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General Motors Corp Vehicle Engineering Center

This project consisted of a new eight story Tower and a renovated three-story Podium totaling 2 million square feet. The new one million square foot Tower is surrounded by water on three sides and interlocks with the renovated one million square foot Podium. While the buildings abut, they are structurally independent. Both buildings share a common lobby and interactive Hub. Podium renovations were phased to allow existing engineers to work in the building while their ….

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General Motors Corp Building #23 Renovations

Building #23 is used for general offices and training for GM personnel. Roncelli was contracted to perform complete demolition of the architectural, mechanical and electrical components of the building. This consisted of demolition of the first and second floor walls, doors, ceilings, HVAC system, existing lighting panels, receptacles, wiring, and auxiliary systems. The construction activities were coordinated, sequenced and scheduled to minimize disruption to the ongoing adjacent building activities. While renovating the first and second ….

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General Motors Corp Road Load Simulator Relocation

This project involved the relocation of a full Vehicle Road Simulation Dynamometer from Pontiac Plant 17 to the Milford Proving Grounds – Building No. 73. All work was completed within a 90 day schedule. Work included the cut and removal of concrete flooring, excavation, form work, steel reinforcement installation and the placement of concrete for the large inertia mass foundation pad and the steel bed plates for the dynamometer. Debris, dust and air borne particulates were ….

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General Motors Corp Powertrain South Expansion

General Motors Powertrain Division located in Pontiac, Michigan consolidated most North American Powertrain testing into a new state-of-the-art 427,000 SF facility. The new facility consisted of two Dyno Wings, a Fuel Farm, a Central Energy Plant, and a Southwest Addition to their existing testing facility. The Dyno Wings consolidated 157 outdated test cells from four locations into 98 high flex and new technology cells. The Fuel Farm, with 27 different fuels, 36 storage tanks, and ….

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General Motors Corp Hybrid Battery Systems Laboratory

The Global Battery Systems Laboratory project located in the Vehicle Engineering Center at the General Motors Technical Center, Warren, Michigan, consisted of four primary phases of design and construction over a five year duration. The initial phase of work involved the relocation of the original Hybrid Battery Testing Labs from within the GM Research Mechanical Building to a larger location within the Alternative Energy Center Building at GM’s Tech Center campus. Subsequent phases enlarged the laboratory ….

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General Motors Corp Fairfax Assembly Addition

Roncelli, Inc. expanded the paint shop oven and related conveyors without affecting production. Project challenges consisted of a compressed schedule, adverse weather conditions, production equipment modifications and working around ongoing production. The project utilized 3-D BIM (Building Information Management) design.

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General Motors Corp BAC IV Migration

This building expansion consisted of two phases totaling more than 400,000 square feet of new plant floor area. The first phase, consisting of 100,000 square feet, provided new shipping and receiving areas along with warehousing functions to provide GM with uninterrupted material handling. The construction and modification of existing truck docks and new building areas in a phased approach was necessary to ensure uninterrupted plant production while the phase two body shop addition work was ….

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Ford Motor Company Non-Destructive Evaluation Pilot Facility

The Ford Livonia Non-Destructive Evaluation Pilot Facility is the first and only one of its kind in the automotive industry, utilizing two Aracor Linear Accelerators to x-ray vehicles to test for and find the root causes of part failures. Roncelli constructed the 3,600 square foot x-ray room, which comprises of an 8-foot thick reinforced concrete main wall with three other walls, each 3.5 feet thick, 30 feet tall. The structural roof of the project consisted ….

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Ford Motor Company Structural Steel Upgrades

Ford’s new overhead conveyor system required significant rework of the building’s structural steel to support the equipment and product loads. Roncelli’s team performed extensive reinforcement to the building’s entire structural steel system by welding additional structural steel into the existing trusses and adding structural members to the side and end walls. The process also involved lead abatement treatment to the exisiting steel before the start of any rework. Most of the work was elevated, requiring ….

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Ford Motor Company LVL Expansion Program

This project added 150,000 square feet of plant assembly area, allowing for the introduction of Ford Motor Company’s new Low Volume ( LVL ) Engine Assembly Line in addition to a New Head and Cam Assembly Line and relocation of the plant’s Niche Assembly Line. This project not only included additional manufacturing space, but also entailed upgrading the plant’s primary electrical service substation, as well as relocation, expansion and modernization of the plant’s main shipping ….

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