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Identifying the optimal site and production network strategy in Mexico.

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AN AUTOMOTIVE EXPANSION

Meeting new production demand.
PROJECT
Tenant improvements and expansion of manufacturing facility in Aguascalientes, Mexico
WHAT WE DID
Worked with client to grow and take on new business in a short period of time
CLIENT
A German manufacturer of interior moldings for luxury vehicles
TIMELINE

First stage began March 2021 and ended with the expansion in February 2022

PROJECT INFORMATION

In 2021 the client needed support in implementing tenant improvements for a large expansion in Aguascalientes, a state in the central part of Mexico known as Bajío. There is a large automotive presence in the zone, and the client was seeking a fast ramp-up to take on new business.

To keep pace with the expansion, Prodensa helped the client acquire a small warehouse within the same industrial park. This allowed the client to meet production demands. By February 2022 the complex expansion was completed.

The Expansion

EARTHWORKS

  • Acquisition of 29,988.11 m2 of land for the expansion

  • Process drainage system consisting of 4-4m2 independent systems

  • Storm water channel and city water distribution

The Expansion

STRUCTURAL

The expansion consisted of 22,081.37 m2 of standard metal-roofed construction with precast walls and insulated metal sheet roofing.
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Painting and assembly of metallic structure.
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Axis A wall removal and preparation for expansion connection.

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Precast walls formwork.
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Aluminum and glass in the offices area.
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Moisture Control Room
The Expansion

ELECTRO-MECHANICAL SYSTEMS

Within the scope included the preparation of:

  • A  specialized painting process
  • A compressed air system
  • A water chiller system
  • Water cooling towers
  • Dust collection system
  • WIP paint finishing room
  • Moisture control room
  • Natural gas distribution loop with 4" pipe
  • Electrical system
  • Reverse osmosis water treatment system
  • Specialized flooring for plastic injection molding machines

THE EXPANSION

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Construction-Management-Mexico-Aguascalientes-Expansion-2
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CHALLENGES

One of the most significant challenges in the building expansion was the removal of existing precast concrete walls to physically and operationally merge two separate buildings into a single, cohesive production facility. This process presented several technical, logistical, and safety-related obstacles that needed to be addressed to ensure a seamless transition and minimal disruption to operations.

  1. Structural Integrity & Engineering: Removing load-bearing precast walls required engineering assessments and temporary supports to maintain stability and prevent damage.

  2. Operational Continuity: Phased demolition was necessary to keep production running, with work scheduled during off-peak hours and dust control measures in place.

  3. Demolition Logistics: Specialized equipment, including cranes and cutting tools, was needed for safe removal, along with proper waste management and recycling compliance.

  4. Building System Integration: Electrical, HVAC, fire suppression, and drainage systems had to be merged, requiring adaptive engineering solutions for seamless functionality.

  5. Regulatory Compliance: Permits, safety regulations, and coordination with authorities were essential to prevent delays and ensure legal adherence.

 

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