Ford Motor Company Chooses Flowcrete for Plant Renovation

A number of flooring solutions from Flowcrete Americas were chosen by the Ford Motor Company when it undertook a comprehensive renovation of its large-scale Romeo (Mich.) Engine Plant. 
Ford recently embarked on a $150 million program of upgrades with general contractors Walbridge to enhance its capacity and prepare the plant for the future.

Flowcrete Americas provided a turnkey flooring service that included the delivery and application of 200,000 square feet of its specialist flooring solutions. 

The chemical resistant epoxy floor coating system Flowcoat OP was applied across a wide, 160,000 square feet area of flooring in the main production zone.

For the spaces that would be faced with more challenging demands, 40,000 square feet of the highly durable epoxy floor mortar Flowtex was installed. This system has enhanced abrasion, wear, scratch and chemical resistance. 

Light grey was chosen for the main floor area with a darker shade used to designate forklift truck and pedestrian routes around the site. Yellow and red line-markings were added to clearly mark out specific spaces and to highlight key hazards around the site.

During the application, Flowcrete Americas and its approved contractor partner had to ensure compliance with the new Occupational Health and Safety Administration (OSHA) standard on crystalline silica dust, which affected multiple parts of the process.

Once laid down, the floor’s slip resistance was tested to make sure that it would provide a safe platform underfoot for the site’s many employees. Testing was undertaken every 5,000 square feet to check that the coefficient of friction stayed within the acceptable parameters. Core samples were also taken every 25,000 square feet to confirm that the floor’s thickness and strength met the required levels.