Project Overview
The client, a global leader in electrical and industrial product solutions, needed to revitalize an 80,000 sq ft manufacturing facility that had been affected by years of oil and dirt contamination on its ceiling and walls. With a focus on improving both the environment and lighting, a three-coat industrial painting system was recommended to cover the existing contamination without disrupting operations. The project was completed in 12-hour shifts over 14 weekends, ensuring minimal downtime. The result was a brighter, cleaner workspace that enhanced employee morale and production efficiency, all while maintaining the integrity of the facility.
About the Client
The client is a leading global provider of electrical and industrial product solutions, serving a diverse range of industries worldwide. In business for 55 years, they have built a strong reputation for innovation, quality, and reliability. With a workforce of 890 employees, the company operates across multiple sectors, including energy, manufacturing, and infrastructure, providing high-performance products and solutions to meet the needs of both established and emerging markets.
Project Scope
- Size of Project: 80,000 sq ft of manufacturing ceiling decks and walls, heavily contaminated with years of grease, oil, and dirt buildup.
Challenges
- Problem: The ceiling decks and walls were heavily contaminated with years of cutting oil, dirt, and grime, permeating all surfaces. This created a dim and uninviting environment, further compounded by a highly congested space filled with equipment and machinery.
- Client Needs/Goals: The client wanted to transform the space with a fresh, brightened appearance to enhance the overall work environment, improving both visibility and employee morale.
The Industrial Painting Solution
- Recommended Paint Solution: We recommended a durable three-coat system, including a primer and two gloss topcoats, designed to prevent bleed-through of grease and oils while covering existing compromised coatings and contamination. The selected coatings were solvent-free, ensuring no harsh odors that could disrupt production or interfere with employees working nearby.
- Design Considerations: The client aimed to enhance the work environment while preserving the structural integrity of the facility.
Customization: The color scheme featured a bright white industrial coating for the walls and ceiling, with pipes color-matched according to the client's specifications for a cohesive and clean look.
- Installation Process:
- The manufacturing plant was highly congested, with sensitive equipment requiring careful maneuvering.
- Using manlifts around this equipment raised significant safety and protection concerns.
- To minimize disruption, the project was completed in consecutive 12-hour shifts.
- Work was scheduled around the clock to ensure production downtime was limited to Friday evening through Monday morning.
Implementation
- Project Timeline: The project required extensive scheduling and logistical coordination to stay within scope and meet deadlines. It was successfully completed over 14 weekends, ensuring minimal disruption to operations.
- Challenges Overcome:
- Coordinating work around ongoing production to minimize disruption.
- Carefully mapping out work sections and collaborating with the client to create a feasible plan that aligned with production schedules.
Results & Outcomes
The project successfully enhanced the overall appearance of the facility, creating a brighter, more inviting workspace that positively impacted employee morale. Additionally, the improved lighting quality not only brightened the environment but also contributed to better visibility, leading to a more efficient and safer production process.
