Toyota bets on 3,100 tons of steel to transform the Sorocaba plant, expand the built area by 56,000 m², and prepare for more flexible production in the future.

Written by Caio Aviz

Published on 13/05/2026 at 15:13

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Expansion of Toyota’s factory in Sorocaba is expected to be completed by the end of 2026 with 56 thousand square meters of new built area, use of 3,100 tons of steel, hybrid structure with metallic and pre-molded pillars, in addition to engineering aimed at creating large spans, reducing internal interferences, accelerating industrial assembly and allowing future adaptations in production lines, automated equipment, logistics systems, and new industrial processes

Toyota advances in the expansion of its factory in Sorocaba, in the interior of São Paulo, with a structural solution aimed at the production of the future. Therefore, the project not only increases the built area but also reorganizes the industrial logic of the unit.

According to engineer Bruno Paisana, one of those responsible for the work, the expansion will have 56 thousand square meters, will use 3,100 tons of steel, and is expected to be completed by the end of 2026. In this context, the architectural project was developed by the office Minerbo Fuchs, while the metallic structure was manufactured by Alufer S.A. and the execution was carried out by Teixeira Duarte Engenharia e Construções.

Steel takes on a central role in the new structure

According to Bruno Paisana, the adopted system combines pre-molded and metallic pillars with steel beams and roofing. Thus, the steel organizes the structural set, as it receives loads, integrates systems, and distributes efforts.

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More spans, fewer pillars, and more flexibility

According to the Brazilian Center for Steel Construction, metallic beams and trusses allow overcoming large spans with less self-weight. With this, the number of internal pillars is reduced and the free areas are expanded.

In this scenario, this configuration facilitates the installation of overhead conveyors, technical walkways, ducts, and industrial equipment. Thus, the operation encounters fewer physical barriers and can adapt more easily.

In practice, this choice defines how much a production line can grow. It also determines which equipment can be incorporated and how entire areas can be reorganized.

Industrialized construction accelerates the project

According to engineer Edson Luiz, also involved in the project, the metal structure facilitates the integration of ventilation, exhaust, and air conditioning systems. Additionally, it allows for the direct attachment of ducts, supports, and technical equipment to the structural elements.

According to Edson, the industrial manufacturing of components ensures dimensional control and geometric precision. Therefore, this condition favors the installation and operation of automated equipment.

As a result, the steel assembly brought a time advantage. Part of the work progressed in parallel with the foundations, which increased predictability on the site.

Environmental efficiency is also considered

Finally, Edson Luiz states that environmental efficiency begins even before the unit’s operation. This is because industrialized manufacturing reduces material waste and waste generation.

At the same time, steel is fully recyclable. The dry assembly reduces water consumption, while the lighter structural weight improves logistics, reduces transportation, and lowers emissions.

Thus, the expansion of Toyota in Sorocaba shows how metal structure, industrial engineering, and productive flexibility have started to go hand in hand in large factories. After all, how many automakers will still have to adapt their units to keep up with the production of the future?

Toyota bets on 3,100 tons of steel to transform the Sorocaba plant, expand the built area by 56,000 m², and prepare for more flexible production in the future.

Steel takes on a central role in the new structure

More spans, fewer pillars, and more flexibility

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Toyota bets on 3,100 tons of steel to transform the Sorocaba plant, expand the built area by 56,000 m², and prepare for more flexible production in the future.

Steel takes on a central role in the new structure

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