Powering Progress: How Sherwin-Williams Helped an Automotive Giant Speed Up EV Battery Production

A top automotive OEM faced critical challenges as they expanded their existing multi-billion-dollar manufacturing facility where batteries for their hybrid and fully electric vehicles (EVs) built in North America are made. Traditionally, a competitor’s product had been the OEM’s primary choice for flooring solutions, but after discussing with the lead design-build firm for the first building in the project, Sherwin-Williams brought a more effective flooring system to the table. Armed with flooring system testing data that showed extreme resistance of N-Methyl-2-pyrrolidone (NMP), Matt Apsley, Project Development Manager at Sherwin-Williams, was able to provide the lead design-build firm with the key benefits Sherwin-Williams’ flooring systems offered.

Apsley made a clear case for why Sherwin-Williams' Resutile HPS/HTS topcoats, with their superior chemical resistance and durability, holding up to the aggressive properties of NMP, were a better fit for the project's unique needs. The testing data backed up these claims, building trust with the design-build firm and paving the way for Sherwin-Williams to be listed as the approved alternate in the project specification, ultimately winning the bid with contractor, The David Allen Company, for the first building in the project.

Understanding the Roadblocks

Following the success of the application and installation in the first building, Apsley collaborated with additional general contractors and design firms for the next building. His goal was to better understand the unique challenges and problems posed by a facility of this scale. “Having different general contractors and design teams for each building added a layer of complexity to the project,” said Apsley. “Clear and continuous communication across all teams was essential in overcoming these challenges, and ultimately helped us deliver a solution that met the customer’s needs without delays.” In addition to the need for durable flooring with strong chemical resistance, there was a need for moisture mitigation and electrostatic dissipation (ESD). Testing and applying a flooring system with all these key attributes might have caused scheduling conflicts and delayed the construction of the facility. With temperatures frequently dropping below 30°F, environmental conditions would prove to be an obstacle, making complications with the installation of the flooring systems more likely.

Navigating the Project as a Team

Using the R&D data from extensive NMP exposure testing, the Sherwin-Williams High Performance Flooring team tailored a flooring system to satisfy the customer’s specific needs – a urethane cement flooring system with advanced NMP resistance was the ideal solution. Backed by a comprehensive warranty, this flooring system eliminated the need for moisture testing, significantly reducing project timelines and labor cost. With its unique reservoir system acting as a buffer that absorbs and controls moisture, the flooring was going to exhibit high durability and longer lifespan.

The High Performance Flooring team also proposed an innovative plan for the applicators to install the urethane slurry base coat before the building was fully acclimated, allowing it to serve as a working surface and enabling wall construction to continue without delay. This meant quicker project completion and less maintenance across the lifecycle of the facility, keeping the project on schedule and ultimately saving the customer money without sacrificing quality.

With the number of general contractors, design firms, engineering teams and subcontractors, communication was critical. Multiple application training sessions by Sherwin-Williams onsite technical service representative, increased understanding of the various coatings systems used across the project. "The Sherwin-Williams team involved with the project was dedicated to solving a lot of the problems that an end user, general contractor, and installer might face on a mega project such as this one,” said Tyler Strickland, Division Manager, The David Allen Company, “Not only did the specified products exceed performance requirements, they set my team up for success in executing a large-format phasing plan in the field which allowed us to quickly turn over key areas of the building to the client, accelerating the overall project schedule." Through multiple pre-construction mock-ups and hands-on sessions for the contractors and other partners, everyone involved felt comfortable with the product and application methods before installation began. Frequent check-ins also helped resolve any potential issues, and by maintaining regular communication, potential problems were identified and addressed early on. This proactive approach helped foster a strong partnership across the board.

The temperature fluctuation in the southeast at the time forced the team to stay flexible with the application methods when installing the floor system. The applicators tested the limits of the system and worked closely with tech service on the best method for installation, which changed a few times during installation phases. This teamwork directly contributed to the successful installation of the systems and increased the overall confidence of all involved. Additionally, the resilience demonstrated by the flooring system, despite the low temperatures and modified application technique, is a testament to the quality and standard of the product itself.

Sherwin-Williams also worked closely with electrical teams to seamlessly integrate ESD grounding points into the flooring, streamlining the process and reducing the likelihood of complications further down the line. The result was a well-coordinated effort that saved time, minimized costs and help maintain a safe environment, while also enhancing the durability of the flooring system.

With more than 875,000 square feet of high-performance flooring installed and 80,000 gallons of coatings used, Sherwin-Williams provided the ideal coating solutions for a battery manufacturing facility, which also included steel coatings, tank linings and general painting throughout the facility. These solutions streamlined the construction process, improving efficiency while ensuring a safer, faster, and simpler project.

Putting more EVs on the Road Faster

The impact of this project will be felt for years to come as Sherwin-Williams continues to help put more EVs on the road faster.  As demand for EV battery production grows, Sherwin-Williams is positioned to play a key role in helping manufacturers scale efficiently, reduce project delays, and meet evolving industry standards. By delivering high-performance coatings that enhance durability, safety, and operational efficiency, Sherwin-Williams continues to reinforce its reputation as a trusted partner in EV battery facility construction, solving not only today’s facility needs but pioneering solutions. The ability to respond and adapt to any challenges demonstrates Sherwin-Williams’ agility and commitment to delivering high-quality results.