Production Capacity Structure

CHALLENGE

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.  

SOLUTION

TESLA needed a huge, rapid-deployed, semi-permanent tent structure. The VOLO team designed and fabricated a custom steel-framed, fabric tensioned 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. 

RESULT

VOLO designed, engineered, manufactured, delivered, and completed two Steel Framed Tension Fabric 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.  

PRESS RESPONSE

Tesla Fremont GA4.5 Nears Completion, Hints Next Level Model Y Production Rate In Q3

Tesla files to expand Fremont factory, make Model Y ‘tent’ permanent (teslarati.com) 

Tesla Has Started Process Of Making Its Fremont ‘Tent’ Permanent (insideevs.com) 

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