Ford Motor Company chose several high performance flooring solutions from Flowcrete during the upgrade of their engine plant in Romeo, Michigan.

The Romeo engine plant has been a critical part of Ford’s operations since the early 70s, making engines for some of the world’s most renowned vehicles such as the Ford Super Duty, E-Series and Ford Shelby GT350 Mustang. Spread across an area of 2.2 million square feet, the facility has a workforce of over 1,000 employees working on two production lines, with a single 4,000-foot line producing a breath-taking 140 engines an hour.

Aiming to enhance the capacity and get the plant future-ready, Ford recently embarked on a $150 million upgrade program with general contractors Walbridge. As part of the renovation, high performance resin flooring was installed throughout the vast manufacturing facility covering 200,000 square feet.

The iconic plant required a new floor that would not only meet the site’s exceptionally high standards but also continue to perform in the face of complex, demanding and intensive operational activity. The Romeo Engine Plant’s commitment to high standards is exemplified by the numerous awards and accreditations received by Ford for quality, environmental efficiency and manufacturing excellence.

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

Flowcoat OP, a chemical resistant epoxy floor coating system was applied across 160,000 square feet of flooring area in the main production zone. Recommended for large expanses of flooring within manufacturing facilities, the durable Flowcoat OP can withstand impacts, exposure to substances, traffic, temperatures and other deteriorating factors. Being seamless and impervious, this flooring system facilitates a quick and effective cleaning regime as it leaves no room for grease, dirt, spillages and contaminants to collect.

For spaces with more challenging demands, Flowcrete installed the highly durable epoxy floor mortar, Flowtex on 40,000 square feet. Offering enhanced resistance to abrasion, wear, scratch and chemical exposure, this floor is suitable for even the most heavy-duty processing environments.

Flowcrete’s resin flooring solutions allowed Ford to create a colourful floor area, with important safety and navigational signage incorporated into the finish. An attractive 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 as well as highlight key hazards around the site.

The flooring installation was carried out over a 12-week schedule, with Flowcrete delivering a floor fit for the modern automotive industry. During the application, Flowcrete Americas and its approved contractor partner ensured compliance with the new Occupational Health and Safety Administration (OSHA) standard on crystalline silica dust, which affected multiple parts of the process.

Following the installation, the floor’s slip resistance was tested to make sure it would provide a safe platform underfoot for the site’s 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.

Thanks to Flowcrete’s expertise, specialist flooring materials and attention to detail, the Ford Motor Company’s Romeo Engine Plant renovation was put on a firm footing with a reliable floor that would support the site well into the future.