Where infrastructure meets renewable energy

With the transition to renewable energy growing around the world, Michels Construction, Inc. uses multiple Liebherr drilling rigs to set the foundation for one of the largest lithium-ion manufacturing facilities in the United States.

The Ford Blue Oval City battery plant based in Staton, Tennessee, is one of the largest lithium-ion battery plants in the US to support the production of electric vehicles. This project requires the installation of 1,313 caissons to anchor and support the building foundation in a high seismic zone. The caissons ranged in diameter from 4-6 ft (1-2 m), and the depths ranged from 30-50 ft (9-15 m). In total, Michels is drilling more than 72,000 ft (21,945 m) and building the caissons utilizing eight drilling rigs, four of which were Liebherr including the purchase of two LB 35 and one LB 25.

Michels frequently works on large, challenging projects like this one. Building its foundation requires careful coordination between the Michels foundation crew and all other crews on site, causing a tightly interwoven schedule.

Not only does Michels have to work on a strict schedule around multiple other teams, but they also have to work safely with immense precision. The foundation required to support a facility of this size in a high seismic zone requires attention to detail and quality assurance monitoring to ensure compliance in tight tolerances. Due to a high-water table and flowing marine sand in the area, the shafts were poured under slurry using polymer slurry.

During peak production, eight drilling rigs were being used simultaneously. Each rig produces an average of three shafts per day and 15 shafts per week. The Liebherr rigs provided the power, torque, and strength required to meet the project’s demands. Michels will continue to utilize Liebherr machines to support projects that advance energy transition and renewable initiatives.

“Each project success is the result of the experience and expertise of our people and of the tools we use,” said Josh Senk, VP of Foundation Operations at Michels Construction, Inc. Michels purchased two LB 35 and one LB 25 drilling rigs for this project. The LB series of Liebherr drilling rigs were built to last in all climates and offer high torques, a wide range of applications, and useful assistance systems for improved operator comfort and increased safety in one elegant design.

The LB 35 is the successor of the proven drilling rig LB 28-320. Among its main characteristics is the simple transport including folded leader as well as the wide working area due to the parallel kinematics. Additionally, the LB 35 has a robust leader which can easily handle high torques and great tractive forces of the rope crowed system. “The LB 35 is an ideal drilling rig as it ensures fast operating cycles aiding in Michels’ tight schedule,” says Tobias Haemmerle, Divisional Director of Crawler Cranes and Deep Foundation Machines.

The focus of the LB 25 is providing optimal mobility. The rig can be transported fully mounted, ensuring the fast movement of the machine between different jobsites, thus positively affecting the cost-effective operation of the rig. Both the LB 25 and 35 also offer various drilling axles suitable for all types of applications.

The LB drilling rigs high performance in difficult conditions, modular design for flexible applications, easy transport and set up, as well as innovative comforts providing optimized field of vision and data displays were all factors in Michels’ deep foundation purchase.

Founded in 1959 as a regional gas distribution contractor, Michels Construction, Inc. has evolved into an energy and infrastructure contractor, supporting the energy, foundations, marine, transportation, trenchless, water, wastewater, as well as energy transition and renewables industries. Michels has been performing deep foundation work for more than 20 years. In 2022, Michels Construction, Inc. was officially established as a member of the Michels Family of Companies to focus on deep foundation and marine construction needs. With a focus on deep foundations, Michels Construction, Inc. currently owns 50 vertical drill rigs from various manufacturers including Liebherr.