Complex Truss Connections for Ford Facilities
About the Fordland Electric Vehicle Center project
The Tennessee Electric Vehicle Center (TEVC) is a Ford manufacturing facility near Stanton, Tennessee, that builds electric F-series vehicles. The facility is part of Ford's BlueOval City, a $5.6 billion campus that aims to create a new way of manufacturing vehicles and batteries.
IMEG was responsible for designing connections for the Fordland Electric Vehicle Center, a 1.2 million-square-foot facility requiring 7,500 tons of steel. With 1,000 unique truss configurations, the project required an approach that could handle complex geometries and varied load paths.
The challenge was managing the extensive number of unique truss connections while maintaining accuracy and efficiency. IMEG addressed this by using IDEA StatiCa to break down complex connections into clear and understandable models. The software allowed IMEG to check stress distribution, ensuring accurate load transfer and code compliance.
Unlike traditional connection design software, which often struggles with non-standard configurations, IDEA StatiCa provided IMEG with the flexibility to test various load path scenarios, including non-linear and eccentric loadings common in large truss systems. This level of detail was critical in preventing structural vulnerabilities and optimizing force distribution.
United States
Steel Connection Design for the Fabricator
IMEG also provided detailed steel connection designs specifically for the steel fabricator, ensuring that each connection was not only structurally safe but also practical for fabrication. By aligning the design and fabrication process, IMEG minimized potential errors and facilitated a smoother construction workflow, reducing costly rework and delays.
Improving Efficiency with Connection Templates
To handle the high volume of repetitive truss connections, IMEG created connection templates within IDEA StatiCa's Connection Library, enabling engineers to reuse and adapt designs quickly. This approach not only reduced modeling time but also maintained consistency and reliability in connection design across thousands of connections.
Why IDEA StatiCa?
Since 2021, IMEG’s Philadelphia office has integrated IDEA StatiCa into their workflow for:
- Non-standard steel connections beyond the scope of traditional software
- Complex load paths requiring advanced analytical methods
- High seismic applications demanding rigorous design validation
- Concrete elements, including deep beam transfer girders and strut-and-tie modeling
For the Fordland Electric Vehicle Center, IDEA StatiCa allowed IMEG to deliver optimized and reliable connection designs, ensuring both safety and constructability. This project demonstrates how advanced connection design tools can support large-scale, high-complexity projects and influence best practices in structural engineering.
Other connections designed by IMEG with IDEA StatiCa
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