The facility in Romeo, Michigan has been a critical part of Ford’s industrial muscle since the early 70s and the company has recently embarked on a $150 million program of upgrades with general contractors Walbridge to enhance its capacity and to prepare the plant for the future.

As part of this process, the plant required a new floor that would meet the site’s exceptionally high standards – and which would continue to do so in the face of the complex, demanding and intensive operational activity. Failing to meet this benchmark was not an option for a facility tasked with making engines for some of the world’s most renowned vehicles, such as the Ford Super Duty, E-Series and Ford Shelby GT350 Mustang. 

The Romeo Engine Plant’s commitment to high standards is exemplified by the fact that it has achieved awards and accreditations for quality, environmental efficiency and manufacturing excellence. The scale of the 2.2 million square foot operation is illustrated by the that fact that more than 1000 employees work on two production lines, with one 4000-foot line producing 140 engines an hour.

To create a floor area that would be up to the task, Flowcrete provided a turnkey flooring service that included the delivery and application of 200,000ft2 of its specialist flooring solutions. 

The chemical resistant epoxy floor coating system Flowcoat OP was applied across a wide, 160,000ft2 area of flooring in the main production zone. Flowcoat OP is suitable for large expanses of flooring within manufacturing facilities, as its durable nature will withstand the impacts, substances, traffic, temperatures and deteriorating factors to which it will inevitably be exposed. Additionally, the seamless and impervious properties of this system facilitates a quick and effective cleaning regime, as it leaves grease, dirt, spillages and contaminants with nowhere to hide. 

For spaces that would be faced with more challenging demands, 40,000ft2 of highly durable Flowtex epoxy floor mortar was installed. This system has enhanced abrasion, wear, scratch and chemical resistance, making it 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. A light grey colour 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.

Using this specification, a floor fit for the modern automotive industry was successfully created within the project’s 12-week schedule. 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. This important health and safety criteria was properly adhered to throughout the project.

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 5000ft2 to check that the coefficient of friction stayed within the acceptable parameters. Core samples were also taken every 25,000ft2 to confirm that the floor’s thickness and strength met the required levels.