In a major expansion of the American EV supply chain, Beck & Pollitzer recently completed a massive mechanical and electrical (M&E) installation project in Kansas, USA. Partnering with a global leader in advanced manufacturing and construction management, we delivered a turnkey industrial installation of sophisticated material handling and automated storage systems for a premier battery manufacturing facility.
The challenge: The primary challenge of this 15-month project was its evolving scale. During execution, the project scope expanded by 76%, necessitating exceptional logistical flexibility and resource management to maintain the timeline. Furthermore, the site was a high-density construction environment. Our team had to coordinate daily with up to 50 concurrent contractors, ensuring that our mechanical rigging and electrical wiring activities did not interfere with the wider facility’s development.
Our solution: Operating with a peak workforce of 100 skilled operatives, Beck & Pollitzer managed the full lifecycle of the installation from unloading and uncarting to final alignment and commissioning.
Mechanical & rigging scope:
- ASRS systems: Installation of two large-scale Automated Storage and Retrieval Systems across seven operational areas.
- SRM units: Precision installation and alignment of 17 Storage and Retrieval Machines.
- Conveyance: Installation of over 1,500 linear feet of STV (Sorting Transfer Vehicle) tracks and automated conveyors.
- Support structures: Assembly of four major maintenance platforms and various support frameworks.
Electrical & control scope:
- Installation of comprehensive cable tray networks.
- Mounting and wiring of primary power and control panels.
- Full-system power and control wiring to ensure seamless integration with the facility’s warehouse management system (WMS).
Delivering results safely: Despite the project’s duration exceeding 12 months and the significant increase in scope, the team maintained an impeccable safety record. Over 111,328 project hours were completed with zero recordable safety incidents.
By successfully managing the 76% scope increase while adhering to strict quality standards, Beck & Pollitzer has ensured the facility is equipped with the high-volume, automated material handling capabilities essential for long-term battery production growth. Contact us today to discuss your next project!
