NextStar, a joint venture between Automaker Stellantis and battery manufacturer LG Energy Solution, selected Barton Malow to build Canada’s first large-scale, electric-vehicle battery production facility. Now owned solely by LG Energy Solution, the plant produces more than 49 gigawatt-hours annually.
Construction was completed in late 2025, and full electrode and cell production began in November 2025. The facility surpassed one million battery cells produced in February 2026, and a groundbreaking ceremony was held one month later.
The greenfield site occupies 240 acres on which we erected 4.23 million square feet of world-class manufacturing spaces. The largest structures are the Cell Building at 2.7 million SF, and the Module Building at 332,000 SF.
Additional structures include a master substation and switchyard, central electrolyte supply system, safety building, waste storage and treatment, solvent recovery and purification, exhaust gas recovery, and administrative offices.
Preconstruction services included progressive estimates, constructability reviews, cost forecasting and modeling, design development and management, major equipment procurement, progressive schedule forecasting, and trade-partner selection. We qualified multiple subcontractors for specific trades to ensure adequate experience for the novel facility.
Responding to the unique demands of the project, Alberici-Barton Malow strategically coordinated preconstruction services across languages and design standards. We established an early understanding of expectations for project delivery and protocols for ensuring scope alignment between all parties.
