The 507-F Expansion at Toyota Motor Manufacturing North America in Huntsville, Alabama, was awarded to Walbridge as a $35.6 million general construction package for the 460,000-square-foot Phase III expansion to the Engine Plant. The scope of work included the main plant expansion, as well as a cooling tower addition and the expansions of administration and office spaces, the cafeteria, utility area, quality control and waste water treatment.
Walbridge was also responsible for the following: all structural steel, foundations, mechanical, electrical and fire protection. The site work for the expansion consisted of additional trailer marshalling, re-routed roads and utilities, and the creation of a new parking lot requiring a re-graded and re-landscaped site, underground fire mains, storm sewers, and concrete and asphalt paving.
The project was assigned a very tight schedule and several changes and design issues continually increased the difficulty. The biggest hurdle the Walbridge team faced was completing the work without affecting the existing plant operations. Much of the work, especially mechanical/electrical tie-ins and demo, were done on second- or third-shift and weekends.