The Challenge
Scaling capacity within a high-density construction programme
As battery and EV manufacturers scale up to meet growing demand for electrified powertrains, expanding automated storage and material handling capacity within a high-density construction programme has become a defining capacity challenge. Beck & Pollitzer delivered automated storage and material handling installation at a major US battery manufacturing facility in Kansas, working with a global advanced manufacturing and construction management partner.
During delivery, project scope grew by 76%, and up to 50 contractors worked concurrently on site. This meant maintaining installation quality and safety on a live construction site, while the programme itself kept expanding, over a schedule extending to 15 months, without disrupting the wider build.
Our Solution
Rigging, ASRS installation and electrical integration by one team
Because scope and site conditions kept changing, Beck & Pollitzer mobilised a single team to carry the installation from unloading and rigging through to electrical integration and commissioning, rather than handing scope between separate contractors at each stage.
Unloaded and rigged equipment across seven operational areas
Installed two ASRS systems and 17 storage and retrieval machines
Delivered more than 1,500 feet of STV conveyance infrastructure
Integrated cable tray, panel and control wiring with the facility’s warehouse management system
Managed resourcing through a 76% scope increase without a break in progress
Unloaded and rigged equipment across seven operational areas |
Installed two ASRS systems and 17 storage and retrieval machines |
Delivered more than 1,500 feet of STV conveyance infrastructure |
Integrated cable tray, panel and control wiring with the facility’s warehouse management system |
Managed resourcing through a 76% scope increase without a break in progress |
Unloaded and rigged equipment across seven operational areas |
Installed two ASRS systems and 17 storage and retrieval machines |
Delivered more than 1,500 feet of STV conveyance infrastructure |
Integrated cable tray, panel and control wiring with the facility’s warehouse management system |
Managed resourcing through a 76% scope increase without a break in progress |
Unloaded and rigged equipment across seven operational areas
Installed two ASRS systems and 17 storage and retrieval machines
Delivered more than 1,500 feet of STV conveyance infrastructure
Integrated cable tray, panel and control wiring with the facility’s warehouse management system
Managed resourcing through a 76% scope increase without a break in progress
-
Unloaded and rigged equipment across seven operational areas
-
Installed two ASRS systems and 17 storage and retrieval machines
-
Delivered more than 1,500 feet of STV conveyance infrastructure
-
Integrated cable tray, panel and control wiring with the facility’s warehouse management system
-
Managed resourcing through a 76% scope increase without a break in progress
The Outcome
Scalable warehouse automation, zero safety incidents
A single, continuously adjusted plan, rather than a fixed one, let Beck & Pollitzer complete the programme safely despite the 76% scope increase and the density of the site, logging zero recordable safety incidents across more than 111,000 project hours.
The completed systems give the facility automated material handling capacity that scales with production, supporting the wider shift toward electrified powertrains without adding disruption as output grows.
Programme length
15 months
Need to know more?
Why did the workforce need to scale up during the project rather than stay fixed?
As scope grew by 76% during delivery, resourcing was adjusted continuously to match it, reaching a peak of 100 operatives rather than being fixed to the original project plan.
How did the team keep installation moving while 50 contractors worked on site at once?
Continuous coordination with the client, equipment OEMs and other contractors managed interfaces across the site, so mechanical rigging and electrical wiring activities didn’t conflict with the wider facility’s ongoing construction.
What does the warehouse management system (WMS) integration actually involve?
It covers the full-system power and control wiring needed to connect the newly installed ASRS and conveyance equipment to the facility’s WMS, so the automated systems can be directed and monitored as part of daily operations.
