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Tesla Has Started Process Of Making Its Fremont 'Tent' Permanent
Tesla Fremont Factory Tension Fabric Structures
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Overview
To meet Tesla’s accelerated production demands, VOLO designed and constructed 1,380 linear feet of tension fabric structures in 11 days, using a 164-pier helical foundation system and maintaining uninterrupted factory performance.
Challenge
Chosen from a field of eight bidders, VOLO Events Agency was selected by Tesla to accelerate expansion of its Model 3 and Model Y production facility at the Fremont headquarters, responding to record-setting demand and critical space limitations.
Time pressure, strict regulatory requirements, and limited available space in a highly congested active worksite made traditional factory expansion nearly impossible. The COVID-19 pandemic further increased complexity, and the project site, located in a liquefaction zone along the Hayward earthquake fault - required specialized engineering solutions.
VOLO was the only bidder willing to accept full accountability for the entire scope of work, leveraging its reputation for solving complex structural challenges and delivering custom tension fabric structures in difficult environments.
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Solution
The VOLO team designed and fabricated tension fabric structures for the Tesla Fremont factory in less than 30 days.
Tesla needed a large, rapidly deployable tension fabric structure to expand production capacity. VOLO designed and fabricated a custom steel-framed tension fabric building for the Fremont factory in under 30 days. To meet the site’s geotechnical challenges, the structure was anchored with 164 custom-engineered helical piers, providing long-term stability and structural integrity. The system carries a 20-year guarantee.
VOLO achieved substantial completion in just 11 days, with a 65-person crew working two shifts around the clock. The structure was built immediately adjacent to Tesla’s 24/7 manufacturing operations - with more than 10,000 workers active on site - without disrupting production. The completed facility includes covered truck bays, custom access points, and factory-specific entry systems, and is fully insulated to R-30 performance standards.
Service components
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Result
VOLO designed, engineered, manufactured, delivered, and completed two Steel Tension Fabric Structure Buildings in 30 days.
The tension fabric structures spanned a combined 1,380 ft (420.62 m) - longer than the Empire State Building is tall, and covered more than 140,000 square feet of operational space. Despite crew restrictions, pandemic-related safety requirements, and the challenges of an active California worksite, VOLO delivered the project accident-free and in full compliance with CAL-OSHA and all state regulatory standards.
Achieving substantial completion in just 11 days, VOLO’s rapid deployment was described by the media as “amazing.” Tesla immediately began installing production equipment upon substantial completion, allowing Model 3 and Model Y manufacturing capacity to scale faster than expected.
VOLO provided end-to-end services for the project, including budgeting, scheduling, architectural and structural design, engineering, helical pier foundation engineering, sealed construction drawings, material fabrication, welding, heavy equipment operations, and specialized installation labor. The project demonstrated why VOLO is recognized among leading tension fabric structure companies capable of delivering custom, large-scale deployments in demanding environments.
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PAGE SUMMARY
TESLA selected VOLO EVENTS AGENCY from among 8 bidders to help them quickly expand their Model 3 and Model Y production facility due to unprecedented demand and space limitations at their Fremont, California headquarters facility.
Time requirements, regulatory constraints and limited available space in an active, highly congested worksite made traditional factory expansion difficult. The raging COVID-19 pandemic further complicated an already difficult task, as did the site’s geotechnical challenges – it was in a liquefaction zone on the Hayward earthquake fault. VOLO was the only bidder that committed to full accountability for the work to be performed.
VOLO’s reputation for resolving even the most difficult scenarios was put to the test with these tension fabric structures.
TESLA needed huge, rapid-deployed, tension fabric tent structures. The VOLO team designed and fabricated a custom steel-framed, tension fabric tents building for the TESLA Fremont factory in less than 30 days. To solve geotechnical challenges, the structure was anchored by 164 custom designed helical piers which provided both foundational support and structural integrity. The structure is guaranteed for 20 years.
VOLO successfully reached substantial completion in an astounding 11 days, using over 65 crew members working 20 hours per day in 2 shifts. The structure was built adjacent to a TESLA factory working 24/7, with 10,000 workers on site, without interruption. The structure included covered truck bays, custom entries and doors specially designed for the TESLA factory – and was fully R30 insulated.
VOLO designed, engineered, manufactured, delivered, and completed two Steel Tension Fabric Structure Buildings in 30 days. The combined length of these buildings (1380 ft – 420.62 m) exceeds the height of the Empire State Building. Total square footage was 140,000 square feet.
Amidst crew, and site COVID restrictions, the project was completed accident free thanks to VOLO’s meticulous standards and complete compliance to California regulatory code, including CAL-OSHA, throughout the duration of the build.
VOLO’s ability to reach substantial completion in a record-setting 11 days was heralded by the press as “amazing”. As soon as substantial completion was reached, TESLA began installing its production equipment even as the VOLO crew was finishing the build out. Model 3 and Model Y production demand was met on an accelerated schedule as a result of VOLO’s timely installation.
VOLO Services provided to TESLA included budgeting, scheduling, design, architectural, engineering, foundation design, foundation engineering, complete sealed drawing sets, construction, heavy equipment, welding, the manufacture or preparation of all materials and specialized installation labor. VOLO met and exceeded the exacting high standards expected by TESLA.
