International Motors - Formerly Navistar

Huntsville, Alabama

110,000 SF expansion delivered without disrupting production

Project Overview

JESCO, Inc. delivered a 110,000 SF expansion to the fully operational International Motors Big Bore Diesels (formerly Navistar) manufacturing facility while maintaining 100% production capacity throughout construction. The project was carefully staged with dust barricades and a temporary demising wall to fully isolate work areas from active operations.

The addition was seamlessly tied into the existing structure, with construction systems and utility infrastructure integrated to support ongoing and future production demands.

1.5 million SF distribution facility

Floor storage (430,000 SF) & Rack storage (450,000 SF) Employee Amenities Advanced logistics capabilities

Employee Amenities

Advanced logistics capabilities

1.5 million SF distribution facility

Floor storage (430,000 SF) & Rack storage (450,000 SF) Employee Amenities Advanced logistics capabilities

Employee Amenities

Advanced logistics capabilities

110,000 SF facility expansion

Zero production interruptions

7.000 CY concrete self-performed

Advanced electrical and piping systems

Data Point - Callout - Brief Summary

Project Duration

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Project Duration: 12 months

Project Scope

Scope/Components

Structural Systems: 38-foot tilt-up concrete panels serving as both façade and structural members; structural steel with joist girder/bar joist framing
Concrete Work: 7,000 cubic yards of foundations, slab-on-grade, and tilt-up walls, all self-performed by JESCO
Electrical Systems: Installation of 1250A, 2000A, and 300A busducts with new switchgear
Process Piping: Chilled water, fuel, and gear oil lines spanning the new and existing buildings, tied into a complex delivery system at the tank farm

This distribution center significantly enhances Mercedes-Benz’s parts logistics network in North America, combining high-volume storage, precision inventory management, and efficient loading/unloading systems in a single, fully integrated facility.

Impact

This expansion increased International Motors’ (formerly Navistar) manufacturing footprint and utility capacity without disrupting production, a testament to JESCO’s expertise in executing complex projects in active industrial environments.

Challenges
& Solution

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Challenges

Solution

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Testimonials

It's just been a

pleasure to work with the JESCO team, all the way around.,"

Hank Eubanks

Regional Vice President at Volkert

We've been fortunate

enough to work with JESCO and partner up with them. They've been very responsive to our changes. They pick up the phone, they answer, they're quick to respond.,"

Jordan Townsend

Plant Manager at Peco Foods

We've built a true

partnership with JESCO, we identified that they recognized the quality of our company and our product as an important aspect, and incorporated that into the construction of this concept.,"

Lex Lemmers

Director of Program Management & Resident Engineering at PACCAR

What I can say is

working with JESCO, I've never felt that sort of collaboration and team work, and that solutions-oriented type of approach that we have with JESCO.,"

Mark Timbrook

Principal at FSB

Grammer Inc

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