Projects

Mahaffey MegaStructure™ Solution Wins Race For Global Automaker

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A global luxury-car manufacturer faced a massive backlog in production. The customer demand for luxury vehicles far exceeded the plant’s capacity and production pace. Preordered vehicles were “sold” before they rolled off the assembly line and droves of anxious customers awaited their arrival. Local dealerships anticipated disaster with impending delivery dates and urged the manufacturer to find a fast fix to the problem.

The manufacturer’s response was an urgent call for an off-site, fully-customized warehouse structure to handle the final detailing of vehicles and speed up production. Along with the daunting task of speeding up the process, came the additional issues of customizing the structure for automotive production and employee habitation.

They tapped Mahaffey to provide turnkey services for their project based on a long-standing, ongoing working relationship. They knew from experience that Mahaffey was the only temporary-fabric structure partner who could handle the exacting customizations in the timeframe allowed.

The Challenge

The most significant challenges included the client’s firm deadline request of only three weeks from the project’s start to a fully-operational warehouse. In addition to the tight deadline, the structure had several customizations that were critical to its success.

One critical customization was insulating the structure to keep employees stationed inside safe and comfortable. The detailing area needed to begin production during the summer months when temperatures are hottest in the southeast. The climate meant the client required a product durable enough to withstand the harsh environment, so they asked Mahaffey to provide insulation for the entire structure. They also wanted the structure to remain on-site indefinitely, so it needed to consist of a sturdy semi-permanent material. 

The client requested the structure size be at least 16,000 Sq. Ft. to perform the detailing functions. Additionally, they asked for customized garage doors to provide expeditious movement of vehicles.


The client’s structure needed:

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Fast installation


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Fully insulated 


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Customized for automotive manufacturing
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Large enough to house personnel and multiple vehicles
       
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Garage doors for vehicles
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Personnel doors for employees
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Ensure compliance with city regulations
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Lighting and HVAC packages
       


The Solution

Mahaffey’s team carefully considered the timeline and exact specifications of the client’s request. Mahaffey’s custom products and unique experience was essential for several of the requested customizations for this project.

The Mahaffey MegaStructure™ was proposed as the ideal solution to fit the customer’s needs. This industrial fabric structure is best suited for semi-permanent applications of at least three months and is suitable for industrial projects, turnaround events and those applications located in areas with harsh climate conditions, including extreme heat.

The proposal included Guardian™ insulated-steel hard-side panels to provide crucial insulation necessary for the structure. Mahaffey then offered a custom solution to ensure a fully-insulated structure – the addition of fitted, rolled insulation under the roof.

The design included customized gables and eaves to allow the installation of specialized garage doors. Mahaffey recommended five garage doors with electric motors and motion sensors to assist the flow of vehicles.

Mercedes #2 07.24.19

In addition to fast, professional installation, Mahaffey proposed secure access personnel doors, four 25-ton HVAC units and four custom duct socks to complete the request.

Mahaffey’s team worked closely with the manufacturer to design and customize the product. The team also devised an implementation plan to complete well within the timeline desired.


Mahaffey’s solution included the following features:

  • 17,224 sq. ft.– MegaStructure™ (peak height: 34’)
  • 5 motorized garage doors
  • 3 single personnel-entry doors
  • LED lighting package
  • 4 25-ton HVAC units
  • 4 custom duct socks for HVAC
  • Insulated-steel hard sides
  • Insulated roof with custom liner
  • Expert project managers, designers and installation team

 

Even though the timeline was tight, the heat index high and the customizations formidable, Mahaffey’s team of experts managed to install and customize the whole project in only 20 days!

The Result

The manufacturer was impressed but NOT surprised that Mahaffey was able to meet its manufacturing deadline and provide every custom detail requested. The structure is currently serving its intended purpose. The client is so happy, they’ve already asked Mahaffey to install two additional structures at other locations.

The Takeaways

Mahaffey’s team delivers on its promise. Mahaffey has years of industry experience and many custom proprietary products in its arsenal to back up the promise. No other fabric provider offers an equivalent to Mahaffey’s complement of services. That’s why clients choose Mahaffey over and over again.

No request is too complicated for Mahaffey’s team of experts. The Mahaffey team worked rapidly to complete this installation professionally, safely, on schedule, and within budget.

Do you need a quick, reliable, professional partner? If so, call one of our expert project managers at Mahaffey.

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Topics: Warehouses and Storage Manufacturing