Mercedes-Benz Plant 205 Project Plant Expansion


Tuscaloosa, Alabama

This is a multifaceted project as part of the
inclusion of C-Class car production at this facility.

  • Approximately 40,000 square feet of roof supported conveyor mezzanines in new and existing (operating) paint shops.  In addition to horizontal conveyor equipment, several vertical lifts were located on these mezzanines.

  • Two new body stacker buildings approximately 30’ wide by 230’ long by 90 tall.  Each building was designed with an automated 85’ tall conveyor/elevator to transport car bodies the length of the building and be stored in stacked bays.  Each building is capable of storing 160 car bodies.  These buildings are located directly adjacent to existing (operating) stacker buildings and structural design required consideration of ongoing operation.

  • Analysis and design of reinforcement for existing roof trusses throughout the plant for new conveyors and mezzanines designed by others.

  • Addition and reconfiguration of roof supported mezzanines in an existing assembly shop for new fluid filling equipment, electrical substation and conveyor upgrades.

  • Addition of new assist devices in an existing assembly shop.  This required analysis of existing hanger assemblies (with existing assist devices) and reinforcing of roof trusses.

  • Modifications of existing main operating floor construction for new equipment loads as well as new openings for vertical lift devices.

3300 CAHABA ROAD • SUITE 210 • BIRMINGHAM, ALABAMA 35223 • 205.879.5660