Overview: FTI Leads $24M EV and Modular Battery Production Facility Project in Clarksville, TN
FTI was invited by DPR Construction to participate in a site walk for a confidential client’s first U.S. manufacturing facility dedicated to electric vehicle (EV) and modular battery production in Clarksville, Tennessee. Recognizing FTI’s expertise and proven track record, DPR selected us to lead the budget management and design for this $24 million project.
Challenges: FTI Faces Challenges in Engineering, VDC and Budget Management: Ensures Successful Completion of EV Battery Manufacturing Facility with Zero Incidents
FTI provided design assistance and installation, repurposing a former brake manufacturing facility to support EV batteries and energy storage production. A key aspect of the project involved rebuilding the electrical infrastructure from under 10 megawatts (MWs) to nearly 18 MWs to accommodate the client’s cleanroom manufacturing requirements. Additionally, approximately $5 million of the project was allocated to sourcing and installing the necessary switchgear, ensuring the plant became fully operational on time and within budget. Much of the engineering, virtual design and construction (VDC) and budget management on this project happened simultaneously. More than half of the project was built while FTI was still completing the design, requiring close collaboration with the engineer. Another challenge was the over-engineered electrical switchgear package, which risked delaying the project. Additionally, the evolving technology of EV batteries and storage solutions required continuous design modifications, which FTI successfully navigated while keeping the project on track. Lastly, working with a new client and general contractor also required building trust while maintaining a focus on safety.
Solutions: Design Precision and Strategic Partnerships Power Faster, Smarter Delivery
FTI’s team met multiple times per week to refine schematic designs, using them to price the project, control costs and ensure code compliance. FTI’s VDC team modeled these designs for construction. We also leveraged our partnership with Schneider Electric to optimize the design, reducing lead times and costs while ensuring early delivery and installation.
Results: FTI Achieves 47,000 Safe Labor Hours and Expands Role in Advanced Manufacturing and Energy Projects
FTI completed 47,000 labor hours with zero recordable incidents, reinforcing our commitment to safety. FTI’s commitment to flexibility, innovation and safety has paved the way for future opportunities with both this client and DPR in the advanced manufacturing and industrial markets. This client expanded FTI’s role, awarding an additional $3.4 million contract for processing equipment power connections and enlisting FTI to deploy and install battery storage units on their West Coast solar projects.
