One of the world’s top automotive suppliers, Continental specializes in electronic brake systems, powertrain and chassis components, and other parts for the automotive industries. When the company sought to add a new product line at their Morganton, North Carolina, plant, they selected Gresham Smith to design an approximately 83,000-square-foot expansion of the facility.

We worked closely with Continental to provide a solution to the challenges of a limited site, tight budget and schedule, while maintaining the 24/7 operations of the existing plant. The expanded facility now produces approximately 3.2 million brake system units a year, including Continental’s next-generation MK C1® integrated brake system used in electric and automated vehicles.

83k+

square-foot expansion

15k+

square-foot renovation of existing spaces

150

new jobs estimated over 5 years

Enhancing What They Do

Enhancing What They Do

The expansion adds more than 83,000 square feet of production floor space as well as logistics material-handling space for receiving and shipping, and two large automated storage and retrieval systems. It also supports and increases production for original equipment manufacturer (EOM) customers by enhancing the facility’s manufacturing, engineering, quality control, maintenance and assembly capabilities.

Along with designing the facility, we provided program management services—including scheduling, cost-estimating, site supervision, change management, final inspection and handover support—to the Continental team.

Keeping it Clean

Keeping it Clean

Estimated to generate 150 new jobs over a five-year period, the state-of-the-art plant expansion creates a “clean” manufacturing area that allows Continental to provide strategic components to the automotive industry that enable vehicle automation while contributing to safe and dynamic driving.

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Project Contact

Our team designs with genuine care for ingenious solutions.

Design with us.

David Verner, RA, NCARB
David Verner, RA, NCARB
Executive Vice President, Industrial