Gestamp Alabama has expanded by 140,000 square feet at its plant in McCalla, which opened just two years ago.
Gestamp designs, develops and manufactures metal automotive components. The company specializes in developing products that achieve increasingly safer and lighter vehicles, thus reducing energy consumption and environmental impact.
The expansion will allow Gestamp to increase the number of metal automotive components its manufactures in Alabama.
Hoar Construction, a general contractor with offices in Birmingham, Houston, Austin, Orlando, Nashville and Washington, D.C., began working on the $12.5 million design-build project in the fall of 2018, collaborating with Gestamp Alabama leaders and plant employees to plan and design the expansion. The main challenge was demolishing one of the building’s exterior walls, building the new structure and then tying the two buildings together seamlessly without slowing Gestamp’s ongoing work.
“Through a detailed preconstruction and design review, we were able to keep the plant operational throughout construction and ensure Gestamp could deliver on commitments to their customers without interruption,” said Hoar Project Manager Casey Cobern.
During the design process, Hoar employees suggested a mechanical system solution that increased efficiency, optimized Gestamp’s machinery performance and reduced operating costs, which led to also replacing the mechanical components in the existing building to improve the plant’s entire operation.
Other partners on the buildout were Designform LLC, Tucker Jones Engineers, Sain Associates, RJ Mechanical, Ace Electric, American Fire Protection, Greater Georgia Concrete, Ingle Demolition & Salvage and ECS.