Ford Engine Plant Renovation

  • Ford Motor Company
  • Flowcoat OP and Flowtex Applied at Ford Motor Company
  • Industrial Flooring at Ford Motor Company
  • Flowcrete Americas Installs Industrial Flooring at Ford Motor Company

Ford Puts Engine Plant on a Fresh Footing with Flowcrete

Apr 30 2018

  • Flowcrete Americas flooring chosen for large-scale factory renovation at key Ford plant.
  • The Romeo Engine Plant’s upgrade program required new high performance floor finishes.
  • 200,000 square feet of resin flooring was installed throughout the vast manufacturing facility.

A number of high performance flooring solutions from Flowcrete Americas was chosen by the Ford Motor Company when it undertook a comprehensive renovation of its large-scale Romeo Engine Plant.

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

As part of this process, the iconic plant required a new floor that would meet the site’s exceptionally high standards - and that 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 a workforce of over 1,000 employees work on two production lines, with one 4,000-foot line producing a breath-taking 140 engines an hour.

To create a floor area that would be up to the task at hand, 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. Flowcoat OP is ideal for large expanses of flooring within manufacturing facilities, as its durable nature will withstand the impacts, substances, traffic, temperatures and deteriorating factors that it will inevitably be exposed to. 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 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, making it suitable for even the most heavy-duty processing environments.

Flowcrete Americas’ resin flooring solutions allowed Ford to create a colorful 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 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 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 Americas’ 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 as it transformed for the future.


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Notes to Editors

Flowcrete Americas has its headquarters in Spring, Texas and and is part of the global Flowcrete organization. Flowcrete is part of Euclid Group, the international construction chemicals group of RPM International Inc.

A world leader in the manufacture of seamless industrial and commercial resin floor, wall and coving solutions as well as other specialist coating technologies, Flowcrete Group has international manufacturing facilities in the Americas, Europe and Africa as well as Central and South East Asia.

Flowcrete supplies world-class seamless flooring solutions to transform environments across the globe including; decorative seamless resins, waterproof car park deck coating systems, seamless resin terrazzo, durable antimicrobial flooring, corrosion protection, self levelling underlayments, underfloor heating and now underfloor acoustic insulation.

Flowcrete's ambitious and dedicated team, led by President Craig Brookes, is inspired by excellence in people, products and service as well as continual innovation and sustainable growth.

Flowcrete continues to use its global expertise to introduce environmentally friendly, hygienic and aesthetically attractive floors to create a better and more sustainable world.

For further information please contact +1 936 539 6700. Or visit us on the web at

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