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When Allied Mechanical took on a massive battery plant expansion, they weren’t just tackling another project. Instead, they were stepping into a new era of explosive growth. With a five-month period of continuous estimating and negotiations, the company faced a critical question: not if it is going to do this, but how?

“We felt confident in our team, our communication and our infrastructure,” says Jason Boersma, Director of Business Development at Allied Mechanical. “But even then, you don’t fully realize the scale until you’re deep into the job, and there’s no turning back.”

For Allied Mechanical, the project wasn’t just a challenge; it was an opportunity to prove their ability to handle large-scale work while maintaining their existing customer base. Larry Decker, Sheet Metal Operation Manager, recalls the intense preparation process.

“We went through five months of estimating changes before even stepping onto the job site,” Decker says. “Once we locked into a lump sum contract, there was no looking back.”

That contract helped the company mitigate financial risk and ensure they could move forward with confidence. The company also had to secure additional equipment to prevent failures in ductwork production and maintain efficiency.

Expanding the Workforce at Lightning SpeedTaking on a project of this magnitude required strategic planning and a rapid workforce expansion. “We went from 60 sheet metal workers to over 150 in a six-month period,” says James Oudbier, Estimator and Project Executive. “It was a taxing process, but we had incredible support across the board.”

The need to grow quickly brought internal conversations about resources, workload and long-term impact. It wasn’t just about completing one massive project. It was about setting the company up for continued success.

The Role of BIM and Technology
A job of this scale also required advanced technological integration. 

With a 1.7-million-square-foot facility and 2.5 million columns to account for, the company relied heavily on Building Information Modeling (BIM).

“Keeping ahead of changes in technology was critical,” Oudbier explains. “BIM allowed us to model every aspect of the job, helping drive our success and keep the project moving forward.”

Partnering with external BIM firms proved to be a smart move, as it streamlined workflow and provided essential real-time data.

Infrastructure and Logistics: Preparing for the Future
The company’s strategic investments in infrastructure proved to be a game-changer. Allied Mechanical operates two fabrication shops in Grand Rapids, Michigan, with 230,000 square feet of fabrication space.

“We had been searching for a facility to house our air compression tools for six years,” Decker says. “By sheer luck — or divine intervention — we found the perfect location right before this project began, situated between our two shops.”

With additional space and advanced equipment, the company positioned itself for future expansion, ensuring seamless operations even during high-demand periods.

As growth surged, the company needed more than just equipment and contracts. They needed buy-in from employees willing to put in extra hours.

“You can have the best project managers in the world, but if you don’t have workers in the shop ready to go the extra mile, you can’t get it done,” Boersma says.

That meant having tough conversations about how much work they wanted to take on, how far they were willing to travel and whether it was sustainable. Expanding into new states like Indiana, Ohio and Kentucky required licensing adjustments and logistical shifts, but the team was up for the challenge.

New Equipment, New Opportunities
Growth on this scale also forced the company to rethink its equipment strategy.

“Through this project, we realized new opportunities for long-term success,” Boersma says. “We didn’t just want to complete the job. We wanted to keep the employees we gained and expand our capabilities for future mega-construction projects.”

This mindset led to investments in cutting-edge technology, duplicated shop setups to reduce production risk, and expanded licensing to multiple states, allowing them to bid on even larger projects.

Not all growth comes without resistance. Boersma acknowledges that internal challenges and tough discussions arose along the way.

“We knew this would cause internal turmoil, but we worked through it,” he says. “You have to mitigate those challenges through clear communication and leadership.”

Financially, the job operated on a net 30 payment schedule, but the general contractor wasn’t always on time. “They knew they had to show progress,” Oudbier says. “We were the only trade moving forward, so we leveraged that to ensure payments kept coming.”

While the battery plant expansion was a milestone, Allied Mechanical isn’t stopping there. Their reputation has now positioned them as a go-to firm for major industrial projects, and they’re continuing to expand their presence in the mega-construction market.

“If a customer wants us on their job, we’ll estimate it, price it and deliver,” Boersma says. “This isn’t just about one project. It’s about setting the stage for the next wave of growth.”