Major Turnkey Manufacturing Facility Upgrade

Sylvan is supporting a major automotive manufacturer’s $3 billion retooling project at its flagship Ontario assembly complex, a facility spanning more than 5 million square feet across nearly 500 acres. As the manufacturer transitions production toward next-generation vehicle programs, Sylvan has been entrusted with delivering a broad range of critical installation and construction services to help modernize the facility and prepare it for future production demands.

Despite aggressive schedules and significant project changes, including a major mid-program scope shift following the removal of an electric vehicle production line, Sylvan’s team has remained adaptable and focused on execution. Following the completion of demolition activities, work progressed into phased installation efforts, supporting the facility’s modernization timeline and overall production objectives.

At peak staffing, more than 1,300 skilled tradespeople, including millwrights, ironworkers, pipefitters, and electricians, were mobilized onsite to support project delivery. Many of these resources were strategically redeployed from a previous large-scale battery manufacturing project, allowing Sylvan to quickly provide experienced personnel and maintain project momentum.

Through disciplined project management, workforce flexibility, and a strong safety-first culture, Sylvan continues to play a key role in advancing one of Canada’s most significant automotive manufacturing investments while helping position the facility for the next generation of vehicle production.