Becknell Industrial partnered with Cosma International on a groundbreaking facility in Blue Oval City, designed for the next-generation Lightning F-150 electric truck. The 800,000+ SF manufacturing center includes a 200,000 SF High Bay structure built to accommodate over 200 robots and an advanced Ecoat system used for the frame and battery tray assembly.

This project stood out for its technical demands and rapid execution. Located in a seismic Class D zone, it required specialized foundations, significant earthwork involving more than 1 million cubic yards of cut, fill, and import, and high-volume power infrastructure to support robotic welding. The High Bay alone features 54’ clear height and integrated pits to house the Ecoat process.

Despite the complexity, Becknell delivered results under an aggressive timeline. Awarded the contract on June 4, 2023, the team mobilized within a week and had equipment on-site by June 13. Steel arrived in November, and by January 28, the High Bay— including pits and slab—was complete after 24/7 construction over several weeks.

Becknell’s success stemmed from a combination of longstanding relationships, design coordination expertise, phase permitting strategy, and a national subcontractor network that bridged local labor gaps. Our ability to secure financing and move swiftly into construction proved decisive in winning the project and meeting Cosma’s production deadlines driven by Ford Motor Company.