Innovative Battery Manufacturing Facilities Construction management consultancy for building innovative battery manufacturing facilities in the United States. Bechtel is at the forefront of constructing innovative battery manufacturing facilities in the U.S. Our expert team ensures compliance with local codes and…
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The Bechtel-built mine, one of the largest copper resources, features a first-of-its-kind desalination plant and will operate on 100% renewable energy by 2025.
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Bechtel is delivering one of Australia’s largest infrastructure projects — a state-of-the-art airport designed to handle 10 million passengers annually.
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Projects
In 2022, our team completed construction of one of the biggest manufacturing projects in the U.S., the Shell Polymers Monaca plant. At the time, this project marked one of the largest union construction jobs in the U.S. with more than 9,000 workers on site at peak construction. The plant is producing 1.6 million tonnes of polyethylene per year for use in a wide range of everyday products from packaging and containers to automotive components.
The project was nearly a decade in the making, involving craft professionals from across the U.S., represented by 15 unions, working 47 million hours during the construction phase.
253 modules produced across four module yards
1,620 pieces of equipment
The construction phase used 241,000 cubic yards of concrete, 42,000 tons of steel, and over 1 million feet of pipe, highlighting the project’s scale and complexity.
The facility can produce 1.6 million tonnes of polyethylene pellets annually, providing essential materials for everyday products.
During peak construction, about 9,000 workers contributed to 47 million hours of work across 15 unions.
This megaproject generated significant local economic activity by purchasing materials, equipment, and supplies.
Bechtel prioritized local businesses, collaborating with over 150 local suppliers, including 65 minority- or women-owned companies. The project involved close teamwork among Shell, Bechtel, Great Arrow Builders, unions, and local contractors.
The facility includes an ethane cracker, three polyethylene units, a 275MW power plant, a water treatment facility, and extensive storage with rail and truck loading capabilities. Bechtel served as the Main Works Contractor for the entire construction, commissioning, and startup process.
Ethane Cracker Unit
The Quench Tower stands 288 feet tall, equivalent to a 27-story building.
Cogen and Power Supply
Generating approximately 20 megawatts of electricity, the Cogen system powers the entire facility and can supply excess energy to about 2,000 homes in Beaver County.
Polyethylene Production
The plant produces polyethylene (PE) pellets, which are essential for everyday items like food packaging, household products, and toys.
Cooling System
The cooling tower operates with pumps that circulate up to 370,000 gallons of water per minute, maintaining a continuous flow of 2.7 million gallons.
Railyard Infrastructure
The railyard can accommodate 1,400 rail cars along its extensive 30-mile track network.
Pilbara, Western Australia
2017
The Wheatstone LNG project, led by Bechtel for Chevron Australia, boosts natural gas supply, supports local employment, and fosters indigenous business growth.
Karratha, Western Australia
2025
Bechtel is adding a new LNG train and domestic gas facilities at Woodside Energy’s Pluto facility, driving economic benefits for Western Australia.
Texas, U.S.
2025
In partnership with Cheniere Energy, Bechtel is expanding the Corpus Christi Liquefaction project to deliver cleaner, flexible energy worldwide.
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