and renovated it to meet their needs and to better align the plant’s power usage with Viridi Parente’s goals of producing products with sustainable energy.

SSOE partnered with Alberici to provide mechanical, structural, electrical, data / fire / security, as well as fire protection engineering services on this project because of our specialized lithium-ion battery plant design expertise. Our team worked together with the client and Alberici to provide design solutions that are both sustainable and cost-effective. The newly expanded spaces include 30,000 SF for lab and assembly space and an additional 30,000 SF for increase shipping and receiving capacity. Prior to the expansion, the company occupied 120,000 SF of the campus facility with 60,000 SF of battery and machine assembly space featuring automotive-grade QA/QC, a fully integrated assembly process. It also included 20,000 SF of office and lab space, including a dedicated state-of-the-art battery testing lab for life cycle cell and module testing, thermal testing, and R&D as well as 40,000 SF shipping and receiving warehouse.

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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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A well known OEM forecast a significant increase in electric vehicle production. To meet the unprecedented demand this would create for lithium ion batteries, the automaker formed a strategic partnership with a leading battery manufacturer. Together, they aimed to construct a shared plant that would produce both electric motors and battery packs.

The facility is being built in phases, the first of which was made up of multiple sections of the plant totaling 6 million SF. The phase-one project was unique in that all facets of its design and implementation were led and executed by an internal team under the manufacturer’s authority—meaning the owner was also the designer, engineer, and construction manager. The team selected SSOE as a design partner for this phase with the flexibility to embody their out-of-the-box thinking and make their progressive goals a reality. SSOE provided key on-site and remote staff augmentation, in support of these critical functions:

  • Process Integration – assisted with design and specification for a portion of the initial process-related facility packages (including local DI water stations and local wastewater lift stations), engineering support for the process systems, and a significant amount of PIPE-FLO modeling for many plant utility systems.
  • Process Chemical – performed HAZOP, pipe supports, facility integration, and redesign of several bulk systems to meet updated needs or code requirements. Additionally, SSOE acted as a design and equipment specification “sanity check” for components on several of the small and bulk chemical handling systems.
  • Utilities – provided a significant portion of the Revit modeling for utility systems, as well as equipment layout in the utility support buildings.
  • Mechanical / HVAC – provided a substantial share of the Revit modeling and engineering support for the mechanical / HVAC systems for the facility.

The fluidity of design on this project created complications due to multiple sections of the facility being worked on interchangeably. SSOE’s engineers tackled these challenges by proactively solving problems, independently finding missing information, and piecing together details to achieve aggressive deliverables and goals that other A/E firms deemed impossible.

Ultimately, SSOE collaborated seamlessly with the manufacturer’s internal team. Drawing on industry expertise, the augmented staff was able to provide input on decisions that resulted in operational efficiencies, an improved layout, schedule compression, and more than $5 million in savings.

The facility will not only meet its lofty production goals, but also produce batteries for significantly less cost. Notably, it will be powered by renewable energy sources, with the goal of achieving net zero energy.

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