Upgrading automotive plant flooring is crucial for maintaining a safe, efficient and productive work environment. The flooring in these facilities must withstand heavy machinery, chemical spills, and high traffic while also ensuring the safety of employees and the efficiency of operations.
However, the process of upgrading automotive plant flooring is daunting, especially when downtime or halting production is not an option. Removing existing flooring, preparing the base, installing new flooring, and allowing for curing time presents challenges and disrupts regular operations.
Automotive flooring must also have a high-gloss, reflective finish, so operators quickly identify gears, spills and hazards. Additionally, the need for battery charging areas for electric forklifts, and smooth surfaces where robots operate further complicates the process.
Read on to learn how to upgrade automotive plant flooring without halting production.
Understanding the need for automotive plant flooring upgrades
Before deciding to upgrade automotive plant flooring, understanding the needs and challenges specific to the facility is crucial. Upgrading automotive plant flooring is essential for several reasons:
Wear and tear: Heavy machinery, daily operations and high traffic cause wear and tear on flooring, leading to cracks, uneven surfaces and other hazards.
Chemical damage: Chemical spills—such as oil, brake and other automotive fluids—damage flooring and create safety hazards.
Delamination: Over time, the adhesive holding flooring surfaces in place weakens or deteriorates, causing delamination or separation of the flooring from the base.
Loss of gloss top coat: The top coat on automotive plant flooring “rolls down” over time, making the surface dull and less reflective.
Heaving or cracking in concrete or joints: Uneven surfaces disrupt assistive robots and employees from moving goods and materials efficiently, which results in damaged products or delays.
New safety or environmental regulations: Upgrading flooring is necessary to meet newly implemented safety or environmental laws.
Benefits of a well-maintained and upgraded floor
Investing in a well-maintained and upgraded floor provides numerous benefits.
First, upgrading the flooring enhances safety by reducing slip and fall hazards, which is critical in environments where oil, chemicals, and water are frequently present.
Second, to upgrade is the reduction in maintenance costs, particularly for equipment like forklifts and tow trucks, by addressing issues such as deteriorating control joints.
Third, a smoother, more even surface allows machines and forklifts to operate more efficiently, reducing downtime and increasing productivity.
Finally, upgrading the flooring gives your facility a fresh look that makes your employees proud and reflects the quality of your operations.
Planning the upgrade
Meticulous planning is crucial to upgrading automotive plant flooring without halting production. Careful planning ensures that the process is smooth and minimizes disruption to daily operations.
Start by conducting a thorough assessment of the current flooring to identify areas that require attention. Determine what you need for the flooring, such as repairing control joints or upgrading specific sections.
Then consider the different activities that occur on the floor. Does it get wet frequently or experience impact from dropped tools or heavy loads? This information significantly helps when choosing the right flooring materials and coatings.
Conduct a final inspection to determine whether you need to make any changes before beginning the upgrade process.
Scheduling the upgrade
Scheduling the upgrade in stages is essential to keep production running smoothly. Typically, businesses schedule these upgrades during holidays when the owner shuts the plant down to limit the impact on production. If this is not an option, consider upgrading one section of the floor at a time to keep production going and meet quotas. Additionally, plan to perform upgrades during downtime, such as during shift changes or weekends.
Using fast-curing flooring materials
The type of flooring materials is another critical aspect of planning. At Rio Flooring Systems, we offer fast-curing materials, but they still require three to four days to cure fully. Preparing the fast-curing material and waiting for it to cure takes time and careful coordination.
Choosing the right flooring material
When planning to upgrade automotive plant flooring without halting production, the flooring material makes or breaks its success.
Types of flooring materials
Selecting the proper flooring material is crucial to the success of the upgrade. The type of flooring material chosen depends on the facility’s specific needs.
Epoxy: Epoxy is an excellent choice for patching and is particularly suitable for warehouse spaces with deteriorated concrete or joints, bad patches or spalling.
Polyurethane: Polyurethane is ideal for areas where a high gloss, high reflectivity finish is necessary. This material is also chemical resistant, making it perfect for environments where spills are usual.
Others: Polished concrete is another option for areas like warehouses where oils or chemicals are not present. This material provides a durable and low-maintenance solution.
Factors to consider
When choosing your flooring material, consider its durability, as automotive plants operate heavy machinery and experience high traffic, requiring a material that can withstand constant wear and tear. Additionally, ensure the cost of materials and installation aligns with your budget while still guaranteeing the flooring's longevity. Lastly, opt for materials that are easy to clean and maintain, which will help save time and money in the long run.
Case study
A case study involving Mercedes-Benz highlights the benefits of upgrading automotive plant flooring. Rio Flooring Systems performed over 20,000 feet of line striping in their Tuscaloosa, Alabama, plant, helping to organize the facility and block off areas for safety. This upgrade not only improved the aesthetics of the plant, but also enhanced safety and productivity.
The bottom line
Careful planning, the right materials and a strategic approach are crucial to successfully upgrading automotive plant flooring without halting production. When you understand your facility’s unique needs, tactically schedule upgrades and choose durable, fast-curing materials, you get a successful flooring upgrade that enhances safety, efficiency and aesthetics.
Are you ready to upgrade your automotive plant flooring without halting production? Rio Flooring Systems has the expertise and experience to help you achieve your goals. Contact us today to learn more about our tailored solutions and start on your project.
