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Automotive

NextStar Energy EV Battery Plant

Windsor, Ontario, Canada

Canada’s first large-scale lithium-ion battery production plant

Market

Automotive

Key Services

Construction

Preconstruction

Self-Perform

Steel Fabrication

Strategic Partnerships

Virtual Design & Construction

Delivery Method
Design-Build (DB)
Capacity
4,000,000 SF
Work Hours
6,500,000

The challenge

Ц-Barton Malow (A-BM) is the design-builder for NextStar Energy’s new lithium-ion battery plant in Windsor, Ontario.

NextStar, a joint venture between global automaker Stellantis and battery manufacturer LG Energy Solution are building Canada’s first large-scale, electric-vehicle battery production facility. When complete, the plant will produce more than 49 gigawatt-hours annually.

The greenfield site occupies 220 acres on which we erected more than four 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 445,000 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.

Key Facts

2M+ square feet of clean room/dry room


100 percent Canadian craft labor force


220-acre Advanced Manufacturing facility

Challenge met

Ц’s steel fabrication division, Hillsdale Fabricators, supplied the project’s 38,000 tons of structural steel, and A-BM is self-performing miscellaneous concrete pads.

Preconstruction services included progressive estimates, constructability reviews, cost forecasting and modelling, 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, A-BM strategically coordinated preconstruction services across languages and design standards. We established early understanding of expectations for project delivery and protocols for ensuring scope alignment between all parties.

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