The BMW Stacker Next Upgrade project is part of BMW’s $1.7 billion investment to start the production of electric vehicles at the company’s sprawling 8-million-square-foot vehicle manufacturing facility in Greer, South Carolina. Graycor was responsible for construction of the Stacker Next Upgrade—an addition that serves as the Stacker Building’s pre-zone area—and construction of a new conveyor tunnel interconnecting to the existing fully operational H30 building. Graycor also built the pad foundation and completed site work and associated structural upgrades for the 36,890-square-foot, 95 feet 3 inches tall Body-in-White (BIW) Stacker building.

The pre-zone area manufacturing addition stands 32-feet tall. The new conveyor tunnel was built on the roof of the Hall 30 building which remained operational throughout construction. The project also included construction of a surrounding road, pavements, underground utilities, stormwater management and integration into the site.

The Stacker Next Upgrade was delivered under a compressed fast-track schedule. Teamwork through collaboration, coordination, communication and innovation, as well as out-of-the-box planning were keys to success. With a live operational plant on one side and another contractor building the BMW Stacker Building on the other, the team safely delivered the addition within a pocket-sized site. The tight schedule with aggressive milestones (no floats), demanded exceptional planning and execution.