Project Scope:
Johnson Controls Inc. (JCI) is the world’s seventh-largest auto supplier. In 2011 JCI began a $138.5 million expansion of their Holland, Ohio battery plant, nearly doubling the facility size. The project would accommodate conversion of the production line from traditional lead-acid automotive batteries to those with newer absorbent glass mat (AGM) technology.
IPS was contracted to install storage silos, conveyors, structural steel, HVAC, and complete all of the new electrical systems.
The expansion at Johnson Controls allows for more storage capacity and increased deployment of the emerging batteries. The new batteries allow an affordable option for consumers who would like to buy a more fuel-efficient car for little cost up front.

Challenges:
The area where the new equipment was installed was extremely tight, making it difficult for workers and complicating the electrical installation. IPS prepared a comprehensive site logistics and safety plan, detailing work routes and safety procedures to ensure zero interruption to ongoing manufacturing operations.

$138.5mil. Total Construction
$9.2mil. Project Cost
11/2012 Completion Date
18 Project Duration
bid build Delivery Method

Project Scope:

Fenner Dunlop is the world’s leader in the field of conveyor belting, manufacturing the most comprehensive range of conveyor systems for many industries and applications.

IPS was contracted to provide setting, aligning, and installation services for five (5) process equipment lines: calendar line; steel cord press line; fabric belt press line; inspection line; and laminating line. Scope of work include process piping, process electrical, and equipment installation.

The preplanning for the equipment moves began while the building was being erected. Provisions had to be made for the process piping runs to be integrated within the building and the process electrical runs that had to be embedded within the concrete. Additionally, alignment plates were strategically placed in order to ensure that each individual process line was precisely installed to meet the required tolerances.

IPS was also responsible for the installation of all electrical work in the new building to support the expansion. Planning and pre-work was completed prior to the substation retrofit, which took place during a 72-hour shutdown over Thanksgiving. IPS worked around-the-clock to ensure the substation was available to the customer a full day earlier than required.

2/2013 Delivery Method
9 Delivery Method
design build Delivery Method
$38mil. Total Construction
$3mil. Project Cost
2/2013 Completion Date
9 Project Duration
design build Delivery Method

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