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How Prodensa Delivered a Forklift Factory Faster than Ever

PROJECT
1.1M ft2 industrial campus construction in northern Mexico; FM Global, LEED Certified, CTPAT 4 manufacturing buildings + testing in outside finished good storage
WHAT WE DID

Construction project strategy, permitting, design-build pre-construction, and construction management. The project strategy focused on different priorities like production, shipping, and then R&D.

CLIENT
American company that manufactures work lifts and platforms used in construction, maintenance, and warehouse sectors throughout the world.
TIMELINE

Phase 1: April 2021 - May 2023

Phase 2: August 2023 - June 2025 

Phase 3: May 2024 - May 2025 

Phase 4: TBD

 

PROJECT INFORMATION

A company that manufactures work lifts and platforms used in construction, maintenance, warehouse stocking, announced a new facility in 2021.

The American company made an investment of $140 million USD in a new plant in Ciénega de Flores, in the state of Nuevo León, which has led to the creation of 1,500 jobs in the region.

The facility will serve to house product lines that will be shifted to Mexico, including a range of the company's products that are currently produced in China and the United States. 

The facility earned the prestigious LEED® Gold Certification by the U.S. Green Building Council in October 2023.

BEFORE

The project was build on a green field within an industrial park north of Monterrey, in the state of Nuevo León. At the time of the real estate transaction, the park was at the point of expanding the perimeter and infrastructure to encompass the chosen lot of xxx ft2. 

The land was flat, with two creeks running across it. Prodensa conducted all preliminary studies for permits, including topography land survey, soil mechanics study, and hydrologic study as part of the construction project management service.

During the initial phases of construction, the Prodensa Project Manager had to coordinate and align the project to the infrastructure development of the park, making sure there were no miscalculations in levels for water flow and drainage. At the start of the process, the design and development decisions of this industrial park expansion were not defined, so the coordination was paramount to the success of simultaneous projects.

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CHALLENGES

  • Project began during the global pandemic, operating under an uncertain and ever-changing regulatory environment
  • Global supply chain issues and shipment delays were a common threat to the timeline
  • Corporate personnel were unable to make frequent visits to the site, so digital communication was essential
 
  • Prodensa needed to think outside the box to obtain the environmental permits on time. 
  • The project had build-to-suit, high-specifications which required a high level of technical knowledge and coordination
  • Special compliance with LEED Gold Certification depended primarily on Prodensa's successful implementation
SUCCESS STORY

THE RESULTS

How Prodensa Delivered a Forklift Factory Faster than Ever

The project is still ongoing, with Phase 2 & 3 projected for a mid-2025 delivery date.

Additional works included:

  • Complimentary exterior rooms
  • 16 LPS well-water infrastructure
  • 18 MVA electrical infrastructure
  • FM Global and LEED Gold standards
  • CTPAT authorization
  • Testing area
Phase 1

More than 500,000 square feet of shell, small offices and a cafeteria were constructed to meet first production goals

April 2021-May 2023

Phase 2

More than 350,000 square feet additional construction of shells, additional offices, warehouse, distribution/shipping center and testing areas are being added

August 2023-June 2025

Phase 3

Over 200,000 square foot R&D shell, additional offices, and +1.4 million square feet in docking, transport and parking are being added

May 2024-May 2025

Phase 4 TBD

PHASE ONE

Phase 1, encompassing the primary production facility, was completed a remarkable three months ahead of schedule. Despite encountering a 3% budget overrun due to change orders expanding the project's scope, the team successfully brought the phase to completion within the accelerated timeline.
 
Although global supply chain disruptions delayed the arrival of air conditioning units, the systems installation proceeded as planned, with the infrastructure prepared to accommodate the units upon their delivery.
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"When you head on out to the Moon, in very short order, and you get a chance to look back at the Earth, that horizon slowly curves around in upon himself, and all of sudden you are looking at something that is very strange, but yet is very, very familiar, because you are beginning to see the Earth evolve."
Gene CernanAstronaut, Apollo 17
Before 2
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PHASE TWO

Phase 2 began in August 2023 and is ongoing. The scope includes two additional buildings, one for warehouse activities and the other will be a distribution center. There will also be an outdoor test track. As of June 2024, the project was at 9% completion. 
 
This post will be updated as the project advances.
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PHASE THREE

Phase 3 began in May 2024 and is ongoing. The scope includes .... its going.....

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