Midwest Industrial Complex
Comprehensive restoration of a 180-acre industrial park featuring 12 buildings with diverse coating requirements, from heavy manufacturing to climate-controlled warehouses.
Project Overview
This massive industrial complex serves as a critical manufacturing and distribution hub for multiple Fortune 500 companies. The comprehensive coating project required coordinating across diverse facility types, each with unique operational requirements and specialized coating needs.
Our team successfully managed the complexity of applying 15 different coating systems across the campus, from food-grade epoxies in processing areas to chemical-resistant urethanes in manufacturing zones, all while maintaining continuous operations and exceeding safety standards.
Complex Building Portfolio
Each facility type required specialized coating systems tailored to specific operational needs.
| Facility Type | Buildings | Square Footage | Coating System |
|---|---|---|---|
| Manufacturing Plants | 4 | 1.2M | Chemical-resistant epoxy |
| Warehouses | 3 | 800K | High-durability acrylic |
| Office Buildings | 2 | 300K | Energy-efficient elastomeric |
| Maintenance Shops | 2 | 150K | Oil-resistant urethane |
| Administrative Center | 1 | 50K | Premium architectural finish |
| Total | 12 | 2.5M | 15 Systems |
Chemical Resistance
Specialized epoxy systems for manufacturing areas exposed to acids, solvents, and caustics
Impact Protection
High-build urethane coatings for warehouse areas with heavy forklift traffic
Temperature Control
Thermal barrier coatings for cold storage and heat processing areas
Strategic Project Execution
Complex logistics required military-precision planning and coordination.
Phased Implementation
Phase 1: Critical Infrastructure
Manufacturing plants and production facilities requiring zero downtime
Phase 2: Storage & Warehousing
Distribution centers and warehouse facilities with managed inventory relocation
Phase 3: Support Facilities
Maintenance shops and utility buildings with flexible scheduling
Phase 4: Administrative Areas
Office buildings and administrative center with weekend work
Command Center Operations
Challenges & Solutions
Managing complexity at scale required innovative problem-solving and meticulous coordination.
Complex Challenges
- Coordinating work across 12 different buildings simultaneously
- Each building requiring different specialized coating systems
- Maintaining 24/7 operations in critical production areas
- Managing complex logistics across 180-acre campus
- Meeting different regulatory requirements for each facility type
- Extreme temperature variations between cold storage and heat processing areas
Strategic Solutions
- Dedicated project teams for each building type with specialized expertise
- Custom coating specifications tailored to each facility's needs
- Strategic phasing plan with zero production interruption
- On-site command center for real-time coordination
- Comprehensive compliance documentation and certification process
- Temperature-specific application protocols and specialized equipment
Safety & Regulatory Excellence
Maintaining perfect safety records across diverse industrial environments.
Comprehensive Safety Protocols
Project Results & Long-term Impact
Delivering exceptional value through quality, efficiency, and sustainability.
Client Success Story
"Managing a coating project across 12 buildings with different operational requirements seemed impossible without significant production disruption. Moorhouse Coating not only completed the project without a single day of downtime but also delivered exceptional quality that has dramatically reduced our maintenance costs. Their project management, safety protocols, and technical expertise are unmatched. The specialized coatings they recommended for each facility have performed beyond expectations, and the energy savings alone will pay for the project within five years."
Operational Excellence
- Zero production interruption
- Completed 3 weeks early
- 8% under budget
Technical Achievement
- 15 specialized coating systems
- 99.8% adhesion test pass rate
- All certifications achieved
Sustainability Impact
- 1,200 tons CO2 saved annually
- Low-VOC coatings throughout
- 98% waste recycling rate
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Ready for Your Multi-Building Project?
Trust Moorhouse Coating for complex industrial projects. Our expertise in managing large-scale, multi-facility coating projects ensures exceptional results with zero operational disruption.