A large-scale battery manufacturing facility—developed through a joint venture between a global automotive manufacturer and an international technology partner—required full mechanical system installation at scale. The 3.5 million square foot facility was designed to support high-volume production for next-generation electric vehicles and involved coordination across multiple design teams and global equipment suppliers.
The complexity of the project demanded seamless collaboration among domestic and international stakeholders, along with careful management of logistics, scheduling, and installation across a 24-month construction timeline.
Sylvan was engaged to perform all mechanical process pipping and sheet metal installation for the facility. Our team led full coordination and construction of all mechanical process systems, including the supply and installation of process-related sheet metal ductwork and piping throughout the site.
To support field operations and material management, Sylvan established a large warehouse area, including a temporary structure measuring 100′ x 265′. This enabled efficient staging, organization, and distribution of materials across the expansive jobsite while maintaining productivity and workflow continuity.
Through close coordination with project stakeholders and global suppliers, our team ensured alignment across design, procurement, and construction, maintaining control over quality, safety, and execution throughout the project lifecycle.
The project was substantially completed in January 2025 following more than 1.2 million safe manhours, reflecting a strong commitment to safety and disciplined execution. Sylvan managed a peak of 950+ workforce, including direct labor and subcontractors, while maintaining high standards for quality and schedule performance.
Based on Sylvan’s performance, the customer selected our team as its trusted mechanical partner for ongoing maintenance and future projects—establishing a long-term relationship built on proven capability, effective coordination, and successful delivery in a complex manufacturing environment.
