Confidential Hybrid/Electric Vehicle Battery Plant
Project Overview
Sauer Group served as the mechanical contractor for a confidential 3,000,000 SF hybrid/electric vehicle battery plant in Jeffersonville, Ohio. The project required fabrication and installation of more than 21,000 linear feet of large-bore welded carbon steel pipe for the plant cooling system, along with underground sanitary waste piping, storm piping, and refrigeration piping supporting data room cooling.
With a 450-acre jobsite shared by more than 200 other trade contractors and over 7,000 workers, Sauer’s team maintained productivity through disciplined coordination, careful material handling, and an aggressive installation schedule designed to stay ahead of project demands.
Contract value
$35M
Completion
APR 2025
Sector
Industrial
Manufacturing
project type
Hybrid/Electric Vehicle Battery Plant
Contract value
6 days per week,
10 hours per day
Construction mgr
Turner / Yates / Kokosing
Architect/Mechanical Engineering Partner
Gresham Smith
Jobsite
450 acre, 21,000+ linear feet of large-bore welded carbon steel piping
Sauer role
Mechanical Contractor
Workers/contractors
7,000+ workers and 200+ trade contractors active on site
Reference contact
Turner Construction Co.
The Challenge
This large-scale manufacturing facility required Sauer Group to deliver complex mechanical systems on one of the region’s most active construction sites. The project combined heavy industrial piping, plant cooling infrastructure, plumbing systems, and data room refrigeration support within an aggressive schedule and a highly congested work environment.
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Massive Scale
At 3,000,000 square feet, the facility required a mechanical scope capable of supporting high-volume battery manufacturing operations. The size of the plant, combined with the 450-acre jobsite, created significant coordination and logistics demands. -
High-Density Jobsite Coordination
Sauer Group’s work took place alongside more than 200 trade contractors and over 7,000 workers. Maintaining productivity required precise coordination, clear communication, and detailed material handling plans to keep crews moving efficiently without disrupting other scopes. -
Schedule Pressure
To stay ahead of the mechanical installation schedule, Sauer Group worked six days per week, ten hours per day. The project demanded consistent labor planning, equipment readiness, and responsive field coordination. -
Complex Mechanical Infrastructure
The scope included more than 21,000 linear feet of large-bore welded carbon steel pipe for the plant cooling system, plus underground sanitary waste, storm piping, and refrigeration piping for data room cooling. Each system required careful sequencing and quality control to support the facility’s operational needs.
Scope of Work
HVAC
- Chilled water piping
- Refrigeration systems
- Data room cooling support
Plumbing & Piping
- Large-bore welded carbon steel piping
- Underground sanitary waste piping
- Storm drainage piping
Industrial / Plant Infrastructure
- Plant cooling system piping
- Mechanical infrastructure supporting large-scale manufacturing operations
The Sauer Group Solution.
Sauer Group brought large-project mechanical contracting experience, field coordination discipline, and fabrication expertise to support the fast-moving battery plant construction schedule. By combining prefabrication planning, skilled field installation, and proactive jobsite coordination, Sauer helped keep the mechanical scope moving across a complex and crowded site.
Prefabrication & Welded Piping Execution
Sauer Group fabricated and installed more than 21,000 linear feet of large-bore welded carbon steel pipe for the plant cooling system. The team’s experience with heavy industrial piping helped support quality, consistency, and installation efficiency across the large-scale mechanical scope.
Site Logistics & Material Handling
On a 450-acre site with thousands of workers and hundreds of contractors, successful execution depended on more than field labor alone. Sauer Group coordinated material movement, staging, and installation sequencing to maintain productivity and reduce delays caused by congestion or competing work areas.
Schedule-Driven Field Installation
Sauer Group worked a six-day, ten-hour-per-day schedule to stay ahead of mechanical installation milestones. This approach helped support the broader project timeline while maintaining the field presence needed for such a large, fast-paced facility.
Integrated Mechanical Systems
The project included multiple interconnected systems serving manufacturing, building infrastructure, and data-support spaces. Sauer Group’s scope included HVAC, chilled water piping, refrigeration systems, plumbing, storm drainage, and underground sanitary systems.
Project Results.
Sauer Group completed a major mechanical scope for one of Ohio’s large-scale battery manufacturing facilities, supporting the infrastructure needed for hybrid and electric vehicle production.
21,000+ LF
Large-bore welded carbon steel pipe
3Mil SF
Hybrid/electric vehicle battery plant
450 Acres
Large-scale coordinated jobsite
$35M
Mechanical contract value
200+ Trades
Coordinated across a high-density jobsite
April 2025
Project completion
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