Clarios Facility and Process Expansion in Multiple States
At a Glance
| Company: | GEM Inc, Rudolph Libbe Inc |
|---|---|
| Location: | Holland, Ohio |
| Industry: | Chemical, Industrial / Manufacturing |
| Service: | Concrete, Electrical, Equipment Setting / Rigging, Guided Process Solutions, Structural Steel Erection |
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At the Clarios auto battery manufacturing plant in Holland, Ohio, a multiple-phase construction project was needed to聽significantly increase production capacity of automotive Absorbent Glass Mat (AGM) batteries.
The GPS Design/Build Advantage puts the owner’s process first
Based on the complexity, traditional construction methods for this project would not 聽work as designs would need to be created around the owner鈥檚 process, not done to spec. By using the Guided Process Solutions (GPS) system for this project, the project was not only feasible, but could be done affordably.
Preconstruction planning enabled a complex build, with the plant still running
Careful preconstruction planning and the ability to adapt as the equipment design evolved were essential factors to the success of this installation.
The first phase of the project called for a new processing tower, however, a simple installation wasn’t going to be possible since the roof of the plant was a unique design with post-tensioned concrete roof panels. For a tower to be installed, the complicated roof had to be supported and removed.聽Portions of the roof large enough to bring the tower鈥檚 support columns through were cut. The new concrete foundations for the tower were poured beneath existing battery equipment as it was operating.
The 75-foot high, multi-level tower was then constructed above the existing roof and equipment. Once completed, the battery line was relocated, and three levels of supporting process equipment were connected with the facility鈥檚 upper floors.
Bringing聽a new product to market
Once the structural addition was complete, 聽oxide phase two聽process expansion was begun which included the installation for ore equipment. 聽The GPS system was again deployed due to tight space with no room to store materials. 聽Phase project steps with just-in-time equipment delivery were needed. 聽For example, lead dust collecting equipment – critical to the plant’s success – were hung from the rafters so that the floors could be finished first, after which the dust collectors were lowered into place. 聽A control room was built in place due to space constraints. 聽The existing chilled water system required phased work as it had to keep up with the oxide production while the new system was brought on line.
The 探花精选’s team brought not only expertise and experience to the project, but also the unique GPS approach of designing solutions tailored to the owner鈥檚 individual process requirements. The company鈥檚 investment resulted in increased production capacity of six million automotive AGM batteries at this facility, the first Clarios plant in North America to make them.
Since the time聽these projects were聽completed, RLG has managed oxide additions at three other Clarios 聽plants in Delaware, Missouri and North Carolina.
