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Work Advances on $1.6B Auto Factory in Huntsville
In a construction milestone, the first steel beam is put in place. A group of team members signed it as a symbolic gesture.
Company officials and construction crew members celebrate the installation of the first beam.
By Cindy Riley CEG CORRESPONDENT
In a construction milestone, crews have installed the first beam of the new, $1.6 billion Mazda Toyota plant in Huntsville, Ala. The erection of the manufacturing facility is well under way, with 2,500 workers projected to be on site by late summer. “Mazda Toyota Manufacturing U.S.A. [MTMUS] will assure competitiveness in manufacturing, allowing us to respond quickly to market changes and help ensure sustainable growth for both automakers as we continue our efforts in the future of mobility,” said Mark Brazeal, MTMUS vice
president of administration. “By combining the best of our technologies and corporate cultures, Mazda and Toyota will not only produce high-quality products, but also create a world-class manufacturing plant that our team members will be proud to work at. We want to become a vibrant part of the community, and hope the cars assembled at the plant will enrich the lives of their owners.” In mid-April, a small group of team members gathered on site to celebrate the first steel column going into place, signing it as a symbolic gesture. “The first steel ceremony is one of several milestones as we ramp up construction and begin vehicle assembly in
2021,” said Brazeal. “We wanted to share this unique experience with our team members to build greater comradery as our challenges continue. Building a greenfield manufacturing plant is a once-in-a-lifetime experience for many of our team members, and it was a very significant moment.” Brazeal noted that many factors go into selecting a greenfield plant site. “Alabama was ultimately chosen because of its highly qualified workforce, infrastructure, quality of life in Huntsville/North Alabama and the longstanding partnerships created as a result of Toyota’s engine plant,” he said. “Alabama has invested heavily in the kind of workforce and see HUNTSVILLE page 2
Deteriorated Roads Cost Birmingham Drivers Over $1,800 Per Year Roads and bridges that are deteriorated, congested or lack some desirable safety features cost the average Birmingham area driver $1,846 per year — a total of $5.3 billion statewide — due to higher vehicle operating costs, traffic crashes and congestionrelated delays, according to a recent report from TRIP, a Washington, D.C.-based
national nonprofit transportation research organization. The report, “Birmingham Transportation by the Numbers: Meeting the Region’s Need for Safe, Smooth and Efficient Mobility,” finds that in the Birmingham area, approximately two-fifths of major locally and statemaintained roads are in poor or mediocre
condition and four percent of locally and state-maintained bridges (20 ft. or longer) are structurally deficient. The report also finds that the Birmingham area’s major urban roads are becoming increasingly congested, causing significant delays and choking commuting and commerce In addition to the statewide report, TRIP also has prepared
regional reports for the Anniston-OxfordGadsden, Birmingham, Florence, DecaturHuntsville, Mobile, Montgomery and Tuscaloosa urban areas. Adequate investment in transportation improvements at the local, state and federal levels is needed to relieve traffic congestion, see ROADS page 4
Page 2 • June 19, 2019 • www.constructionequipmentguide.com • Alabama State Supplement • Construction Equipment Guide
Completion of New Mazda Toyota Plant Expected By 2020 HUNTSVILLE from page 1 “Seeing the first steel going into place was a significant milestone for our team and parttraining program needs that manufacturers ners,” said Brazeal. “It represents the rising of require. The great collaborative efforts not only our project, but one that will create a between local and state agencies also gave community where we’ll become a good corAlabama a competitive edge.” porate neighbor, and one everyone will be Brazeal noted that the ultimate purpose of proud of.” MTMUS is to build a company in which the Site clearing has been completed, along best manufacturing practices, innovation and with stormwater control, some interior roads, sustainability of both organizations are shared. most foundations and temporary facilities for The agreement between both companies construction management. As work moves was announced in August 2017. Specifically, forward into the summer months, Brazeal said they agreed to establish a joint venture that crews must also be mindful of the elements. produces vehicles in the United States, as well “Weather and environmental conditions are as develop technologies for electric vehicles always a concern when considering the health and connected-car technology. They will also and safety of construction workers and our collaborate on advanced safety technologies team,” he said. “As the seasons change, the and expand complementary products. changing risks are considered and mitigated.” Brazeal said it’s extremely satisfying to play With steel construction under way, the next a key role in bringing new jobs to the area. significant development will be the topping “With a $1.6 billion investment, MTMUS out of the buildings. Other major accomplishwill create up to 4,000 direct jobs, plus ments will include the completion of the shell, employment opportunities at our supplier and the electrical and utility infrastructure within business partners,” he said. “The labor market in the Huntsville/North Alabama region is Construction on the $1.6 billion Mazda Toyota plant in Huntsville, Ala., com- the buildings and the utility infrastructure on the site, as well as the installation of process very competitive, and as a result, the joint ven- menced in June 2018 and is scheduled for completion in the summer of 2020. equipment. ture’s HR team is developing comprehensive The job site was previously used for farmstrategies for the recruitment and training for these new team and a highly qualified workforce to draw from.” Although a heavy rain season has presented challenges, ing and was mostly clear. Site preparation involved some members. “We want to think innovatively and do our best to become construction of the advanced manufacturing facility remains leveling and the installation of stormwater controls. Clearing a company in which our team members and the entire com- on schedule. A total of 3 million cu. yds. of dirt has been of trees wasn’t required, but some small buildings had to be munity are proud. We are confident in the region’s and state’s graded for site preparation, enough to fill the Empire State removed. “The site was mostly clear and reasonably level from the workforce abilities for several reasons, including Alabama’s Building twice. In addition, 150,000 cu. yds. of gravel has heavy investment in the kind of workforce and training pro- been poured to create the plant foundation, equal to filling beginning,” said Brazeal. “However, the amount of land being prepared required a lot of equipment to complete the almost four dozen Olympic-size swimming pools. grams that all manufacturers require.” Construction commenced in June 2018 and will end in the work on schedule, and a few bulldozers and dump trucks Toyota has been operating an engine plant in Huntsville summer of 2020. Equipment installation will begin soon would not have been up to the challenge. Instead, large tracfor 17 years. “The plant has expanded five times, and currently thereafter. Currently, site utility infrastructure is underway. tors with dual scraper pans and off-road dump trucks had to employs more than 1,400, demonstrating its continued con- Primary shops are nearing completion of foundation work be brought in to level and prepare the site. “The real project challenge with respect to the land lies fidence in the local workforce,” said Brazeal. “Also, and steel erection has begun. Approximately 18,000 tons of Huntsville/North Alabama has a pro-business environment steel will be used on the plant. see HUNTSVILLE page 4
A total of 3 million cu. yds. of dirt has been graded for site preparation, and 150,000 cu. yds. of gravel has been poured to create the plant foundation.
Construction of the buildings must be coordinated with the installation of the equipment and processes intended to go inside of them.
Construction Equipment Guide • Alabama State Supplement • www.constructionequipmentguide.com • June 19, 2019 • Page 3
Birmingham, AL 205.841.6666 Madison, AL 256.350.000 06 Mobile, AL 251.633.4020 Montgomery y, AL 334.262.664 42 Oxford, AL 256.832.5053 Tuscaloosa, AL 205.848.4147 Pensacola, FL 850.479.3004 Atlanta, GA 404.696.7210
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Page 4 • June 19, 2019 • www.constructionequipmentguide.com • Alabama State Supplement • Construction Equipment Guide
Aggressive Schedule a Challenge for Huntsville Auto Project HUNTSVILLE from page 2
beneath the surface. Building safe structures on this scale required several deep foundations that must interact with geology below the surface.” A total of 6 million cu. yds. of dirt and other material will be moved on the project. Machinery required includes heavy earthmoving equipment and cranes. Materials being used include concrete, steel, electric cabling and utility piping. According to Brazeal, meeting the aggressive schedule between project kickoff and start of production in 2021 is the team’s biggest challenge. “Addressing this challenge requires a departure from traditional construction sequencing and adaptation to ‘fast track’ methodology, where construction starts while design is ongoing,” he said. “In this scenario, design must progress at a rate that facilitates construction, and change management becomes important because all scope is not entirely known when work begins.” Coordination between process design and building design is important and time-intensive, as construction of the buildings must be coordinated with the delivery of the equipment and processes intended to go inside of them. In addition, building an auto plant differs from other construction projects because while materials for the shells of most industrial facilities are very similar, the layout of an auto plant is fit for only one purpose, Brazeal said. “Also, the size of the buildings required for auto manufacturing sets them apart from most construction,” he added. “Very few industries require millions of square feet for production space.” Mazda Toyota Manufacturing U.S.A. is a jointly owned and operated automotive production plant. The facility will have the capacity to assemble up to 300,000 vehicles a year. “While this project is a massive undertaking that requires many resources and has its sets of challenges,” Brazeal said, “we are confident that our team members, the community and the entire state of Alabama will be able to say ‘built in Alabama’ with pride.” CEG
The job site was previously used for farming and was mostly clear. Site preparation involved some leveling and the installation of stormwater controls.
Report: 21 Percent of Major Roads in Birmingham in Poor Condition ROADS from page 1
improve road, bridge and transit conditions, boost safety and support long-term economic growth in Alabama, the report states. Driving on deficient Birmingham area roads costs the average driver $1,846 annually in extra vehicle operating costs (VOC) as a result of driving on roads in need of repair, lost time and fuel due to congestionrelated delays, and the costs of traffic crashes in which roadway features likely were a contributing factor. The TRIP report finds that 21 percent of major locally and state-maintained roads in the Birmingham area are in poor condition and another 20 percent are rated in mediocre condition, costing the average motorist an additional $549 each year in extra vehicle operating costs. These costs include accelerated vehicle depreciation, additional repair costs, and increased fuel consumption and tire wear. Driving on rough roads costs the state’s drivers a total of $2 billion each year. Traffic congestion in the Birmingham area is worsening, causing 37 annual hours of delay for the average motorist and costing
the average driver $990 each year in lost time and wasted fuel. Alabama drivers lose a total of $1.5 billion annually in the form of lost time and wasted fuel due to congestion. “Year after year, infrastructure ranks among the Birmingham Business Alliance’s top legislative priorities because we know what an impact it can have on economic development, workforce accessibility and the overall quality of life for citizens in the Birmingham seven-county region,” said Brian Hilson, president and CEO of the Birmingham Business Alliance (BBA). “The BBA is continually committed to a safer and more efficient transportation infrastructure across our region.” In the Birmingham area, 4 percent (43 of 1,049) of bridges are rated structurally deficient, with significant deterioration to the bridge deck, supports or other major components. This includes all bridges that are 20 ft. or more in length. Nearly half — 49 percent — of Alabama’s bridges are at least 50 years old. On average, 84 people were killed in traffic crashes in the Birmingham area each year
from 2015 to 2017. The financial impact of traffic crashes costs each Birmingham area driver an average of $307 annually — a total of $1.8 billion statewide. Alabama’s overall traffic fatality rate of 1.34 fatalities per 100 million vehicle miles of travel is higher than the national average of 1.16. The fatality rate on Alabama’s noninterstate rural roads is more than two and a half times higher than on all other roads in the state (2.38 fatalities per 100 million vehicle miles of travel vs. 0.87). The buying power of the state’s 18-centper-gallon fuel tax has been more than cut in half by inflation and increased fuel economy. The vast majority of Alabama’s current transportation budget is devoted to preserving the existing system, leaving only $150 million available annually for new projects. To raise additional revenue, help meet the perceived need, a 10-cent-per-gallon increase in the state gas tax to fund road and bridge construction was signed into law March 12 by Gov. Kay Ivey. The efficiency and condition of Alabama’s transportation system, particular-
ly its highways, is critical to the health of the state’s economy. Annually, $432 billion in goods are shipped to and from sites in Alabama, mostly by trucks, relying heavily on the state’s network of roads and bridges. Increasingly, companies are looking at the quality of a region’s transportation system when deciding where to re-locate or expand. Regions with congested or poorly maintained roads may see businesses relocate to areas with a smoother, more efficient and more modern transportation system. More than 940,000 full-time jobs in Alabama in key industries like tourism, retail sales, agriculture and manufacturing are dependent on the state’s transportation network. “Driving on deficient roads comes with a $1,846 yearly price tag for Birmingham motorists — $5.3 billion statewide,” said Will Wilkins, TRIP’s executive director. “Adequate funding for the state’s transportation system would allow for smoother roads, more efficient mobility, enhanced safety, and economic growth opportunities while saving Alabama’s drivers time and money.”
Construction Equipment Guide • Alabama State Supplement • www.constructionequipmentguide.com • June 19, 2019 • Page 5
Page 6 • June 19, 2019 • www.constructionequipmentguide.com • Alabama State Supplement • Construction Equipment Guide
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Construction Equipment Guide • Alabama State Supplement • www.constructionequipmentguide.com • June 19, 2019 • Page 7
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Page 8 • June 19, 2019 • www.constructionequipmentguide.com • Alabama State Supplement • Construction Equipment Guide
Montgomery • Jefferson • Talladega • Calhoun • Russell • Walker • Lawrence • Dekalb • Morgan • St. Clair • Tuscaloosa • Morgan • Shelby •Alabama… Bibb •Hale • Fayette • Marion • Winston • Cullman • Shelby • Chilton • Chambers • Covington • Baldwin • Clarke • Monroe • St. Clair • Chilton • Escambia• Montgomery • Jefferson • Russell • Fayette • Conecuh • Coffee • Geneva • Montgomery • Jefferson • Talladega • Bibb • Coffee • Calhoun • Russell • • Walker• Lawrence• Dekalb • Morgan • St. Clair • Tuscaloosa • Bibb• Hale • Fayette • Monroe • Clarke • Winston • Cullman • Shelby • Chilton • Chambers • Covington • Baldwin • Clarke • Monroe • Montgomery • Jefferson • Talladega
‘The Yellowhammer State’ Highway Project Lettings
The Alabama State Department of Transportation received bids for transportation-related improvement projects. Following is a list of some of the projects let.
County: Houston Contract ID: 20190125003 Project: Additional lanes. Location: On SR 210 (Ross Clark Circle) from south of Bauman Drive to south of SR 12 (U.S. 84) in Dothan. Contractors and Bid Amounts: • Midsouth Paving Inc. — $4,732,225 • Wiregrass Construction Company Inc. — $4,933,125 County: Hale Contract ID: 20190125008 Project: Bridge replacements and approaches. Location: On CR 192 over Hardin Creek east of Stewart and on CR 198 over Gile Creek northeast of Havana. Contractors and Bid Amounts: • Gillespie Construction LLC — $827,356 • H & L Construction Inc. — $916,226 • Glasgow Construction Company Inc. — $997,439 • Cornerstone Civil Contractors LLC — $1,029,344 County: Etowah Contract ID: 20190125012 Project: Bridge replacement and approaches. Location: On CR 568 (Yates Road) over Black Creek. Contractors and Bid Amounts: • Gillespie Construction LLC — $1,690,997 • MSE Building Company Inc. — $1,798,530 County: Talladega Contract ID: 20190125025 Project: Safety improvements (grade, drain, pave and stripe). Location: On SR 38 (U.S. 280) to east of the junction of Old Birmingham Highway in Oak Grove. Contractors and Bid Amounts: • McCartney Construction Company Inc. — $1,834,532 • Cornerstone Civil Contractors LLC — $1,859,378 • Dunn Construction Company Inc. — $1,866,082 Counties: Autauga and Elmore Contract ID: 20190125028 Project: Resurfacing, safety improvements, cable guiderail and stripe. Location: On I-65 from north of the Cobbs Ford Road Interchange to the Chilton County line. Contractors and Bid Amounts: • Wiregrass Construction Company Inc. — $15,275,850 • Midsouth Paving Inc. — $18,164,168 County: Cherokee Contract ID: 20190125018
Project: Bridge replacement (grading, drainage, pavement and bridge). Location: On SR 9 over Terrapin Creek Southeast of Centre. Contractors and Bid Amounts: • Wright Brothers Construction Company Inc. — $7,264,066 • Scott Bridge Company Inc. — $7,640,163 • Dement Construction Company LLC — $7,931,972 • The Bridge Builders of Alabama LLC — $8,117,599 • McInnis Construction LLC — $8,452,861 • Summers-Taylor Inc. — $8,565,737 County: Baldwin Contract ID: 20190125031 Project: Planing, resurfacing and traffic stripe. Location: On I-10 from the SR 59 interchange in Loxley to 0.300 mi. east of the CR 64 (Wilcox Road) Interchange. Contractors and Bid Amounts: • H. O. Weaver & Sons Inc. — $2,549,677 • Mobile Asphalt Company LLC — $2,813,865 • John G. Walton Construction Company Inc. — $2,989,000 County: Mobile Contract ID: 20190125035 Project: Planing, resurfacing, sidewalk installation and stripe. Location: On I-165 (service roads) from 0.040 mi. south
of Bay Bridge Road to 0.080 mi. north of Whistler Street. Contractors and Bid Amounts: • John G. Walton Construction Company Inc. — $1,724,277 • H. O. Weaver & Sons Inc. — $1,728,557 • Mobile Asphalt Company LLC — $1,759,717 County: Etowah Contract ID: 20190125045 Project: Safety widening, resurfacing, sidewalk, guardrail and stripe. Location: On SR 1 (U.S. 431) from Little Wills Creek (mp 265.175) in Attalla to Line Creek (MP 269.290) southwest of Ridgeville. Contractors and Bid Amounts: • Whitaker Contracting Corporation — $2,249,503 • McCartney Construction Company Inc. — $2,587,314 County: Walker Contract ID: 20190125054 Project: Slide repair. Location: On SR 69 from east of Luther Dutton Road to west of the junction of CR 43 near the Cullman County line. Contractors and Bid Amounts: • Ikaros LLC — $3,730,000 • Chilton Contractors Inc. — $3,758,723
Construction Equipment Guide • Alabama State Supplement • www.constructionequipmentguide.com • June 19, 2019 • Page 9
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Construction Equipment Guide • Alabama State Supplement • www.constructionequipmentguide.com • June 19, 2019 • Page 11
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Page 12 • June 19, 2019 • www.constructionequipmentguide.com • Alabama State Supplement • Construction Equipment Guide