BMW High-Voltage Battery Assembly Factory

The Challenge

Barge Design Solutions (Barge) designed BMW’s new 1.6-million-sqaure-foot production building and pumphouses, including feasibility studies, cost estimates, and sustainability evaluations. The team delivered the project through a design-build approach, including civil, structural, mechanical, electrical, and plumbing design services. The 230-acre site presented several challenges. Topographical issues required moving 4.5 million cubic yards of earth while also preserving a large wetland area. Adding complexity to the development, the site featured three parcels with different zoning requirements, with residential areas bordering two sides.

Additionally, the process slated for the plant had yet to be fully developed, making flexibility for future decisions paramount. In the ever-changing world of battery production, the need to adapt to be able to produce new generations of batteries was critical for BMW. Because the project required extensive utility systems to support the building, including electrical power, water, fire protection, and stormwater management, all of these systems were designed to meet both current and future needs. This made coordination and space awareness critical to constructability both now and for the future.

The Solution

Design services were provided across multiple disciplines, addressing all aspects of the project, from infrastructure to sustainability. The team designed systems for traffic flow, guardhouses, parking, and emergency power, and included specialized facilities like an energy center, fire station, and waste management area. All these areas and systems are connected and monitored through BMW’s internal fiber optic network.  Master planning was completed to ensure that future development was considered while working around environmental site constraints.

The energy center was designed to support current operations and future expansion, with the building’s capacity set to increase from 45 to 120 high-voltage battery units per hour. The design also incorporated a conference center, kitchen, and medical area, with plans to accommodate up to 3,000 associates. To ensure smooth coordination, the team used BIM 360 models for design collaboration. Sustainability features included rainwater harvesting, energy-efficient lighting, heat recovery, chilled water storage, and support for photovoltaic panels on the roof. The building was designed as an all-electric facility, with no natural gas use on site. 

The Result

The new facility will be a key part of BMW’s campus, providing a modern, efficient space for production and logistics. The sustainable design ensures the building is prepared for future growth while meeting BMW’s high standards for energy efficiency and environmental responsibility.