Wieland, a supplier of copper and the copper alloys used in electric vehicles, has hired contractors Graycor and Helmkamp Construction Co., as the design-build contractor for construction of a $500-million expansion and modernization of its manufacturing facility in East Alton, Ill. 

Vestal Corp. will provide civil, structural, architectural, and building M/E/P design services and Salas O’Brien will provide process engineering design services. 

Wieland reports that the modernization will allow increased and improved production of copper and copper alloy components for EVs, EV charging infrastructure and renewable energy production through the installation of a new hot rolling mill. 

The multi-phase project will replace Wileand's existing hot-rolled copper coil production facility that was built in 1916. The new plant will feature hot-mill lines, milling lines, a cold-rolling mill, high-bay storage with automated material handling and overhead cranes.

The project will increase the casting capacity and quality of copper product production at the facility, the company said in a statement. The phased project includes deep foundations to support new casting equipment, an overhead crane for equipment setting, a furnace, a re-cooling system, distribution switchgear, the building's superstructure, controls, and commissioning. The building structure will have metal siding and roofing over heavy structural steel to support the building and the equipment. 

“Construction will occur adjacent to live plant operations and within a very tight site,” the company said in its news release.  The team is currently in preconstruction for the plant expansion phase. The project is slated for completion in mid- 2028. 

“To accelerate the overall project schedule, the project team is working closely with the major equipment vendors to design and build a facility in parallel with the design and fabrication of the equipment,' says Steven Crowley, project executive for Graycor. Another challenge of the project will be completing construction as Wieland continues to operate at full capacity using its existing production lines. 

“Because the project touches many parts of the facility and all previous green spaces have been or will be consumed with site improvements and structures, our biggest challenge is to safely complete the work while controlling site logistics to allow the facility to maintain high operational capacity," Crowley adds. 

Wieland's total incentive package from the state includes $231 million in funding through the state's Reimagining Energy and Vehicles program and other incentives. Wieland is eligible to receive tax benefits totaling $172 million over 30 years through REV. Other benefits include capital funding for infrastructure projects in East Alton, which includes the construction of a new electricity substation, funds for workforce support and additional tax incentives.