Setting New Milestones.

High Performance, High Quality Solar Cells

One of the world’s largest and most recognized photovoltaic (PV) manufacturers, Qcells is known globally for its premium solar cells and modules. The customer identified a growing demand from the U.S. and realized that the best way to serve this new market was to establish a production plant closer to its customer base, where the company could assemble and deliver high-performance PV modules.

Qcells needed its initial manufacturing operation up and running as soon as possible and challenged Gray to complete the project on a fast-track schedule. Thanks to an around-the-clock effort from project teams, subcontractors, and trade partners, Gray was able to complete the project in just nine months.

“We are pleased to have partnered with Gray for providing timely delivery of our manufacturing facility,” said Mr. Byeong Yong (James) Choi, Qcells President/COO.

Upon completion of the facility, Qcells became the largest-capacity solar power producer in the U.S., boasting an annual capacity of nearly 1.8 gigawatts—a measure comparable to the peak output of the Hoover Dam.

In recognition of the project’s quality and success, Qcells placed first in the Associated Builders and Contractors (ABC) of Alabama Excellence in Construction^® awards. Each year, the premier competition recognizes construction projects of outstanding merit within the region.

“The Gray submittal for Qcells was a shining star for our banquet this year,” said Jay Reed, president of ABC Alabama. “The safety, quality control, and expedited schedule set it apart from the competition immediately.”

Qcells Chooses Gray for Massive Production Expansion

Following the success of its initial U.S. operation, the customer selected Gray to expand the Georgia complex with additional manufacturing and storage facilities to increase its annual production capacity from 1.8 to 3.1 gigawatts, which will cement Qcells’ Dalton operation as the largest solar module plant in the Western Hemisphere. When completed, the combined production complex will measure more than 1 million square feet—more than tripling the size of the original plant. The new facilities will add 420,000 s.f. of production space, a 380,000 s.f. warehouse for raw and finished goods storage, and 12,000 s.f. of office space.

Gray is providing a wide range of services for the project, including virtual design and BIM, custom-fabricated process skid systems, and process & packaging systems engineering that incorporates automated guided vehicles (AGV) for efficient product movement. The company was once again challenged with an aggressive project schedule, which included the procurement and installation of cooling towers, rooftop HVAC units, switchgear, chillers, dust collection skids, and other production and utility equipment.

Throughout each project phase, the Gray team has prioritized developing a close partnership with the customer, consistently meeting project deadlines, and delivering first-class facilities. As Gray deepens its ties with Qcells, it has continued to enrich the surrounding communities by bringing hundreds of manufacturing jobs and quality sustainable products to the U.S.