Client
Tesla Gigafactory Berlin (Grünheide, Germany)
Advanced Manufacturing Hub
Hardware
4x CoreShelter Units
Stainless Steel, Weather-Resistant
Users
Factory Staff
Employee Benefits Program
Access control
RFID Integration
13.56 MHz MIFARE Badge System
Impact
Risk Mitigation and Improved Staff Experience
The challenge: The unmanaged perimeter risk
Tesla’s Giga Berlin-Brandenburg operates at a scale and velocity that leaves no room for unmanaged variables. As e-mobility adoption grew among the workforce, the lack of dedicated charging infrastructure became a significant operational friction point. Without a designated external solution, high-capacity lithium-ion batteries were being brought into the main facility daily.
Charging occurred at desks or along hallway corridors of the factory, introducing fire risks into a highly controlled €5+ billion manufacturing environment. The challenge was to relocate this risk outside the building without creating a barrier to staff e-mobility.
The solution: Integrated, staff-centric infrastructure
Tesla installed four CoreShelter units at its existing bike parking zones, addressing a primary source of unmonitored site risk.
Frictionless Badge Access: The lockers were fitted with RFID locks compatible with Tesla’s existing 13.56 MHz MIFARE employee badges. Staff could use their standard access card to secure a charging box, eliminating the need for extra keys or secondary apps.
Shift-Rotation Logic: The locks utilize a 12-hour cycle logic, opening automatically after 12 hours in order to prevent long-term use and ensuring that charging capacity remains available for every arriving shift, maintaining a high-capacity flow.
Active Fire Mitigation: The hardware is built for high-stakes protection. Each unit features EV-grade mica lining and integrated sensors, ensuring that in the rare event of a battery malfunction, the risk is contained far from the people and the production line.
The impact: Reinforcing the safety standard
The CoreShelters successfully transitioned the facility from ad-hoc risk to a professional, high-performance infrastructure, contributing to the improvement of the staff's operational day.
Asset & Production Security: By moving 100% of charging outdoors, Tesla successfully protected its massive capital investment and high-value production lines from the threat of indoor thermal runaway via e-bike batteries.
Lightening the Commuter Experience: Employees now enjoy a streamlined arrival routine. Charging happens directly where the bikes are parked, eliminating the physical strain of transporting heavy batteries through the building premises.
Infrastructure Integrity: In a world-class factory, ad-hoc charging solutions are a liability and a risk. PowerShelter provides the fire-rated active infrastructure that functions as an extension of the site’s safety protocol.
