Carbon Fiber Production Expansion Built Beside a Fully Operating Plant

Toray Composite Materials America is the largest carbon fiber producer in the United States. Its Spartanburg, South Carolina plant makes high-performance carbon fiber for aircraft, defense, industrial, and clean energy uses. Phase 2 of the plant's expansion added 300,000 square feet of new production space to keep pace with growing aerospace demand across North America, and it strengthens South Carolina's standing as a center for aerospace and advanced materials manufacturing.

Clayco and LJC designed and built the expansion, working with Tucker-Jones Engineers Associated and Alliance Consulting Engineers on the design side. Southern MEP handled the plumbing scope under Clayco. The new addition went up right next to an active chemical facility, so every phase of work was planned around a plant that never stopped running. Strict permitting, real-time vibration monitoring, and daily coordination with plant leadership were part of the job from the first day to the last.

Our team stayed with this project for more than three years, adjusting as process designs evolved and field conditions changed. The expansion wrapped up in February 2026, on schedule and ready for move-in, with plant operations never interrupted. Toray now has the room to produce more of the carbon fiber that goes into today's aircraft, made right here in the Upstate.

Project Details