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Our Next Energy Battery Production Facility Wins CAM Magazine Project Achievement Award, Featured in Special Issue

Our Next Energy Battery Production Facility Wins CAM Magazine Project Achievement Award, Featured in Special Issue

Our Next Energy’s (ONE) prototype line – the first phase of a $1.6 billion, 20 GWh battery factory in Van Buren Township, Michigan – was recognized by CAM Magazine with a Project Achievement Award and featured in the magazine’s Special Issue.

Working in partnership with construction management firm KIRCO MANIX, Ghafari provided architecture and engineering services for the 41,070 SF building within a building, which consolidates ONE’s production, storage, supply, and shipping operations under one roof. A key element of the facility program is a 29,240 SF ISO Level 7 clean room chamber with supporting infrastructure that includes truck dock doors, maintenance areas, and raw storage facilities – all essential components of ONE’s comprehensive manufacturing ecosystem.

While ONE executives initially intended to build a new factory from the ground up, looming deadlines prompted the search for a building that could be retrofitted to meet the stringent requirements of a battery facility. The search turned up a 660,000 SF precast warehouse distribution center already under construction. The facility’s core and shell exterior, parking lot, and landscaping were complete when the KIRCO MANIX-Ghafari team stepped in to execute the Phase 1 building within a building.

“When you walk in, you literally see another building inside,” said KIRCO MANIX Senior Project Manager Duane Allison. “The building within the building is something you don’t typically see in manufacturing or commercial, because in the environment to build batteries, you can’t just move into a building with four walls and a roof and say, we’re going to condition the air in that building to get to where we need. And that controlled space has to be a manufactured box, so to speak, with walls and a roof where you can control humidity, temperature, and parts per million for the HEPA filters.”

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After breaking ground in April 2023, ONE determined that the project would need to be accelerated from a 32-week construction schedule to just 24 weeks. Two weeks ahead of the deadline, ONE launched pilot production of its lithium iron phosphate batteries at the new plant.

“Meeting that schedule really is the accomplishment, and the fact that it was such a highly technical project that we did very quickly,” said Ghafari Vice President Scott Hahn. As Scott notes, the closeness of the team helped facilitate its success.

“If any one of the three had failed, it would’ve been a disaster,” he added. “If ONE wasn’t coming through with the information for us to base our design on, we would’ve failed on the engineering side. If Ghafari wasn’t producing the documents fast enough, KIRCO MANIX would’ve failed on the construction side. It really highlights the importance of the communication and the spirit de corps of the team.”

Read the full project profile in CAM Magazine’s Special Issue here.

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