Normal Assembly Plant Has Expanded 164.7% Since Rivian Ownership

[AirplaneDr]

This afternoon I took some time to look at the expansion at the Normal assembly facility since Rivian took over. I used the Google Earth timeline feature to go back in time to look at how things have changed over the years. There are 4 sets of imagery available and I also used the drone video from the Rivian Story posted on 3/25/2025 to estimate the R2 expansion. I've divided the square footage numbers in to temporary and permanent structures.

Pre Rivian (8/8/2019)

	Sq Ft
Perm	2,483,400
Temp	0
All	2,483,400

4/26/2022

	Sq Ft	Sq Ft Incrs	% Incrs
Perm	3,223,700	740,300	29.8%
Temp	90,800	90,800	0.0%
All	3,314,500	831,100	33.5%

10/27/2022

	Sq Ft	Sq Ft Incrs	% Incrs
Perm	3,840,200	616,500	19.1%
Temp	149,200	58,400	64.3%
All	3,989,400	674,900	20.4%

4/29/2024

	Sq Ft	Sq Ft Incrs	% Incrs
Perm	3,840,200	0	0.0%
Temp	212,300	63,100	42.3%
All	4,052,500	63,100	1.6%

3/25/2025

	Sq Ft	Sq Ft Incrs	% Incrs
Perm	6,676,416	2,836,216	73.9%
Temp	212,300	0	0.0%
All	6,888,716	2,836,216	70.0%

This 3/25 estimate is only based on the photos and video posted as a Rivian Story on that date. It includes the addition of three new permanent structures: a large structure east of the main building for R2 body shop and general assembly, a smaller building on the south end for parts painting, and another large building on the west side of Rivian Motorway for unknown purpose.

Bottom line, since taking over this facility Rivian has grown it by 177%, a square footage increase of 4.4 million sq ft.

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[Golfer04]

I live about 45 mins from Normal and get there at least once a week. The expansion has been massive. Because of Rivian QC issues I go to the plant to frequently....lol. I've never understood how they expanded so much square footage, but not production capacity. Not that they have needed it, but it begs to ask the Georgia plant question. Why build that when you are cash strapped? I've taken two plant tours, but you easily get lost in them. Two neighbors work there (software engineers) and they have same question. The footprint over there is just huge. Love the brand (on my third R1T) and hope they make it.

 

[AirplaneDr]

It looks like Georgia development is on hold, or at least slowed considerably.

Rivian has announced that there is a maximum capacity at Normal with the R2 expansion is 215,000 units annually. The R2 will be about 55,000 per shift or max 165,000 per year with the remainder being R1/EDV. It sounds like there is some flexibility with the mix of R1/R2/EDV so R1/EDV could go above 50,000 per year at the expense of R2 capacity. So Georgia will still be needed eventually but Normal is the current priority to get R2 launched at a lower startup cost and quicker than Georgia.

 

[AirplaneDr]

I found an additional source of imagery from the McLean County GIS taken March 2025. This imagery shows all of the new development plus a veritable metric F ton of inventory sitting on the lots around the plant.

This imagery generally validates the square footage estimates that I posted previously. Using this imagery I can accurately calculate that there is now 6,573,600 sq ft or a 164.7% increase since Rivian took over.

I also did a rough estimate of the inventory on hand and found approximately 6,680 R1S/Ts and 5,050 EDVs waiting for delivery, that is an entire quarter of product just sitting. Put another way that is about $1B in inventory. Yikes! R2 needs to get here yesterday and sell like crazy.

 

[Megaman0025]

I would buy one of those R1Ts right now if they weren’t so damn expensive! They have got to find a way to cut the costs!

 

[lefkonj]

Some of the expansion is for motor assembly. The Gen1 Quad motors where from Bosche if I remember correctly. So parts and assembly of motors is part of this expansion. Not to mention other things like seats, Audio systems, blah blah.

To hit sales goals for R2 and R3 they are going to need Georgia but starting in Normal is a big win as building a new facility from the ground up takes time.

 

[UnsungZero_OldTimeAdMan]

Why build that when you are cash strapped?

Because they know how much capacity they will need, by 2028, beyond what is possible at Normal. Because R2 and R3 will be global platforms. Because it's wise to have a second production facility, as hedge against disruptions at either one, so your business doesn't grind to a halt because you have all of your eggs in just one basket. Because GA has given them favorable incentives.

 

[UnsungZero_OldTimeAdMan]

Some of the expansion is for motor assembly. The Gen1 Quad motors where from Bosche if I remember correctly. So parts and assembly of motors is part of this expansion. Not to mention other things like seats, Audio systems, blah blah.

To hit sales goals for R2 and R3 they are going to need Georgia but starting in Normal is a big win as building a new facility from the ground up takes time.

Gen1 Quad are units from Bosch. And there is a law suit over it. Per early Munro tear down, seats are from a subsidiary of Hyundai. I don't believe that has changed.

 

[ThirteenElectrics]

In 2000, Mitsubishi produced 222,000 automobiles a year out of the original, much-smaller-sized plant. I'd like to see capacity per square foot before and after Rivian took it over. Where "capacity" refers to actual production counts, not Rivian fantasy numbers.

 

[iansriv]

I would buy one of those R1Ts right now if they weren’t so damn expensive! They have got to find a way to cut the costs!

If you're open to it, there are a lot of good used R1Ts out there.

 

[AlphaSnowbordergirl]

In 2000, Mitsubishi produced 222,000 automobiles a year out of the original, much-smaller-sized plant. I'd like to see capacity per square foot before and after Rivian took it over. Where "capacity" refers to actual production counts, not Rivian fantasy numbers.

Compared to Mitsubishi though, Rivian is doing a lot of in house manufacturing rather than having others make it which requires more space for the vertical integration. Rivian is pretty into having as much control over everything they can to minimize issues with suppliers, thus why so much space but smaller capacity.

 

[AlphaSnowbordergirl]

I found an additional source of imagery from the McLean County GIS taken March 2025. This imagery shows all of the new development plus a veritable metric F ton of inventory sitting on the lots around the plant.

This imagery generally validates the square footage estimates that I posted previously. Using this imagery I can accurately calculate that there is now 6,573,600 sq ft or a 164.7% increase since Rivian took over.

I also did a rough estimate of the inventory on hand and found approximately 6,680 R1S/Ts and 5,050 EDVs waiting for delivery, that is an entire quarter of product just sitting. Put another way that is about $1B in inventory. Yikes! R2 needs to get here yesterday and sell like crazy.

Don't forget that they also need vehicles already ready ahead of time as they will be shutting down the factory for R2 prep later this year. Don't know how long they will need to shut down for though, but the back up in inventory may possibly be for that reason if the shutdown will occur during months of high sales. But that's just a guess. I don't know what's going on.

 

[DuoRivian]

Don't forget that they also need vehicles already ready ahead of time as they will be shutting down the factory for R2 prep later this year. Don't know how long they will need to shut down for though, but the back up in inventory may possibly be for that reason if the shutdown will occur during months of high sales. But that's just a guess. I don't know what's going on.

They are down for four weeks I believe so they have much more than that in inventory if the drone footage is to be believed.

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