Battery Manufacturing Plant Supercharged for Success

Form Factory 1 Iron-Air Battery Manufacturing Plant

A US Battery Plant for Form Energy in Wierton, WV

Battery Manufacturing Plant. When energy startup Form Energy approached Allied Steel Buildings to design and build their first commercial-scale battery manufacturing plant in Wierton, WV, we saw an opportunity to take on the kind of challenging and impactful work that we find so rewarding.

The client ‘s mission of reforming the global energy system to run entirely on low-cost renewable energy called for a custom flagship facility designed with flexibility in mind. The new manufacturing plant had to accommodate their current battery assembly machinery as well as plans for future growth.

Seeking out a builder who could best meet their project requirements, the client began bidding the job out in November 2022 and quickly discovered the economic advantages of Prefabricated Structures. Allied’s reputation for flexibility, reliability, and quality preceded us and by May 2023 we were breaking ground on phase 1 of the 2 phase project.

Battery Manufacturing Plant  – Flexibility

Amidst the industry’s rapid technological progress, Form Energy’s own needs were ever-evolving, remaining open-minded and delivering a flexible end product was key to Allied’s success. Allied and the client’s architectural firm, Stantec, worked tirelessly to design a solid and attractive structure. Composed of IMP walls running vertically and horizontally and a standing seam roof, the plant is a shining example of Allied’s best-in-class engineering and design.

Transforming Unique Visions into Reality with Punctual Expertise

With delivery and installation scheduled to start in July 2023 and wrap up by September, followed by dry-in in December, the client has plans to start production of their iron air battery systems by mid-late 2024. To optimize the schedule and keep it flowing smoothly, Allied worked closely with the building’s installer, to ensure the structure’s components were detailed in an order that follows the erection sequence.

Form Factory 1 – Topping-Off Ceremony

Follow Form Factory’s Progress

HERE

The client’s year-long search for the facility’s 55 acre site is just the beginning of their investment in their high stakes vision.

In addition to the goal of transforming the global energy system with long-lasting and affordable iron air batteries, they’re expecting to create at least 750 full-time jobs in Weirton, VA.

Having been selected from amongst numerous bids from both conventional steel and pre-engineered steel building suppliers, Allied takes its responsibility for helping make this dream a reality seriously. Our current focus is on exceeding the client’s expectations when it comes to the quality and timing of phase one.