Ford, India

THE PROJECT

Ford India currently operates a modern, integrated manufacturing facility in Chennai in India, which produces an award-winning range of products including the Ford Figo, Ford Fiesta, Ford Classic, Ford Endeavour and Ford Eco Sport. As part of its overall commitment to India, Ford invested $1 billion USD to build a state-of-the-art, integrated manufacturing facility in Sanand, Gujarat. The facility was scheduled to be operational in 2013, with vehicles coming off-line in 2015. With Sanand being operational, Ford India will double its manufacturing capacity in India with an installed capacity of 610,000 engines and 440,000 vehicles. The project consisted of press pits, stamp shops, assembly & engine shops and paint shops.

THE SOLUTION

Fosroc proposed a complete waterproofing solution for the retaining wall and raft for the press pits and various shops. The bottom level of the raft was 7 meters below ground level, and each basement was 60 m x 30 m with a raft thickness of 1.5 m. Inappropriate interface, poor installation, or inadequate product selection could have created weak points that would be expensive to correct. Thus, Fosroc’s systems-based approach was essential in creating and maintaining a value-adding asset. During monsoon season, the water table at the project location in Sanand rises to a very high level. Since the press pits, stamp shops, assembly & engine shops and paint shops at the Ford auto manufacturing plant are critical areas of operation, they should be absolutely free from any water or moisture. Failure to protect them from water could result in shutdown of the plant for a long period, which in turn can incur heavy production losses to the company. Proofex Engage formed the core part of these structures and provided a permanent barrier that retains long-term resistance to water and moisture entry into the structure.

THE BENEFITS

Proofex Engage system yielded many benefits to the client due to which the product has been so successful in this project. The core areas of operations are totally free from water & moisture which helped in maintaining successful operating conditions in the entire plant without any shutdown & production losses. Fosroc solution has exceeded the customer requirements both in technical & commercial aspects. Fosroc all-round support to clients & contractor from product specification to completion of execution of the project on time to their satisfaction gave comfort level to their project time schedules.