BMW High-Voltage Battery Assembly Factory

Location: Ohio
Market: Federal Government
Services: Architecture / Interior Design / Engineering

The Challenge

In 1934, Building 23 at Wright-Patterson Air Force Base was constructed as an aircraft hangar and test facility. More than 70 years later, the U.S. Air Force wanted to renovate the building to provide a modern lab facility for state-of-the-art energy research. It requested a design that retains the historic feel and aesthetic of the original building, while also creating a modern interior that meets security and force protection requirements.

The Solution

A three-story facility was created within the existing brick shell, adding new spaces for material processing, data acquisition, operations, and fabrication. The design also had special acoustical needs due to the use of vibration-sensitive equipment such as lasers and optical equipment. The superstructure is composed of a structural steel frame and designed to resist collapse in accordance with Antiterrorism/Force Protection (AT/FP) requirements.

Barge Design Solutions provided HVAC, plumbing, steam, lighting and power distribution, communications and security, utilities, storm drainage, lighting protection, and fire protection. Site work included sidewalks, curbs and gutters, access drive control systems, and site upgrades to meet AT/FP requirements. Architectural and interior design were also included as part of the project.

The Impact

The renovation of Building 23 was a testament to Barge's engineering expertise and commitment to excellence. Barge successfully transformed a historic asset into a modern, sustainable, and secure facility, meeting the evolving needs of the U.S. Air Force. The team's ability to balance preservation with innovation while also prioritizing sustainability and security positioned Barge as a valuable partner in this critical project. The project exceeded the original goal of designing to a LEED Silver level, making it the first LEED Gold building on the base.

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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.

Architecture / Interior Design

Engineering

Industrial

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BMW High-Voltage Battery Assembly Factory

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