Vehicle Protection Structures: Hail and half of Georgia

Carmakers are increasingly concerned with making their operations more climate friendly in terms of inbound supply, manufacturing and the delivery of finished vehicles. That coincides with higher incidents of an unfriendly climate, where extreme weather events threaten to increase damage rates to production facilities, dealerships and the vehicles moving between them. 

Vehicle Protection Structures (VPS) is addressing both concerns in one groundbreaking project at Kia’s US manufacturing facility in West Point, Georgia by integrating large-scale hail protection combined with utility-scale solar power generation. Providing 297,300 sq.m (3.2m sq.ft) of overhead protection from hail with large-scale solar energy production is reinforcing Kia’s commitment to sustainability and operational resilience. 

Sustainable protection

VPS is renowned for designing and installing innovative solar-integrated vehicle protection. The company specialises in design-build solutions that enhance vehicle security while supporting sustainability initiatives. VPS has already been providing hail protection combined with solar generation for dealerships in the US but this is the first installation at this scale at an auto assembly plant. VPS worked with TransDevelopment, provider of specialised transport facilities, and solar engineering design firm Solmotiv on the infrastructure at Kia’s Georgia plant. The advantage for the dealers and Kia’s plant is that, as well as protecting the vehicles in outdoor storage lots, the energy generated by the solar panels can be used to offset facility energy costs sustainably. The solar array will provide up to 10% of the West Point plant’s power. 

The installation of the solar panels also provides clients with investment tax credits (ITCs) related to sustainable infrastructure under the US Inflation Reduction Act. ITCs provide credit for expenses invested in renewable energy properties, most often solar developments. The Inflation Reduction Act extended the ITC from 2022 through 2032 as a 30% credit for qualified expenditures. 

“What makes the way we combine solar with our hail protection so compelling is how many boxes it checks,” says Keith Busam, Vice President of Business Development and Sustainability at VPS. “First, it significantly cuts the facility’s energy consumption. Second, thanks to the way we design the system, the clients are able to take advantage of a substantial tax credit on the entire structure—not just the solar panels.” 

The supply of energy for the plant from the solar array helps address capacity constraints on the US energy grid, to which the electrification of vehicles is adding. Georgia Power’s strategic decision to invest in and sell its own renewable source of energy meets the demand put on the grid and guarantees revenue savings for Kia at the same time. 

Hail damage

Hail damage is costly to repair and higher in terms of insurance claims but the US is guaranteed to suffer expensive hail events each year from the spring to the autumn. According to the National Centers for Environmental Information (NCEI), there were at least 11 severe hail storms in the US between February and July last year, each resulting in billions of dollars in damage to infrastructure and vehicles.

That is something Kia experienced in March 2023 at its West Point plant when a catastrophic hailstorm caused extensive damage to more than 13,000 vehicles. Beyond the immediate financial impact, the event led to months of supply chain disruptions. VPS engaged with Kia Georgia following the hailstorm when the carmaker was looking for creative solutions. Ultimately, Kia made the decision to invest in the VPS system to safeguard its inventory and mitigate future weather-related risks. 

Solar tree forest

Kia’s West Point plant, which makes the Telluride, Sorento and Sportage SUVs and the all-electric EV6 and EV9 SUVs, will benefit from an extensive protective structure across its storage yard that integrates an innovative solar tree system, with 17,000 bifacial solar panels fixed into the columns of the hail protection structures. Being bifacial means energy is also caught from light reflected from the protective canopy. The VPS structures offer the most reliable protection for customer-ready vehicles. Additionally, this project has the ability to integrate 10+ megawatts of solar-generated energy into the system and will allow Kia Georgia to support corporate global sustainability goals.

“We are thrilled to bring this first-of-its-kind solution to Kia’s West Point facility,” says Wade White, executive vice-president of VPS. “This project sets a new industry standard by combining advanced hail protection with sustainable energy production, and we couldn’t be more excited about the impact it will have on the resiliency of Kia’s supply chain and our planet.” 

The investment aligns with Kia’s global sustainability strategy, including its goal of achieving carbon neutrality by 2045. As part of the RE100 initiative, Kia aims to power all its manufacturing sites with 100% renewable energy by 2040. The solar integration at the West Point facility is a significant milestone toward this vision, reinforcing Kia’s leadership in the transition to sustainable automotive manufacturing. 

VPS hail protection systems are already considered the industry standard for weather protection of large areas of risk, and the integration of solar electricity generation helps manufacturers meet sustainability targets, reduce utility charges, and qualify for available tax credits. Kia Georgia not only believes in building sustainable products but also incorporating sustainable solutions that protect and promote efficiency and quality. 

“Kia is excited about the benefit of this 3.2m sq.ft of hail protection so that they can avoid both the financial and supply chain disruptions they experienced previously,” says Busam. 

Power for the future 

Kia and VPS are partnering with Georgia Power to successfully implement this ambitious project. Through this collaboration, the companies will optimise energy production and ensure seamless integration of renewable energy into Kia’s operations, further reducing the facility’s carbon footprint and dependence on conventional power sources. 

“Our partnership with Kia and Georgia Power has been instrumental in making this vision a reality,” says White. “Working together, we’re not only safeguarding Kia’s vehicles but also helping drive a cleaner, more sustainable future for the automotive industry.” 

With the integration of cutting-edge hail protection and renewable energy, VPS says the project represents a major leap forward for Kia’s West Point manufacturing facility. Not only will it enhance the resilience of Kia’s operations, but it will also contribute to a cleaner and more sustainable future for the automotive industry. 

“This project is a true game-changer, showcasing how automotive manufacturers can integrate renewable energy into their operations while ensuring their inventory remains protected from severe weather,” says White. “It’s a testament to the innovation and engineering excellence that VPS is known for.” 

Since 2003, VPS has been the dominant force in the automotive hail protection and commercial covered parking industries, with millions of square feet of protection installed across North America. Its clientele includes major automotive manufacturers such as Honda, GM, BMW, VW, Audi, and Nissan, as well as OEM facilities, auto dealerships, distribution centres, airports and industrial sites. The latest Kia project sets a new benchmark in the industry by demonstrating how vehicle protection and renewable energy can be seamlessly integrated at scale.