Automotive Manufacturer's EV transformation programme expedited with Flexiscreen
A leading global automotive brand’s shift toward electric and battery vehicle production represents one of the most ambitious manufacturing transformation programmes in the automotive industry. Remodelling existing factories and building new facilities relies on effective management of complex construction programmes. Across three major sites in Europe and the United States, the client faced the same challenge: how to begin interior fit-out works while construction and facade works were still ongoing.
Three sites, one weatherproofing solution
Following an initial introductory call and site survey at the first location, Westgate Global recommended Flexiscreen. This suspended modular panel system hangs from a building’s existing steelwork, with no additional framework or scaffold required, reducing both the complexity and the footprint of the installation. The compact footprint and low personnel requirement made it particularly well suited to heavily congested construction environments, where space and access are at a premium.
Flexiscreen’s unique V-overlap design made it ideal for the project. Overlapping panels create a weather- and dust-tight seal at any height and length, making it ideal for large-scale construction environments. Access points, roll-up sections, curtains, and roll-up doors were also incorporated into the design so that the system protected the works without restricting the movement of people, machinery or materials in and out of the structure.
Although weatherproofing was the primary objective across all three sites, the specific configuration was tailored to each site’s requirements and managed by a different contractor in each region.
Hungary: the blueprint for the future
The first installation was at a brand-new, purpose-built facility in Hungary, which the client described as “the blueprint for the future of automotive manufacturing.” With a target output of up to 150,000 vehicles per year, getting the factory operational on schedule was a strategic priority for the client’s EV transition.
The initial specification called for a weather screening solution that would allow fit-out works to proceed without waiting for the facade to be complete. More than 2,000m² of Flexiscreen was used, helping the programme start interior works earlier and reducing overall programme risk. In addition to the original weatherproofing application, Flexiscreen was also used internally to provide dustproof separation between neighbouring work zones and to support cold-weather concrete pours. Its success on this flagship site opened the door to other global projects.
Germany: reinventing a century-old plant
A long-established German manufacturing site was undergoing a €650 million transformation to become an EV-only manufacturing hub. The scale and heritage of the site brought additional complexity, and construction had to proceed without delay to avoid disruption to ongoing operations. Flexiscreen’s ability to create a dust-tight seal around existing ducts, pipes and steelwork made it an ideal solution at this site. The 5,000m² installation provided weatherproofing and prevented dust from migrating to adjacent areas, providing the high-level seal required for works to continue.
The project in Germany also demonstrated a further advantage. Because Flexiscreen is modular and demountable, the panels could be taken down, relocated, and reinstalled multiple times as the works progressed, providing up to 15,000m² of weather protection through careful reuse. This delivered cost and sustainability benefits over single-use or disposable alternatives and reduced the waste associated with temporary screening on a project of this scale.
USA: building the supply chain
The third project was the construction of a one-million-square-foot battery assembly plant in the southern United States. The plant was set to supply batteries to a nearby manufacturing site for fully electric vehicles, making it a critical link in the client’s North American EV supply chain. With no room for delays on a project of this strategic importance, 3,000m² Flexiscreen was specified and installed, allowing construction phases to overlap and protect active work zones.
