Caterpillar (CAT) Engine Assembly Complex

The Caterpillar Engine Assembly Complex consists of two facilities on 185 acres that total approximately 1.5 million square feet.

Pacheco Koch provided the site civil engineering for the entire 185-acre site which consists of a 500,000 square foot expansion onto a 145,000 square foot building, that is adjacent to an 890,000 square foot assembly building in Seguin, Texas. The first phase of the project, completed in 2009, was Caterpillar’s 820,000 square foot engine assembly facility that features expansive truck dock areas to accommodate the volume of incoming and outgoing deliveries as well a small office component for overseeing operations. The facility has become Caterpillar’s main C9 engine assembly facility in the southwest. Once retained by Caterpillar, Pacheco Koch reviewed the project’s basis for design and offered various value engineered plans to save project costs and allow for more efficient land use in future phases. In addition, Pacheco Koch analyzed the overall 640-acre drainage basin and designed retention facilities to meet city and TxDOT discharge requirements.  Pacheco Koch also prepared mass grading plans for the 185-acre tract that considered future project phasing, provided construction staking services, coordinated with an in-design regional lift station authority, and lead coordination with local jurisdictions on approval of the construction documents.

During the second phase of the project, Pacheco Koch revised the drainage to allow for the new 500,000 square foot expansion onto a 145,000 square foot building, coordinated a public sidewalk along US 90 for the property and coordinated with TxDOT for two deceleration and acceleration lanes for the project. One of the challenges of the project was an existing drainage channel east of the building where it was necessary to coordinate the construction of a bridge to cross the channel in order to access the truck court from the west. An overhead enclosed connector was also added to the project to connect the expansion and the assembly building.


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