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Tesla Energy Storage Gigafactory, located in Shanghai, is Tesla’s first energy storage project outside the United States. Spanning 200,000 m2, this facility specializes in the production of Megapack, Tesla’s cutting-edge commercial electrochemical energy storage system. The project broke ground in May 2024 and achieved full operation within just 9 months, setting a new benchmark for rapid industrial deployment.
As a globally leading smart factory, the facility demanded ultra-high precision in infrastructure to support automated processes, including AGV systems for material transport.
Key challenges included:
Time constraints: a tight schedule of only seven months to completion.
Quality requirements: Ensuring crack control and flatness to meet stringent AGV operational standards.
Cost efficiency: Balancing speed and quality while minimizing material and labor costs.
After extensive collaboration with stakeholders, Bekaert’s engineering team designed a solution that replaced the original rebar design with a high-performance Dramix® f looring solution with significant benefits:
Accelerated timeline: Completed 70,000 m² of assembly hall floor in just 1 month.
Cost savings: Reduced material expenses by 40%.
Sustainability: Cut carbon emissions by 25%.
Durability: Enhanced resistance to dynamic loads and cracks, ensuring long-term performance for AGV operations.
This collaboration between Tesla and Bekaert exemplifies how sustainable practices can drive progress and success. The commercial energy storage batteries assembled in this factory will be shipped globally, contributing to the worldwide transition to a greener future.
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