Facilities
Introduction
Turner, in a 50/50 Joint Venture with WG Yates & Sons (TY), is constructing a 5,500,000 sq. ft. lithium-ion battery assembly factory in De Soto, Kansas. The project includes building the shell, MEP fit-out of the North Wing, a central utility plant (CUP), and MEP support buildings, aiming to achieve 30 GWh annual production capacity. Key features include specialized Clean Rooms and Dry Rooms to maintain under 10% humidity. Foundations, contracted to Kissick Construction, and auxiliary buildings, add to the complexity of this large-scale renewable energy investment.
This project showcases the effectiveness of prefabrication and advanced construction strategies. Through meticulous planning, innovative methods, and efficient labor utilization, the project sets a benchmark for future manufacturing facility construction.
Confidential EV Lithium-ion Battery Manufacturing Plant
Challenge
Workforce Constraints
With De Soto’s small local population of 6,000, the workforce peaks at 2,700, requiring 40% of the labor to be travelers.
Solution
Off-Site Prefabrication
By utilizing Offsite Prefabrication, the project reduces dependency on local labor and ensures a stable, controlled build process.
Modular Trestle
Key to the project’s success is the utilization of offsite manufacturing to build the utility modular trestle. The modular trestle measures 2,200 lf in total length when fully erected. Each module is manufactured in close proximity to the main project site, allowing each delivery to be transported to the site in less than two hours. The 36” chilled water pipes are fabricated offsite to allow for the finished pipe to be delivered to site, lifted into place and connected for service. This approach not only streamlines the construction process but also enhances production quality and control. Additionally, it took hours into a more controlled environment where it significantly reduced pinch points and the need for working at height, both of which are critical safety risks.
Trestle Integration
The project features an integrated modular trestle supporting two manufacturing facility wings and connecting them to the facility utility buildings.
The modular trestle incorporates:
• Structural Steel
• Piping
• Cable Trays
• Off-trestle Supports and T-posts
The 59 trestle module sections range from 13 to 104 feet. These modules integrate structural steel, various piping services and materials ranging from 1.5” to 36”, and electrical conveyance systems to support critical manufacturing processes.
Assembly Process
Offsite manufacturing fulfilled the delegated design requirements provided by the owner to fabricate, galvanize and assemble steel, fabricate piping and integrate the modules. The assembled modules were fabricated in a sequence that complimented the site build constraints.
Results
The offsite manufacturing allowed for construction of the trestle modules to progress on a parallel path with the site build, improve productivity, and relieve congestion in the modular trestle installation area. The modules are being assembled and ready for delivery in advance of the site need dates saving valuable time on the schedule.