Barton Malow, Ghafari, and Mexico partner Ecsar joined forces to design and build a new assembly complex in San Luis Potosí, Mexico for General Motors Corporation. The complex includes a stamping plant, material storage building, body shop building, general assembly building, cavity wax/deadener building, administration building, conveyor and utility trestles as well as security gate houses, fire pump house, process fluids tank farm, and extensive site work for the assembly complex, paint shop and test track.
A mere six months after groundbreaking on this multifaceted 1,101,000 square foot project, equipment installations started. A commitment to Integrated Project Delivery and lean construction principals made this possible. Innovations in the process included co-locating the team at Barton Malow’s Southfield headquarters, primary contractors joining the team early on to have input during the design process, and fly-through BIM models to identify field element collisions before fabrication and installation. Through value engineering, the team implemented an inventive and efficient design plan for repetitive steel. The team also adapted to seasonal heavy rains by using a Sifonic roof conductor system.
In addition to Barton Malow’s key role in the design/build team, the company also provided self-perform mechanical equipment installation services for the assembly complex. Creative solutions included monitors and controls being integrated with the central utilities complex building for HVAC systems with computerized control, and plant security was linked to two other plants in different states.