As automakers transition to electric vehicles (EVs), the demand for facilities that manufacture advanced batteries and related components is skyrocketing. However, these gigafactories come with challenges, including how to ensure safety and efficiency during construction and operation.
Figure 1. The shop application of an intumescent epoxy coating. This off-site fireproofing process allows for safer construction of EV battery gigafactories.
One critical aspect that impacts construction timelines and production safety is the fireproofing of steel structures within manufacturing facilities.
Fireproofing ensures structures can withstand high temperatures without igniting or losing structural integrity. This is achieved through the application of fire-resistant coatings or treatments designed to delay or prevent the spread of fire and protect the structural components from heat damage.
Conventional on-site fireproofing can often be complex, time-consuming, and hazardous. Applicators typically work at height for extended periods, exposing the area to vapors. But there is a safer way, which is critical for EV battery manufacturing sites.
With modern, shop-applied intumescent fireproof coatings, steel arrives at the job site already fireproofed and ready for assembly. Shop application refers to the process of preparing and applying materials in a controlled, off-site facility. It reduces job-site congestion and hazards, streamlining construction schedules and boosting productivity.
In this article, we consider the advantages of using shop application techniques for fireproofing steel in EV battery facilities, emphasizing its speed, safety, and simplicity.
Streamlining timelines
Every minute saved in the construction of EV battery facilities translates to quicker deployment of the vehicles, as well as cost savings. The shop-applied process allows for preparing and applying fireproofing materials in a controlled environment off the job site. This ensures a consistent and high-quality fireproofing application, reducing the time it takes to fireproof steel.
When fireproofing is moved into a shop setting, scheduling, and procurement become an early-stage process. Steel fabrication and fireproofing are bundled as a single package, allowing the steel to be delivered to the site fireproofed and cured.
This can save months of scheduling (depending on the job), conserving valuable time and resources while gaining speed to market. By streamlining the workflow, the shop application significantly reduces the overall construction timeline, enabling gigafactories to become operational sooner and getting more EVs on the road faster.
Figure 2. Fireproofing helps contain fires and prevent their spread, making it essential for safeguarding EV manufacturing facilities — which carry inherent risks associated with EV battery systems and electrical components.
Safer sites
Safety in construction is essential, and technologies that promote safety are more critical in environments that use hazardous materials.
The typical on-site application of fireproofing poses inherent risks to workers due to exposure to harmful fumes, dust, and other environmental factors. Shop application helps mitigate these risks. Workers are protected, minimizing the likelihood of accidents or health complications.
A simpler approach
Complexity often leads to inefficiency. Conventional fireproofing methods requiring on-site mixing and application can be intricate, prone to errors, and sometimes wasteful. This waste typically results from the need to apply multiple coats of water or solvent-based solutions and long curing wait times.
The weather conditions are another added challenge that can impact fireproofing in the field, as extreme temperatures, moisture, and even high winds can all delay the steel assembly schedule, creating schedule setbacks for other trades.
Shop application simplifies the process by centralizing material preparation and application to a dedicated facility. This modern approach employs meticulous planning, precise material measurement, and rigorous quality control measures.
Moreover, the controlled environment minimizes external variables that could affect the efficacy of the fireproofing materials, ensuring consistent and reliable results. For example, when using shop-applied epoxy coatings, projects can save more than 12 days in their schedule. This is due to reduced coats needed and decreased cure wait time (compared to field-applied solvent-based intumescent coatings).
By simplifying the process, the shop application boosts efficiency and minimizes the likelihood of costly rework or delays.
As the demand for electric vehicles continues to surge, embracing innovative methods like shop applications is essential to accelerate the development of safe and efficient EV battery facilities, enabling the transition toward a more sustainable future.
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