Morabito Consultants provided structural engineering services in support of the design-build delivery of Johnson Controls, a large-scale automobile battery manufacturing and distribution facility in Middletown, Delaware. The project required durable, efficient structural systems capable of supporting high-bay production, warehouse operations, truck circulation, and heavy industrial loading.
The facility includes more than 430,000 square feet of manufacturing and distribution space, along with attached office areas to support administrative and operational personnel. Expansive production and storage zones required efficient long-span framing, clear workflow, and structural coordination with specialized battery manufacturing processes.
The building uses durable industrial framing systems designed for production flexibility, heavy equipment loads, loading dock operations, and high-clearance warehouse functions. A second-level office component was integrated within the overall structure, requiring coordination between structural framing, production layouts, circulation routes, and building systems.
The design-build approach required close coordination with the project team to support schedule, constructability, and long-term performance. The completed facility delivers a high-performance industrial environment engineered for large-scale battery production, distribution operations, and future adaptability.