Manufacturing

/in , , /by

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.

/in , , , , /by

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.

/in , , , /by

NPA Coatings Inc. (NPAC), a manufacturer of chemical coating products, purchased a 45 acre re-purposed brownfield site from the city of Chattanooga, Tennessee to build a new facility to manufacture e-coat, acrylic resins, and paint for the automotive industry.

SSOE was selected to provide an Engineering, Procurement, and Construction (EPC) delivery method using a technically-led open book approach. NPAC is fully integrated in all activity, design reviews, procurement, and construction while SSOE offers a single point of responsibility – consistent project leadership from FEL to commissioning. Construction planning began from the project start, which prevents delays in the process install due to site construction and early site / structure packages, while eliminating waste and hidden costs in design hand-off to procurement, fabrication, and installation. Because of the all-encompassing scope of this project, SSOE drew from its extensive bench of engineers and architects from our chemical, facilities, and construction management groups to form an experienced team to work closely with NPAC.

An EPC open book strategy gives SSOE full project responsibility from FEL to commissioning, using one contract between SSOE and NPAC to cover the entire project. SSOE will bid and award hundreds of pieces of equipment and construction contracts, while NPAC will be fully involved in the decision making process and review of all quotations. A target budget will be prepared following the FEL work with a recommended contingency agreed by both SSOE and NPAC, ultimately leading to a reduction of the budget to offset overall risk.

The design includes translation from international practices to U.S. standards, for full safety and environmental compliance, including support for VOC / HAP emissions estimates, building classification evaluation, and storage for chemical compatibility hazardous materials storage, possible flood plain siting issues, and building height constraints within a nearby FAA regulated flight path.

SSOE is performing substantial FEL design to address all major code and safety considerations and resolve multiple design variables to define and provide cost certainty to the facility scope and enable funding approval by the parent company board in Asia. Based on the strength of that design process, NPAC will be able to evaluate and include substantial process controls upgrades in the design basis which will substantially improve product consistency, product quality, and employee safety.

Related to the building envelope, in addition to architectural design, SSOE’s facilities team is providing civil, structural, mechanical, and electrical engineering including fire protection services. NPAC hopes to achieve LEED status for the project and design is ongoing in accordance with pursuit of LEED certification.

Streamlining steel package delivery with BIM2Fab® Steel

To meet the aggressive project schedule, SSOE plans to leverage our BIM2Fab Steel services, an innovative application of virtual design technology that seamlessly integrates steel design and fabrication to deliver exceptional quality. BIM2Fab Steel offers multiple advantages, from minimized risk to reduced cost and schedule—in this case, compressing the schedule by at least 4 weeks and saving NPAC time, trouble, and money in the process. Our BIM2Fab Steel models save weeks on construction schedules and can be used for clash detection and coordination across trades, ensuring a cleaner, better delivered finished product.

In close collaboration with the client and steel fabricators, SSOE’s BIM2Fab Steel team can release fabrication-ready drawings just days, as opposed to weeks, after design documents are released. SSOE will supply detail and erection sheets as well as CNC files for automated fabrication machines, further cutting down the time required to deliver structural members to the field.

/in , , /by

Marking a key development in their North American expansion, YKK AP American Inc. selected SSOE to design the company’s new manufacturing facility in Macon, Georgia. The 400,000 SF space marries SSOE’s industrial and architectural expertise on a greenfield site to a new client.

As the North American arm of the global YKK AP group of companies, YKK AP America needed a space in the U.S. to produce residential vinyl windows, bringing extrusion, production, fabrication, glass, and lamination together under one roof. SSOE partnered with JE Dunn Construction Group to bring the facility to life. Serving as a model for future North American manufacturing facilities, the $125 million plant signifies a recommitment to the community of Macon that has supported YKK AP’s residential business since it was first established in the United States.

Investments in automation were made to improve production capacity, product consistency, and employee safety. Additionally, the facility is scalable to accommodate additional automation, increased capacity, and future business and product expansion strategies.

The new manufacturing facility was built to enhance the day-to-day employee experience. Approximately 12,000 SF of office space features natural lighting including tubular skylights to help draw natural light to the back of the office. The main conference room features a tapestry piece showcasing the client’s residential windows. Outdoors, the plant also has a walking trail and a flexible court that can be used for basketball or pickleball. There are spaces outside the breakroom for exterior dining that can also serve as an event space.

When the project began, the client did not know how much office space was required. Through value engineering, SSOE was able to provide the client $9.2 million in Value Promise. The team was able to right-size the office space from 30,000 SF to 12,400 SF yielding $4,300,000 in construction cost savings, $100,000 in office design cost savings, and approximately $241,155 in annual operating cost savings over a 20-year period.

Right-sizing the office space for the client’s needs yielded $9.2 million in project savings.

/in , , , , /by

To support their North American growth in the production of automotive electronic components, Continental AG chose an EPCM approach to deliver a modern, world-class greenfield facility in central Mexico. Due to our deep understanding of what is currently driving Continental’s business, knowledge of their various facilities, ability to successfully partner on large-scale projects, and proximity to the site, SSOE was selected to serve as designer, construction manager, and owner’s agent on the project located in FINSA Industrial Park.

The expert design team we assembled utilized SSOE’s Revit-based platform to create a complex 3D model that was used for weekly review meetings, and can be further utilized by the client’s maintenance staff to make future updates and repairs. Although our U.S. staff served as the discipline leads, we engaged our multidisciplinary, English-speaking team in León, Mexico to heavily support the design phase and bring additional value to our client. During the design phase, our team suggested design enhancements to achieve Continental’s desired vision for the new facility—suggestions were incorporated with no
impact to the original schedule.

Building areas on the 122,000 sq. m. site totaled 24,250 sq. m. and consisted of a single story manufacturing facility and adjacent two-story office, staff area, and cafeteria. The project also included infrastructure lines on-site, internal roads, parking lots, bus drop off and truck waiting areas, as well as median connections to the park road at the boundary of the property. Design was complete within the aggressive five month schedule.

/in , , /by

SSOE provided architectural design, mechanical, electrical, plumbing, and LEED® and energy modeling services on this new 25,000 SF North Warehouse and Distribution Center for the National Institute of Environmental Health Sciences (NIEHS). This new space now consolidates all warehousing efforts onto the National Institute of Health (NIH) campus, not only increasing security, but eliminating the need for off-site leasing facilities.

The client’s goal was to design and construct the facility as a source basis Net Zero Energy Building (NZEB), a building that produces enough renewable energy to off-set its total source energy consumption on an annual basis. Net zero buildings are recognized worldwide as one of the highest aspirations in energy performance in the built environment. Creating a net zero building requires two basic steps. The first step is to increase energy efficiency through efficient building construction, efficient systems and appliances, operations and maintenance, and changes in user behavior. The second step is to address the remaining energy needs with on-site renewable energy generation. SSOE helped the NIEHS achieve both of these.

Since Title IV mandates that federally owned and operated facilities include LEED, the SSOE team not only designed a NZEB for this project, they also had to achieve LEED compliance for the systems used in the building. While the minimum acceptable certification level for the project was LEED Gold, the project team was able to achieve LEED Platinum in early October 2018. Additionally, the facility is the only NZEB in the U.S. Department of Health and Human Services (HHS). Based on the calculations from the energy model, the project will save the client 157,000 kWh/year or approximately $12,381 year.

/in , , /by

SSOE has been selected to provide engineering, procurement, and construction (EPC) services to a chemical client for a $23.9 million expansion project at their manufacturing facility based upon our previous EPC project experience with the client and their strong ongoing relationship.

The client creates graphite electrodes to service the steel industry. The scope of this project includes the construction of building space and equipment foundations, and installation of a furnace, conveyors, and pressure vessels. SSOE’s Energy, Glass, Chemical, and Manufacturing (EGCM) SBU will work together with SSOE’s construction management division, to provide EPC services.

This is SSOE’s second EPC project with this client, the first a machining building expansion at their Midwest U.S. carbon electrode finishing facility. SSOE helped the client construct a new 30,000 SF space to allow for the integration of new process equipment to replace antiquated equipment in the existing plant. SSOE was able to complete this project, limiting cost impacts to the client in a challenging market.

/in , , , , , , /by

SSOE’s complete steel prefab structural building drawing ultimately saved La-Z-Boy over $500,000.

La-Z-Boy desired a research and development center that reflected the importance of innovation and technology to their company. Their vision was to create a new state-of-the-art R&D facility with larger, modern work spaces that would aid in improving staff recruiting and retention.

The SSOE team, with construction manager Rudolph Libbe, worked closely with La-Z-Boy on this design / build project, utilizing 3D modeling reviews to communicate clearly with the client’s project team to assure they fully visualized the design concepts. This allowed the client to understand the design at each phase and see how their design requirements were being incorporated. The final design included a combination of a 50,000 SF pre-engineered research building and a 20,000 SF conventional building designed with flexibility for the office spaces.

The research / testing area includes shops, wood working, and engineering spaces. The office space has an open floor plan incorporating the flexible workplace strategy, with only one walled office for the vice president. This floor plan, along with the café and outdoor seating areas, follow La-Z-Boy’s overall strategy to have office neighborhoods where people aren’t tied to the same work space on a daily basis, providing employees with a choice of where to work. There are also movable furnishings with electrical outlets located throughout for device charging.

The Innovation Center’s corridor is lined with windows that provide a view into the research and engineering brainstorming “garages” where they refine pieces of furniture and collaborate on design innovations. SSOE’s engineering team designed a special dust collection system used in the facility.

SSOE was pleased to offer architecture, MEP and structural engineering, dust collection, data / fire / security design, steel detailing, and interior design services for this facility that met the client’s goal and vision for a modern and flexible workplace for their employees.

/in , , , , /by

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.

/in , , /by

Over the past 6 years, we’ve managed to save a leading consumer products client more than $8.8 million on SSOE projects demonstrating the ever-increasing value of our partnership. They’ve utilized SSOE as their preferred A/E partner since we began providing our services to them in 2012.

The client had seldom worked with outside firms and was initially apprehensive about working with a new team. Our multidisciplinary team worked diligently and consistently to build trust within the client’s team, while providing world-class service, which has resulted in us delivering 48 projects at the client’s various processing facilities. Here are some of the highlights:

Production Capacity Increase

In order to increase the production capacity of plastic storage bags, the client entrusted SSOE with the conversion of two production lines. As this conversion involved a new product, time to market was crucial and an aggressive schedule was required. The project included the design of a vacuum and reclaim system to feed waste to the front of the production line, along with an exhaust system for new production equipment. We also provided the design of a mezzanine for the support of additional production equipment, an upgrade to the plant power supply, additional process equipment, and various building upgrades that included fire protection systems.

Instrument specification support and electrical upgrades consisting of a new transformer, switchgear, and electrical panels were also required. Our team was able to save the client $58,500 on this project by repositioning hangers to align with existing steel floor beams, reusing an existing roof girder to hang the bridge crane runway beams rather than installing new, and leaving the existing switchgear connected to its transformer to avoid swapping feeds with the new equipment. Additionally, we provided procurement services, construction management support, and package delivery for all SSOE-designed systems.

Innovation Solutions with Technical Know-How

Impressed by the value SSOE brought on previous projects, the client asked SSOE to design or modify various mechanical processes for multiple unique lines across several processing facilities to add new features to its plastic storage bags. Functioning as an extension of the client’s team, we worked directly with their R&D staff to design several prototype subassemblies, which were installed in a pilot line to verify functionality before full-scale design.

Based on the client’s aggressive schedule and launch date, it was evident that a traditional design / bid / build delivery method would not be effective for this project. In addition, there was a requirement to minimize downtime for all lines. We worked with the client to develop a project execution strategy that reduced the amount of downtime from 3 weeks to 2 weeks per line, providing the client more than $3 million in savings. Contractors were pre-selected and participated in review meetings early on to not only collaborate more effectively, but improve external coordination and ultimately the outcome of the project.

One challenge was incorporating more than 10 unique equipment layouts that we designed to fit into different locations within the client’s various facilities. Additionally, the layout for new equipment needed to be installed within the previously mentioned 2-week window—no small feat. We also attained a temporary project license in the location of one of the client’s facilities in order to seal required drawings and keep the project on schedule, which ended up saving the client a projected $2 million in construction package redesign fees.

Expanding Production to Enter New Markets, with More Options

The client was looking to add three additional lines at an existing manufacturing facility to increase production capacity, expand into new retail markets, and create fresh packaging options. Our multidisciplinary team was selected to provide both facility and process support on this $25 million project—performing architectural, civil, structural, and MEP engineering on the project as well as machine design, packaging, controls and instrumentation, and process design for utilities. We were also responsible for purchasing all equipment.

During the project, we worked with the client to install temporary walls to prevent contamination and disruption of other production lines. SSOE’s in-house construction capabilities were also put to use as we helped optimize the construction bidding process for the client, assisted with procurement and cash flow management, and provided on-site field support for the duration of construction. At the peak of the project, the team consisted of more than 25 people.

The project was not without its challenges. At this particular facility, the client was implementing two very large capital projects with aggressive schedules at the same time, creating several obstacles along the way—including a contractor that was new, not only to the site, but also the client, and a modified purchasing procedure that required detailed bid packages be divided by discipline. To keep the project on track, our team assumed leading start-up and commissioning activities and was tenacious in providing the higher level of detail needed for construction documentation, meeting all budget, schedule, and staffing requirements while maintaining a level of quality the client had come to expect from SSOE. We were able to reduce the number of planned packaging lines without negatively impacting production, thus saving them more than $2 million.

Increasing Production Output by Maximizing Technology

When the client set a goal of increasing its production of plastic film storage products within a multi-year period, they again reached out to SSOE for assistance. By this time, our team had worked to seamlessly integrate themselves into the client’s engineering team, assisting them with multiple key capital projects in addition to supporting a number of routine activities. Our on-site team solidified their relationship with the client, leaving them confident in our ability to help them meet their ambitious goal. Due to our positive track record and knowledge of both the client and the site, SSOE was selected to deliver this $65 million capital expansion project, providing conceptual engineering through start-up and commissioning.

The project—designed to cGMP standards—included the design of a new facility on the client’s existing site and two identical packaging lines within: one for carton and case packing, and the other for shrink wrap and bulk packing. The process included new and innovative packaging concepts. In order to address space constraints and operator access issues, the process was designed into a Lean configuration, allowing the system to fit into the designated area while reducing overall operator travel and increasing efficiency. Notably, the SSOE-designed facility qualified the client for a local energy efficiency
program, which equated to an $170,000 credit. Our design optimizations also allowed us to eliminate confined spaces in the new facility and reduce work at heights, helping us achieve more than 180,000 working hours of injury-free construction.

An industry leader in leveraging technology, SSOE employed reality capture, or laser scanning, to significantly improve the speed and accuracy of capturing existing field conditions. By using a long-range scanner—one of three types of scans we have the ability to perform—we not only reduced time spent conducting on-site walk-downs, we were able to create a point cloud that was referenced into a detailed 3D model, which helped avoid costly rework in the field. The resulting 3D model served as the basis for all design reviews, bringing project stakeholders together early on to eliminate hand-offs, reduce waste and cost, and compress the schedule. The approach also allowed for design changes on the fly while providing ongoing clash detection.

Giving the client a lot of credit: the SSOE-designed facility qualified the client for a local energy efficiency program for one of two packaging lines, which equated to an $170,000+ credit.

/in , , /by

SSOE was chosen from a field of other qualified candidates to lead the site selection process for Polaris’ new production facility—nicknamed “Project Axle”—a more than $125 million investment for the premier manufacturer of off-road vehicles. The firm had a broad spectrum of criteria to identify, an RFP to create and responses to evaluate, and cost models to develop. To start, SSOE created a grid listing requirements for the site, the surrounding area, and other relevant issues including the quality of life, utility costs, availability of qualified work force, and dozens more. The process would entail comparing one set of advantages to another. For example, Polaris preferred this plant be located in a right-to-work state, but needed to balance that against a logistical drawback: most of its suppliers are located in northern states.

Polaris desired to be very inclusive in its search, therefore, the site selection RFP was sent to 14 states—union as well as right-to-work states—and proposals were received for 150 sites. After responses were evaluated, the short list totaled eight sites in four states. Once these locations were visited, SSOE was able to narrow the contenders to three sites, each in a different state. Once these contenders were identified, SSOE and Polaris were ready to begin incentive negotiations.

Among the advantages that put the Huntsville, Alabama site on top was its proximity to the interstate and Huntsville International Airport, acreage available for further expansions, good soil conditions, lack of environmental issues, sufficient access to utilities, availability of skilled labor, and a highly professional team of local and state government officials. SSOE also provided civil design engineering services for the new facility, which is expected to generate up to 2,000 jobs by 2020 and create a ripple effect that will boost the area’s economy and making the project one of Alabama’s largest job-creation projects in recent years.

/in , , /by

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.

/in , , /by

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.

/in , /by

SSOE’s approach expedited decision making and helped Goodyear streamline a design process that would typically extend throughout the entire construction phase.

In collaboration with Goodyear engineers and our construction partner, SSOE completed a highly integrated utilities and process installation design for a 1 million SF tire manufacturing facility in San Luis Potosí, Mexico. This is Goodyear’s first new manufacturing facility in the America’s in 25 years and will produce approximately 6 million premium tires will be produced at the facility annually.

Goodyear selected SSOE for its breadth of engineering services and advanced design delivery methodologies. For example, SSOE maximized use of advanced software tools (Bluebeam, Navisworks) for highly efficient, issue-focused design reviews. SSOE’s approach expedited decision making and helped Goodyear streamline a design process that would typically extend throughout the entire construction phase.

SSOE worked with Goodyear’s design engineers to introduce an alternative design approach, establishing a dynamic three-way SSOE-Goodyear-contractor partnership and adding value to this highly successful project.

As a result of our advanced engineering design services, SSOE was also asked to provide piping fabrication spool drawings for a major equipment set to assist the contractor with overall timing and installation.

/in , , /by

The SSOE team documented more than $500,000 in cost savings through innovative approaches on the project.

SSOE was selected to provide architectural, structural, mechanical, and electrical engineering design services for a 150,000 SF tire manufacturing facility expansion in the Southeast U.S. The area for expansion included wire winding, tire build, and tire curing areas which included utility routing to the curing presses through the pit and trench system.

Cooling water and electrical upgrades were required to support the expansion along with the relocation of a main drainage swale and the reconstruction of the fore-bay / detention pond system.

During the initial design meetings, SSOE was given design parameters for a 100’-0” addition. Bay sizes were then discussed as (2) 50’-0” bays +/- and how bay sizes would match with the curing trench locations. SSOE proposed to clear span the entire 100’-0” distance in the curing area and within the ASRS, tire build, and wire wind areas to allow for maximum flexibility within the space. The idea was accepted with a single stipulation of minimum clear heights within the building. The main girders were designed with specific clearance openings to accommodate the utilities so that the clear height could be maintained. While there was a premium in the steel framing for long span members, larger columns and footings, the cost was partially offset by reduced column quantity and foundations / excavations.

SSOE’s scope also included steel detailing services, eliminating the need for steel shop drawing generation and review—resulting in a 10-12 week reduction in project schedule.

/in , , /by

American Axle & Manufacturing (AAM) selected SSOE to assist with conceptual design and construction document development for their new 300,000 SF manufacturing plant in Silao, Mexico.

This project commanded strict design document reviews by all disciplines in order to comply with the requirements of Mexico’s local and state laws, as well as AAM’s international standards. In addition, effective communication between SSOE, the General Contractor, and AAM helped to log sufficient information in order to solve any problem or conflict that was presented.

SSOE also served as Owner’s Representative for the design / build phase of the project with a Construction Manager. We worked full-time on-site reviewing the quality of the construction, making sure that the contractor delivered according to the design and engineering, managing schedules, monitoring progress, and inspecting shop drawings, among many other activities.

/in , , /by

In Mexico, Walmart is ramping up its distribution capabilities with a number of new distribution centers to expedite and improve product delivery to its stores. The new distribution centers will allow Walmart to strengthen and expand its logistics operations, with the goal of reducing time and costs in the supply process.

With an ambitious multi-year schedule for program completion, Walmart’s plan involves the construction of new distribution centers and the upgrading of existing centers. The retailer has engaged SSOE as one of their strategic partners to help design and build new centers in Chihuahua, Tabasco, and Chalco, with potential for additional projects. The facilities in Chihuahua (35,000 m2) and Chalco (60,000 m2) are dry warehouses, while the facility in Tabasco (38,000 m2) is a refrigerated distribution center—a project requiring unique refrigeration experience that other A/E firms in Mexico were unable to provide.

SSOE’s phased design approach prioritizes close communication and coordination between multiple Walmart divisions (including logistics, human resources, safety, and operations) and the SSOE project team. This includes continuously updating coordination and communication tools used for project delivery, and leading workshops and design review meetings that incorporate 3D Virtual Reality walk-throughs. This approach ensures that the integrated design team is able to focus on project goals and provide an operationally efficient and flexible design.

The benefits of SSOE’s ongoing partnership with Walmart include in-depth understanding shared by all team members of Walmart’s goals, needs, and business objectives, as well as the ability to ensure consistent implementation of Walmart’s global design and construction standards from project to project.

/in , , , , , /by

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.

/in , /by

SSOE’s extensive 3D model coordinated the efforts of multiple engineering sources and prevented potential interferences prior to construction, creating savings of $100,000. In addition, a design recommendation increasing the cumulative live load deflection criteria saved $300,000 for a total of $400,000 in savings on design and steel.

SSOE’s extensive structural engineering capabilities were a crucial factor for the success of the upgrade and expansion of the largest sorting and distribution facility and parcel conveyor process in the world. Several of SSOE’s engineers and designers who were part of the original facility’s design were also part of the expansion, bringing extensive knowledge and experience to this project. Included in the scope was the design of primary and secondary steel support, and tertiary steel (grating, handrails, ladders, stairs, catwalks, platforms, etc.) associated with the installation of parcel conveyors. Creating a 3D model for the project, SSOE coordinated information from other engineering sources involved in the various design aspects of the distribution center. The model allowed for automated detection and graphic depictions of potential interferences prior to construction, and proved to be key in resolving critical design decisions for the conveyor installation.

SSOE was faced with many design challenges, including extremely stringent deflection criteria to ensure the proper functioning of highly sensitive sorting equipment. The conveyor layout was very complex with multiple conveying systems, including provisions for future systems, multiple levels of access, and adjacent conveyors that sloped in opposite directions. With this in mind, SSOE recommended a design solution to increase the cumulative live load deflection criteria, which provided more than $300,000 savings for the overall steel costs, all while maintaining the project schedule.

/in , , , /by

14% less energy use for long term savings. Environmental pilot for future facilities.

As part of the Army and Air Force’s initiative to construct all new buildings to green standards, the Army and Air Force Exchange Service (AAFES) made plans for a new, sustainable retail facility on the Randolph Air Force Base in Texas. The one stop, state-of-the-art facility, serving more than 50,000 active, reserve, and retired military personnel and their dependents, was one of the first AAFES facilities to pursue LEED Silver certification. It was also part of the USGBC’s pilot program to develop LEED guidelines for the retail industry. SSOE spearheaded the design of the facility with a with a food court, sales area, specialty vendors, onsite fuel stations, outdoor lifestyle areas, and a loading dock, while also leading LEED certification efforts.

SSOE designed a data / voice, fire alarm, and mass notification combination system for this 167,000 SF facility. As part of the data communication system, a wireless study was performed to determine the best placement of wireless internet antennas. The wireless system was designed to comply with the IEEE 802.11 wireless standard.

Using more than 20% recycled materials, the facility also features an energy management system to coordinate efficient lighting, heating, and air conditioning systems that reduce energy consumption and costs. A roofing membrane reflects 78% of sunlight minimizing energy use within the facility and water-efficient equipment reduces water consumption by 20%. A central cooling tower and chilled water system provide a high efficiency means to cool the complex. Using 14% less energy than a traditional similar facility, AAFES has used this environmental model as a pilot example of how to conduct future design and construction projects. Other distinctive aspects of the project include implementation of Anti-Terrorism Force Protection (ATFP) standards relative to siting considerations, building controls, and security systems.

/in , , /by

SSOE assembled a team specializing in cleanroom design and construction to engineer, design, and support construction of multiple basebuild systems including a cleanroom installation at a facility in Boise, Idaho. The client, a semiconductor and memory manufacturer, relied on our expertise to provide support for the projects under a fast-track schedule, while managing multiple onsite subcontractors as SSOE converted the building into a cleanroom facility.

After meeting with the client and performing an exhaustive investigation of the site, SSOE provided preliminary engineering and scope development services for the facility. The existing structure required a thorough structural analysis to ensure that it could support future equipment installations, which we provided under a tight deadline.

The structural scope included an exhaust stack support, utility racks, a bulk gas tank, and the cleanroom ceiling. Our process team created numerous systems including ultrapure and hot ultrapure water, solvent waste, chemical delivery systems, and bulk and specialty gasses. SSOE designed the cleanroom HVAC system for clean production space, and modified the existing HVAC system for the support areas.

In collaboration with the client, SSOE constructed the house VAC and OFA systems to meet the requirements of the upgraded facility as well as modifying the air handlers to change capacity as needed. The coordination of the bulk tank and chilled water systems required constant cross-discipline communication and careful schedule management. The utilities for tools and building services, and controls were also included in our scope. Understanding the client’s needs, we laid out the facility for future tool installations, and took care to include as much of the existing system as possible, while offering cost-effective recommendations for modifications and upgrades based on future need.

SSOE integrated the client’s existing project documentation procedures with our own, which allowed for swift responses to critical questions and submittals.

/in , /by

More than $1.5 million in total energy incentive rebates, in addition to energy savings of 650,000 therms of gas and 96,000 kWh of electricity per year.

SSOE was instrumental in completing a highly successful manufacturing complex renovation for worldwide energy leader General Electric in Schenectady, New York. Work on the 40,000 SF autoclave piping area involved the renovation and redesign of steam/asphalt co-axial piping, vacuum, nitrogen, steam and condensate systems. SSOE provided comprehensive design and construction management services for the project.

The project included redesign of a largely undocumented complex industrial system and development of a construction schedule to minimize manufacturing operation downtime. SSOE addressed suboptimal routing in the complex using intensive as-builts to compensate for lack of documentation. Prefabricating many of the piping spools off-site helped minimize manufacturing downtime and streamline the construction process.

Hailed as a tremendous success, this project netted approximately $1.5 million in total energy incentive rebates from National Grid, an electricity and gas company that delivers electricity to approximately 3.3 million customers in Massachusetts, New York and Rhode Island. SSOE’s work helped GE achieve efficiency upgrades that will save more than 650,000 therms of gas and more than 96,000 kWh of electricity per year.

“The project savings are substantial. SSOE did an excellent job managing construction. They picked up the design very quickly and drove the project to completion. Our autoclave operators are very happy with the upgrades, especially in the areas of safety and functionality.”

Michael J. McGowan, P.E.
Facilities Mechanical Engineer
GE Power & Water

/in , , , /by

SSOE has deep experience across many manufacturing sectors. The following are examples of GE Power & Water industrial / manufacturing project experience:

  • Punchline Process Improvement
  • Asphalt Distribution System Analysis
  • Powerhouse Backup Fuel Study
  • Storage Tank Building Demolition
  • 160 PSIG Steam Stress Analysis
  • 400 PSIG Steam Stress Analysis
  • De-Superheater Stress Analysis
  • Stress Analysis HPS Steam Main

Punchline Process Improvement (2013)
Schenectady, New York

SSOE performed process analysis for the purpose of increasing product quality and throughput in the following punchline functional areas: stamping, deburring, final coating, and curing operation. Recommendations and costs were provided for replacement and improvement of the existing manufacturing equipment. The project included manufacturing flow diagrams and equipment selections.

Asphalt Distribution System Analysis (2012)
Schenectady, New York

SSOE performed various engineering services for an existing asphalt distribution system in the plant’s bar shop. The project included fluid flow analysis, pipe stress analysis, pipe support system redesign and reconfiguration, project scheduling, and estimates.

Powerhouse Backup Fuel Study (2012)
Schenectady, New York

SSOE developed a study investigating various fuel options for various fuel alternates for an existing 400 PSIG steam plant. The investigation included comparison of propane air mix, natural gas, and #2 and #6 fuel oils. SSOE performed preliminary design services to help develop proof of concept. The firm also performed energy and cost analysis calculations for proof for funding.

Storage Tank Building Demolition (2012)
Schenectady, New York

SSOE provided a demolition design package for an existing abandoned asphalt storage tank and mixer. The project design included demolition and rework required for segregation from the building’s steam and electrical systems. The design required development of system understanding to minimize interruption to existing manufacturing operations. The project included design, project scheduling, and estimation services.

160 PSIG Steam Stress Analysis (2011)
Schenectady, New York

SSOE performed stress analysis per ASME B31.3 for an existing 160 PSIG system to accommodate operational temperature increase. The firm investigated field conditions to verify existing valve classes and piping infrastructure. SSOE mitigated resulting stresses through system modifications and upgrades of existing components.

400 PSIG Steam Stress Analysis (2011)
Schenectady, New York

SSOE performed stress analysis per ASME B31.3 for an existing 400 PSIG system to redesign the damaged support system. The firm provided analysis with a new recommended support scheme.

De-Superheater Stress Analysis (2012)
Schenectady, New York

SSOE performed stress analysis for a new steam loop for de-superheating per ASME B31.3. The firm worked with GE to simplify system design to expansion joints and minimize impact to the 80-year-old boiler house.

Stress Analysis HPS Steam Main (2011)
Schenectady, New York

SSOE completed an analysis of an existing 600 PSIG / 750 F superheated steam piping, 14″ line size, to confirm adequate flexibility prior to modifications performed during shutdown. Autopipe software package was used to perform the analysis and recommendations were provided back to pipe fitters prior to work.

/in , , /by

Creative design planning saved floor space and enabled uninterrupted operations during early phases of construction.

In 2013, SSOE provided comprehensive design services for a wheelbox upgrade for General Electric’s Steam Turbine Test Laboratory in Schenectady, New York. A leading manufacturer of critical high-speed rotating equipment for the power generation industry, GE Power & Water uses the test laboratory to perform vibration testing of turbine wheels.

One of GE’s major test systems, the wheelbox is a large evacuated chamber in which turbines are run through a range of operating speeds to determine bucket vibration response.

Wheelbox 2 SmallFor this project, SSOE performed the design for removing an existing 4,000 HP induction motor located in the Building 262 (B-262) wheelbox drive pit. Our design included removal of associated control and power control equipment and the eddy current clutch. SSOE also provided detailed design to support installation of the new 5,000 HP induction motor with associated new VFD and new isolation transformer. Modifications to existing switchgear, new motor power feed cabling to the switchgear, oil system connections, control system and vibration monitoring system, including associated wiring, were also part of the scope.

Working within an aggressive project schedule, SSOE addressed a number of project challenges, such as floor space limitations and the client’s need for uninterrupted use of existing systems and equipment during the early phases of construction. Creative repurposing of existing space, namely installing the new VFD on the mezzanine above the lab, helped us work within space limitations. Relocating system connection points and modifying system designs to allow for later installation enabled the client to use the existing equipment to complete current ongoing testing.

/in , /by

SSOE was able to reorient the replacement so the conduit could be reused, resulting in a savings of $50,000. By reusing storage and surge tanks and suggesting an alternate insulation for piping, our team was able to save another $60,000. To date, total cost savings equal $110,000. The refrigeration system replacements are expected to produce an annual cost savings of $780,000.

The U.S. Army Corps of Engineers enlisted SSOE to replace outdated equipment that would decrease the environmental impact and reduce energy costs at the Aeropropulsion Systems Test Facility, part of the Arnold Engineering Development Center (AEDC). The AEDC is the world’s largest ground flight simulation complex, testing nearly all the Department of Defense and NASA systems since the 1950s. Work on this project showcases SSOE’s extensive capabilities to support state-of-the-art technology projects and leverages our experience in large-scale facilities and high-tech laboratory environments.

Known as the Turbine Engine Dry Air Capability (TEDAC) program, the goals of the project are to replace the existing 30-year-old refrigeration system, reduce the facility’s dependency on Trichloroethylene (TCE) and R-12 refrigerant, improving reliability and maintainability. These hazardous substances will be replaced by more environmentally friendly fluids.

Utilizing design-build project delivery, SSOE provided full engineering analysis and design for the demolition and replacement of two existing refrigerant systems. These systems supply 3,000 to 6,000 tons of brine to a cooler, measuring 150 feet in length and 42 feet in diameter, that dries and cools process air used for turbine altitude testing. Because simulating altitude conditions for testing these engines requires a climate controlled environment, the HVAC/R systems are a critical component of this facility.

/in , , /by

Saved the client $26,000 through cost effective practices such as using aluminum conductors instead of copper conductors and reducing the quantity of clean agent tanks.

Boeing was contracted to deliver an end-to-end satellite communications system that included two new ground monitoring stations. Each station consisted of a highly technical control room and server rooms. Boeing called upon SSOE to provide mechanical, electrical, and fire protection engineering services for the rooms.

SSOE’s responsibilities included design of the facilities’ Uninterruptible Power Supply (UPS) systems, back-up generators, HVAC systems, and fire protection systems. SSOE used a clean agent suppression system as part of the fire protection that would not harm the sensitive equipment. Additionally, because both facilities are located in extremely hot and dry environments, special considerations were made for the HVAC systems. Seismic considerations were also incorporated into the design for the Mexico City facility.

SSOE designed the stations in accordance with International Building Code and worked closely with the end- user’s construction manager and architect in Mexico.

/in , /by

This fast-track project was completed on time and on budget with documented SSOE generated savings of $12.8 million.

TPCO America, a manufacturer of high quality API Grade steel tube, sought to establish production facilities in South Texas in order to capitalize on the growing demand for steel tube generated by the oil and gas industry. As a subsidiary of Tianjin Pipe Corporation, China’s largest producer of seamless steel pipe, TPCO understood the importance of having American engineering and construction companies on board who are experts in designing and delivering integrated production facilities worldwide. SSOE and its construction partner, Yates Construction, were selected for their vast experience successfully delivering similar projects worldwide.

The design / build team of SSOE and Yates is responsible for the complete design of the pipe rolling / pipe finishing mill, with SSOE providing architectural, engineering, and design services for the plant, including facility and infrastructure design, facility and process utilities design, process integration, equipment installation, and construction support.

Working closely with Yates, SSOE is applying a concurrent design / build approach, which makes it possible for the team to deliver the 1.6 million SF facility on a compressed schedule. The pace of the project increases the importance of SSOE’s job to coordinate all aspects of the work with Yates.
The project site provided significant challenges, as a substantial amount of stabilization was required due to its sandy composition and the need for very stable foundation for processes. SSOE designed a piling network to stabilize the substructure and distribute the load to maintain alignment and functionality of manufacturing systems in the future. To maintain the project budget, SSOE worked with Yates to research and provide the most economical design and construction solutions for this site.

/in , , /by

Taking advantage of the local climate allowed SSOE to design an energy efficient facility, reducing energy costs.

In late 2012, SSOE Group merged with Evergreen EDC bringing significant synergies to both firms’ data center capabilities.

Digital Realty, a worldwide leader in data center solutions, selected SSOE to provide architectural and engineering services for its customer’s new 52,000 SF facility in Hillsboro, Oregon. The 4.5 MW data center was designed using modular and scalable design principles and includes four identical and independent server equipment room PODs, each approximately 4,600 SF and containing 120 cabinets. Two additional PODs have been included on the site master plan and can be added in the future. The modules are organized along a central service corridor, which provides access to the server, electrical, and battery rooms. The rooftop air handlers utilize air side economizers to provide “free cooling” to the data center for up to 10 months a year. Cool air is supplied to an overhead plenum that distributes the air to the server cabinet cold aisles. The cold aisles are architecturally isolated from the rest of the room (hot aisles) using modular wall components, which assures efficient air flow and eliminates the mixing of hot and cold, thus reducing overall energy costs.

The most significant challenge on this project proved to be fitting the building program requirements within a small, sloping site. By implementing a rapid prototyping design process, SSOE was able to quickly produce a wide range of building configurations and site master plans, allowing the owner the opportunity to provide timely input. The use of this design process was instrumental in keeping the project on schedule and ensuring the owner’s needs and expectations were met. In the final design, SSOE maximized the building footprint by wrapping the support spaces around the server room modules.

The result is a dual-corridor system, one for service and the other for client access, which meets the varying levels of security protocol required by the owner. The building was also orientated and formed to take full advantage of the overall depth of the site, while still maintaining a separate and secure entry for both on-site parking and service yard access. SSOE raised the finished floor elevation of the building in order to balance the cut and fill requirement on the site, and to eliminate off-site soil disposal.

SSOE’s design process, relationship, and familiarity with the local code jurisdiction were instrumental in meeting the aggressive project schedule. We worked cooperatively with Digital Realty to design a cost effective, energy efficient data center that met their current demands, while also maintaining flexibility to adapt to future growth.

/in , , /by

SSOE provided comprehensive electrical engineering consulting and design services to GE Intelligent Platforms, a business unit of GE Energy Management. Over the course of a year, SSOE addressed electrical needs for an existing 45,000 SF building and a new 20,000 SF addition to GE’s Huntsville, Alabama, campus.

A key location for GE Intelligent Platforms, the Huntsville campus manufactures an array of high-technology products serving defense and aerospace, medical, semiconductor, industrial, and communications customers.

In the first phase of this project, SSOE performed a detailed site survey to determine costs for construction of the addition and evaluated the existing building for compliance with current codes. SSOE then conducted feasibility and code studies and provided electrical system design criteria and alternatives.

Once the design was finalized, SSOE provided construction administration services for the electrical portion of the project, including shop drawings and submittal review. SSOE also helped the client update electrical plans for the 613 SF Shaker and Control Room and relocate the thermal chambers in the manufacturing area.

Additional work included power and circuiting for the 940 SF single-story storage area addition, modifications to exterior site lighting (metal halide fixtures changed to LED fixtures), and electrical design for revisions to a 10,000 SF second floor in the building.

During the course of the project, the Owner presented a number of revised requirements that demanded quick design modifications. SSOE rapidly incorporated all changes and successfully met an expedited timeline associated with the relocation of GE’s Albuquerque, New Mexico plant operations to Huntsville.

After successful project completion, GE sought SSOE’s assistance in sourcing support during an emergency equipment failure.

/in , , /by

Having successfully performed design work for thousands of greenfield production plants, SSOE was well qualified to serve as the Engineer of Record (EOR) and oversee architectural and engineering services for the configuration and installation of a new steel tube production facility. Strong project management was needed to coordinate the efforts of the design / build contractor, multiple OEM suppliers, and an international client to meet an aggressive time line for production start-up.

Located on a 300-acre, greenfield site, the production facility consists of a pre-engineered metal building with a concrete mezzanine, operations, and production floors. Primary manufacturing operations include billet preparation, piercing, sizing, finishing, testing, and all related furnace and heat treating equipment. Other facilities on the site include in and outbound logistics, administration / training center, utilities, water treatment, chemical treatment, and cooling towers. SSOE also provided site preparation services.

Utilizing the 3D MicroStation design platform and Navisworks, SSOE electronically produced the architectural rendering and video of the plant for ground breaking announcements, contractor outreach program, press releases, and public relations purposes.

/in , , /by

SSOE’s innovative design for the abatement system and operational energy efficiency improvements saved the client $11 million.

SSOE was selected by the site owner to provide engineering services for detailed design and construction to produce ceramic materials at a site in the Southeastern U.S. Although the client already had a specialized engineering team working on the facility, it was recognized that the effort was resource limited, and SSOE had the resources and experience to keep the project on schedule and on track. As part of this effort, SSOE also led the air permitting process and was responsible for other environmental permits required to build and operate the facility.

First priority for SSOE was to assist the local environmental consultant in obtaining information necessary for air permit application and approval. SSOE’s environmental specialists worked with the process specialists and engineers to determine critical process emission information required, and also assisted with communications with the appropriate people in the state environmental office.

In addition to the air permit, SSOE also completed other required federal, state, and local environmental permits. These were separated into preconstruction, construction, and pre-operation / operating permits. Until the client assembled an on-site environmental staff for operations, SSOE acted as the client’s environmental engineer, assigning operating permits and plans to appropriate parties to complete. These plans included permits to install / operate, tank permits, spill plans, wetlands, water withdrawal permitting, NPDES wastewater discharge and stormwater permits and plans, and communication plans.

/in , , , , , /by

SSOE led the value engineering effort for this facility, developing more than $17 million in savings opportunities, resulting in more than $11 million in total incorporated changes.

In an effort to expand their market into the United States, a European tire manufacturer looked to SSOE to provide site evaluation, risk assessment, architectural and engineering services, and construction management for their 875,000 SF greenfield tire manufacturing plant. The scope included pursuing a viable site as well as providing assistance with environmental permitting requirements, including air permitting data. The facility will have the capacity to manufacture up to 4.65 million passenger / light truck tires per year within the first construction phase. The master plan for the greenfield site will accommodate up to 2 million commercial vehicle truck tires manufactured per year.

The plant features just over 100,000 SF of office, 600,000 SF of production, and 130,000 SF of warehouse space to support their projected 800 employees. Each area is unique to the intended user group and includes precast concrete, cast in place concrete, and structural steel framing systems. The process utilities are complex and range from multiple cold and hot water systems, natural gas use, compressed air demands, and high-pressure steam. SSOE provided electrical, power and lighting, data, fire and security, as well as an appropriate architectural statement for the Owner’s first major expansion in the United States.

/in , , , /by

SSOE was selected for this project based on excellent service on a prior KSM project, where SSOE’s intensive value engineering helped KSM reduce estimated completion costs by 33%.

Following a highly successful partnership with SSOE on their first U.S. facility — a greenfield high-pressure aluminum castings plant — KSM Castings again called on SSOE to provide design and engineering expertise for a second U.S. facility, a 53,000 SF state-of-the-art counter pressure casting (CPC) facility. The new facility expands KSM’s U.S. operations and provides a novel cutting-edge casting technology for automotive components manufacturing.

SSOE provided civil, architectural, structural, mechanical, and electrical design services for the CPC facility, incorporating efficiencies developed during the design and carrying those through construction of the aluminum castings plant.

Acting as Owner’s Representative, SSOE planned and coordinated construction activities for the new CPC facility to meet KSM’s facility milestones. To streamline progress, SSOE leveraged proven communication strategies based on Virtual Design and Construction (VDC) tenets and used clash coordination within the model to avoid delays during construction.

Early and ongoing communication with all involved parties, including construction contractors, created a fluid workflow with fewer interruptions, early buy-in, proactive solutions to potential schedule or construction conflicts, and a more successful project overall. KSM is positioned to easily expand in the future.

“SSOE knows us as a company, so they meet our technical needs. It’s very uncomplicated to work with SSOE. They offer us a whole scope, from site selection to architecture and engineering, into construction management. Dealing with only one consultant is very lean and straight forward.”

Jan-Christoph Schwarck
President / Plant Manager
KSM Castings USA

Contact Us

Have a question regarding our services? Need assistance with an upcoming project? Send us an email. We look forward to hearing from you and will follow up soon.

Contact Us

Our Services

© SSOE GROUP 1948-2024
Legal | Privacy Policy | CA Privacy Policy

Employee Portal
Vendors / Subcontractor

Website designed and developed by
Raincastle Communications, Inc.