Nextstar Energy Project, Windsor Battery Plant
The Nextstar Energy Project in Windsor, ON is nothing short of groundbreaking, brought to life by Alberici-Barton Marlow JV, the design build team. As Canada’s first large-scale battery manufacturing facility, this 4.23 million square foot plant employs over 1,000 workers and began mass production of lithium-ion battery cells in October 2024. Unlike traditional electric vehicle battery facilities, Nextstar Energy focuses on energy storage systems (ESS), making it a cornerstone for sustainable energy infrastructure. The scale, precision, and technological demands of this facility make it a truly unique environment – and a perfect showcase for the advanced skills of Beverly Caulking.
Scope
- Fire-rated penetrations in IMP walls and ceilings
- Non-rated penetrations in IMP walls and ceilings
- Door frames
- Caulking in stairwells
Immense Size and Scope
The challenge of this project was immense; not just the size but the complexity required at every stage. Spanning nearly 5 million square feet – roughly equivalent to 4-5 football fields – Alberici/Barton Marlow JV required a caulking partner capable of supporting a massive, long-term construction schedule. In addition, the caulking team demanded expertise in firestopping, mastery of advanced technology, and the capacity to maintain speed without compromising quality. Beverly Caulking rose to the challenge, keeping pace with the demanding flow of construction, automation, and complex wiring installations.
Complexity We’re Proud Of
Beverly’s products and installation methods were rigorously tested to meet all ULC standards required under Canada Safety Codes. We provided firestopping for over 6,000 penetrations – openings designed to safely allow passage of pipes and wiring. Each penetration required a specific ULC dictating how a penetration should be treated, based on factors such as opening size, pipe material, and safety requirements. These procedures are crucial: proper firestopping protects both the building and its occupants in case of fire, ensuring compliance with legal and safety regulations. Precision and consistency were non-negotiable.
To assure accuracy for every application, our technicians utilized the “Fieldwire” platform from Hilti. Each fire-stopped penetration was photographed, documented for ULC compliance, and submitted to the general contractor, who in turn forwarded it to City Inspectors for verification. After 18 months and over 6,000 penetrations, we completed the project successfully- an incredible journey for our Beverly Caulkers.
Partner With Experts
If your project requires firestopping, caulking, or other specialized sealing services, Beverly Caulking is the partner you can trust. Our team delivers professional, reliable service for projects of any size or complexity. From high-tech manufacturing facilities to commercial spaces, we bring expertise, efficiency, and precision to every job. Contact us today to discuss your project and see how we can help protect your building, meet safety codes, and exceed expectations.
Project: Nextstar Energy Project Windsor Battery Plant
Date Completed: August 2025
