Client:

Walbridge

Project Stats

Stanton, TN

Location

Ford Motor Company

Owner

Ghafari

Architect

Design-Assist, Self-Perform Miscellaneous Steel Installation, Self-Perform Structural Steel Erection

Services

4,100,000 SF

Project Size

Project Overview

The Ford Blue Oval SK (BOSK) Battery Plant is part of a highly-anticipated EV development located in Stanton, Tennessee, about an hour northeast of Memphis. The development, Blue Oval City, will be Ford’s most advanced and efficient auto production complex in its 118-year history. Ideal Contracting is serving as the structural and miscellaneous steel erector for the battery plant.

As a trade partner to Walbridge, Ideal Contracting has erected approximately 55,000 tons of steel for the new battery plant, which spans more than 4 million SF. At peak steel erection, Ideal Contracting utilized (7) crawler cranes for the core & shell of the building as well as (3) rough terrain cranes for the mezzanine and utility racks. Over 200 Ideal Contracting skilled tradesmen and tradeswomen were working on the project during its peak. To ensure that there was a sufficient supply of fabricated steel for the project, Ideal Contracting strategically partnered with three different steel fabricators – Merrill Steel, Cives Steel Company, and Dave Steel company. Ideal had previously worked with each of these fabricators on various successful projects, resulting in strong relations being built between our companies.

A unique aspect of the Ford BOSK Battery Plant is that it is being constructed in a seismic zone. This prompted the design to reflect the requirements of a building that can withstand seismic activity, adding a greater degree of difficulty in every aspect of the steel erection process. These difficulties came in the form of larger and heavier steel members, bigger connections between pieces of steel, and a more strenuous material staging process. Ideal Contracting followed a stringent quality control process to ensure the work was executed properly.

An additional challenge were the harsh weather conditions faced by the project team. At one point during steel erection, it rained 1 out of every 3 days for more than three months. These conditions caused logistical issues for material deliveries, the reallocation of manpower and equipment, and a tighter schedule. Ideal Contracting’s project team collaborated with our client to prioritize certain critical path areas while supporting other subcontractors on site so they could complete their required work in a timely, efficient manner.

Ideal Contracting is proud to be a part of the monumental Ford BOSK Battery Plant project. Our team delivered successful design-assist and self-perform services throughout the project, building considerable value for the client and owner. Ideal’s performance on this project has resulted in strengthened relations and a growing expertise in providing steel erection services.

Project Highlights

  • 55,000 tons of structural steel
  • 450,000 man hours
  • 123 utility racks

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