Kansas City Assembly Plant in Claycomo, Missouri is one of Ford’s largest and most technologically advanced manufacturing facilities. It currently produces America’s number one selling vehicle, the F-150 pickup, and the Transit commercial van.
As Ford Motor Company grew and expanded its North American operations, they had the need for a building addition at their truck body shop at the Kansas City Assembly Plant (KCAP) in Kansas City, MO. CCC was contracted by Ford as the general contractor for this 142,500-square-foot, new construction project. The scope of work included demolition of paving and small structures, relocation of underground utilities, grading and drainage, concrete pad work, steel superstructure, siding, roofing, ramps, retaining walls, site utilities, guard protection, doors and equipment, and MEP systems. The addition tied into the existing 4 million square foot structure on one side and required coordination with the existing operation so as not to interrupt production during demolition of the old wall at the tie in location.
In addition to this contract, CCC received three additional contracts at the same plant for additional
improvements driven by the need for additional manufacturing capacity and labor to support the increased line capacity. A 30,500 square foot addition to the Material Planning & Logistics (MP&L) operations was required to support the additional materials and vehicle variations manufactured at the plant. This included tying into the existing structure a light steel structure with new truck docks, slab on grade and MEP systems. This addition took six months to complete. Another addition was soon authorized for a 3-bay addition with three truck docks and access ramp, one 3-bay addition as a warehouse, one single-bay truck dock addition and access ramp, 10,000 square feet of exterior storage pad for rack storage, and 150-foot trainwell extension. Bay work included all electrical, above and below ground mechanical, fire suppression, siding, steel, roofing, concrete and painting. The hardest part of the project was the trainwell extension which had to be completed and inspected in six days with work performed during the Christmas shutdown. This involved removing, demoing and installing an extension to the trainwell, so two addition train cars could fit in it. The crew worked 24/7 to complete the project on time, also emergency work caused by unknown conditions due to an architectural error/omission had to be dealt with. The project was completed ahead of schedule with a day to spare.
In order for Ford to meet demand for their new Transit van, 1,200 workers were hired and a second shift created. To accommodate the workers, a fourth project that included exterior modifications and a new employee parking lot were constructed. The project consisted of exterior modifications to the KCAP administrative building, as well as new flagpoles, signage, landscaping and vehicle displays. Also included was renovating a storage lot into an employee parking lot with a new pedestrian bridge for employee access to the plant, installing new fencing and striping, creating new clear vision track, and repainting existing water tower. CCC used nine subcontractors for the project. Originally the pedestrian bridge was only called to have an accelerated schedule. Once CCC begin the project, Ford requested all the work be accelerated due to plant needs. CCC was able to accelerate all the work, and incorporate multiple changes during the project including new lighting and widening the highway in front of the plant.