In 2020, Gestamp, a manufacturer of automotive components, had outgrown their facility located in Chattanooga, TN. We were chosen to be a part of a design-build partnership to help plan and build a 124,817-square-foot expansion to the existing building. The project included selective demolition to accommodate the new addition, expanding both existing low bay and high bay sections of the building, providing a new 5,160 square foot storage canopy, and tying the two buildings together seamlessly while ensuring that the plant remained fully operational. The low bay expansion was designed to provide four additional dock locations and warehouse storage as well as house a new washing line and additional assembly equipment. The high bay expansion accommodated a new five-stage tandem press which required a mezzanine for the necessary electrical equipment, a tandem pit, and a new scrap tunnel to tie into the existing. It also housed two, sixty metric ton capacity cranes spanning 420 feet with a
new catwalk along the expansion edge that ties into the equipment mezzanine and another new catwalk along the existing building edge that ties into the existing catwalk and stair tower. Additional programmatic elements included a tooling office build-out within the new high bay expansion and the build-out of a toilet room and office area that also served as an equipment platform within the existing high bay area.
During the RFQ process for the Gestamp Chattanooga Phase I project, Gestamp identified additional scope that would be categorized as Phase II. Similar to Phase I, this phase includes selective demolition to accommodate the new addition, expanding the existing high bay sections of the building, providing a new canopy, renovating the existing quality control room, and tying the two buildings together seamlessly while ensuring that the plant remains fully operational. The 27,000 square foot high bay expansion is designed to accommodate a new blanking press and related processes, a mezzanine for the presses required electrical equipment and a thirty metric ton capacity crane spanning approximately 300 square feet.