Projects

Paint shop demo and strip-out sets the stage for a new era in electric vehicles

Facility Retrofit

With an eye on self-driving vehicles, a major automotive manufacturer is transforming a one-million-sq-ft automotive paint shop in one of its assembly plants into the company’s first fully dedicated electric vehicle assembly plant for trucks and SUVs.

The transformation required the comprehensive strip-out of non-structural systems to make room for new machines, conveyors, controls, and tooling and the removal of rooftop systems.

The engineering, procurement, and construction (EPC) contractor selected Michigan-based North American Dismantling Corp. (NADC) to lead the demo and strip-out effort. NADC specializes in heavy industrial demolition, strip-outs, and other aspects of specialty demolition.

Preserving some elements while demolishing non-structural components requires considerable planning and care, particularly under a tight schedule of three months.

Walkways and Decks

Next to safe completion, meeting the owner-defined schedule was of utmost importance for NADC, the EPC, and the client, as the demolition work would set the stage for installing new systems and subsequent vehicle production. To complete the job, NADC assigned a full-time safety and management team to support the workforce crew ranging from 30-130 at any given time.

The job required the complete strip out of the paint and body shop, including the main floor and basement, second-floor conveyors and associated systems, the paint mix area, the fan farm, and electrical, mechanical, fire protection heating and ventilating, and security systems.

Tasks for the interior demolition included:

• Saw-cut 12” thick structural slab and remove concrete for 32 new 6’ x 6’ openings
• Removed remaining concrete curbs after GK scope demolition
• Removal of 4” concrete walkway (100,00 sq ft)
•  Saw-cut and removal of the existing concrete roof deck for new openings (2,300 square ft)
•  Demolition of existing fan farm bases
•  Saw-cut new 10’ x 15’ concrete opening for the new stairway
•  Saw-cut curbs and concrete at penthouse penetrations back to the centerline of existing steel framing for new decking to bare

Paint Shop Spray Booth,
Oven and Process Equipment

Work Performed: Strip Out and Demolition of Paint Shops and Process Equipment

Project Description

Process Equipment Demolition

Warren Transmission Plant, Warren, MI – This project consisted of the final clearing of approximately 440,000 square feet of process area located in General Motors Corporation’s Warren Transmission Plant.

Over the years, the plant went through many changes without any prior removals. The United States Navy and the Hudson Motor Car Company constructed the facility in 1941 to manufacture various artillery and shells. The facility was subsequently owned by Westinghouse and Ford Motor Company before it was purchased by the Chevrolet Motor Division of General Motors in 1961. From 1961 to 1974, the facility was used to manufacture automotive parts and artillery shells. From 1974 to July 1980, Chevrolet continued its automotive manufacturing operations. The Hydra-Matic division of General Motors began operations in 1980 and continues to produce transmissions and various other automotive parts.

It was the task of North American Dismantling to finally clear out all the old and redundant systems that had been collected over the years, including electrical, mechanical, fire protection, heating and ventilating, and security systems. No as-built drawings were available to assist North American Dismantling in this endeavor. Several hundreds of hours were spent identifying and labeling the systems to remain and those to be removed.

All abandoned pipes, conduits, and wires were removed from the inside and below the roof truss of the buildings. Conveyors, mezzanines, catwalks, and their supports no longer used were removed completely. All equipment support brackets were removed. Steel brackets and clamps for pipes and conduits were removed from roof trusses and building columns in the identified dismantling area. North

American Dismantling removed all old equipment structural members, u-bolts, and hangers connected to roof trusses in all areas.

Additionally, North American Dismantling removed 45,000 square feet of wood block flooring, 56,000 sf of concrete pavers, and 244,750 sf of non-monolithic concrete (including topcoats, concrete pads, concrete curbs, and equipment foundations). The wood block flooring and brick pavers were removed and disposed of as regulated materials, and the areas below were scarified to receive new concrete topping.

North American Dismantling also removed several hundred feet of 48” round ductwork, which covered an area of approximately 200,000 sf from the existing roof.

North American Dismantling completed the asbestos abatement of pipes, heater units, and HVAC units located in the truss of the buildings.

North American Dismantling also completed the environmental cleaning of all pits, sumps, flooring, and trenches in all areas.

In addition to our original contract work, North American Dismantling was awarded the removal of approximately 12,000 sf of the existing oven from the roof area. The ovens were contaminated with non-friable ACM. In Addition, North American Dismantling received the proper 40 hr training needed to remove the ovens. The roof, roof panels, and side panels of the Elpo Oven were double-wrapped with 6-mil poly and disposed of as ACM. The remainder of the oven was removed as non-hazardous metal and debris. Because of the high flammability of the roof, North American Dismantling, in conjunction with the Plant Fire Marshall, purchased four plasma cutters and trained its employees to complete these operations.