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Form Factory 1 Iron-Air Battery Production Facility

A fast-tracked new plant to mass produce low-cost, grid-scale batteries

  • $760M

    Construction Value

  • 55

    Acre Site

  • 750

    Jobs To Be Created

  • Weirton, West Virginia

    Weirton, West Virginia

Transformative energy storage technology and battery manufacturing facility contributing to grid reliability and resiliency

Form Energy’s first commercial product is a rechargeable iron-air battery capable of continuously discharging electricity for 100 hours.

The active components of the iron-air battery system are some of the safest, cheapest, and most abundant materials on the planet—low-cost iron, water, and air. When discharging, an iron-air battery breathes in oxygen and converts iron to rust. While charging, an electrical current converts the rust back to iron and the battery breathes out oxygen.

Time to market is critical for battery production plants amid the increase in renewable energy generation and associated demand for energy storage solutions. That’s why Form Energy had to fast-track their new manufacturing facility set to produce 100-hour iron-air batteries.

Our job? To provide architecture, buildings engineering, and industrial engineering services on Form Factory 1—a project which also brought new purpose to the former Weirton Steel Mill site in West Virginia.

Form Factory 1 is expected to begin operation in mid-to-late 2024. When fully operational, the facility will have an annual production capacity of 500 megawatts of batteries and support technologies capable of cost-effectively storing electricity for multiple days—during extended periods of extreme weather, grid outages, or low renewable generation.

Meet Our Team

Jim Radock, Principal

I consider myself fortunate to work at a firm that fosters such a collaborative environment to serve the needs of a wide array of clients.

Dave Calder, Vice President, Regional Growth Leader, Buildings (Global)

My job is to listen to my clients and figure out what their needs are to see if, and how, Stantec can help them.
Dave Calder Vice President, Regional Growth Leader, Buildings (Global) Read More

Alan Schnerch, Industrial Engineering Practice Lead

I work with our clients to ensure that process optimization and building design go hand-in-hand—as they should.
Alan Schnerch Industrial Engineering Practice Lead Read More

Kate Csontos, Principal

Reducing unnecessary static creates a platform where we focus on a common goal and efficiently achieve world and life changing results.

Jeremiah Brooks, Senior Associate

I believe design is processing complex problems and offering simple solutions.

George Halkias, Vice President, Buildings

In my mind, the success of a project begins and ends with a question. Did we enhance the mission of our client?

Jason Decheck, Senior Associate

Successful projects not only focus on the architecture or engineering but also on the people, which influences the final product.

Michael Brennan, Senior Associate

My goal is to design structures that stand the test of time and exceeds our client’s needs.

Jim Radock


Dave Calder

Vice President, Regional Growth Leader, Buildings (Global)

Alan Schnerch

Industrial Engineering Practice Lead

Kate Csontos


Jeremiah Brooks

Senior Associate

George Halkias

Vice President, Buildings

Jason Decheck

Senior Associate

Michael Brennan

Senior Associate

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  • Design your career

    Work with passionate people who are experts in their field. Our teams love what they do and are driven by how their work makes an impact on the communities they serve.

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