Challenge Design-Build Project Delivery Addressed

Design-build allowed Michelin to achieve its product delivery obligations by overlapping and phasing the design and construction activities to meet their fixed start-up date. There were 109 deliverables on the project, with 38 areas that each had multiple phased completion dates. To make things more difficult, an incredible 20 inches of rain fell in just four months during the early stages of the project, forcing the contractor to utilize many of its resources to stabilize the site and continuously remediate temporary roads. Through constant meetings and collaboration with the owner and project team, and reliance on cloud-based technology that enabled real-time communication, Gray was able to adjust the schedule to ensure that key delivery dates were still achieved.

Summary

Michelin North America, Inc., South Carolina’s largest manufacturing employer, invested $750 million to construct a nearly 800,000-square-foot facility in Anderson, South Carolina, its ninth project in the state and one that created hundreds of new jobs. The plant was built in response to heightened demand for Michelin’s Earthmover tires, used by the construction and mining industries. Some tires stand just over 13 feet tall and weigh up to 5.5 tons, with 80% of the tires to be exported, primarily through the Port of Charleston. Michelin’s US10 plant, also known internally as the Red Oak project, marks the fastest greenfield construction in Michelin’s history. Gray achieved the final certificate of occupancy in September 2013, an outstanding 50 days earlier than expected, which enabled the company to begin production of commercially available tires in December 2013. “That we have constructed this state-of-the-art facility in 17 months is nothing short of remarkable,” said Bruce Brackett, senior vice president, Michelin Earthmover & Industrial Tires Worldwide.

Design-Build Team

Client/Owner: Michelin North America, Inc.
Design-Builder: Gray Construction
General Contractor: Gray Construction
Architect: Gray Construction
Engineer: Gray Construction
Specialty Contractor: O’Neal, Inc.
Specialty Consultant: Freeland Harris Consulting Engineers of KY, Inc.
Duration of Construction: 16 months
Project Cost: $163,725,187