AESC Giga 1 EV Battery Gigafactory

AESC Giga 1 set out to create a new piece of national infrastructure – a gigafactory that strengthens the UK’s EV supply chain and accelerates the shift to cleaner transport.

The project’s ambition was significant. A £1b facility the size of 23 football pitches, with multiple contractor‑designed portions and a demanding M&E scope. It needed design work that kept pace with construction and a coordinated approach that worked in the real world.

Defining a clear route through gigascale complexity

Wates SES brought us in as full-time design managers. Two Ridge consultants joined the team for two years, supporting daily design activity on site. Early work focused on understanding design maturity and setting up better processes. We carried out an independent review, identified gaps and defined a design management strategy built around the project’s priorities, providing hands-on, structured design leadership across the programme.

The wider purpose stayed in view. A facility that would help secure battery supply for Nissan and support the UK’s shift to low-carbon transport.

Bringing clarity to design, data and decision making

With more than thirty work packages in motion, the team needed simple ways to stay aligned. We coordinated each package, including multiple contractor designed portions, led weekly design reviews and worked closely with subcontractors to resolve issues early.

Digital tools played a central role. We created bespoke design management systems linked to the project’s Common Data Environment. These improved information flow and made progress easier to track. Real time dashboards supported risk reviews and helped the team respond quickly when priorities shifted.

We also supported the M&E commissioning strategy. Flow modelling and system analysis gave the team clearer insight into how the building would operate, helping shape decisions that supported safe and reliable performance.

A coordinated design ready for delivery

Stronger processes and clear communication helped reduce delays and avoid late design changes. Disciplines worked together more easily and decisions were made with better information behind them.

The completed gigafactory now delivers 12 GWh of battery capacity each year. That supports around 100,000 electric vehicles, strengthening the domestic supply chain and contributing to the UK’s low carbon transport future.

Our work helped create a delivery model that fits naturally with complex industrial projects – practical, digital and ready for gigascale challenges.

Setting the standard for gigascale projects

AESC Giga 1 is now a cornerstone of the UK’s EV manufacturing capability. The project shows how clear leadership, practical coordination and the right digital tools can support a new generation of large-scale industrial facilities. It is a model that works in the real world and sets a benchmark for what comes next.