Minimizing Disruption Through Strategic Execution.

The Ford OHAP expansion is a transformative Design-Build project led by Rudolph Libbe Group (RLG), adding 2.6 million square feet to Ford’s Ohio Assembly Plant. With a $1.5 billion investment, the project supports a new commercial vehicle line and creates 1,800 jobs. RLG’s approach prioritized uninterrupted production, safety innovation, and cost efficiency.

The team overcame jurisdictional complexity, logistical constraints, and supply chain delays to deliver Ohio’s largest industrial construction project to date. Prefabrication, advanced technology, and union labor were key to its success, setting a new benchmark for excellence in automotive facility construction.

Ford Motor Company selected its Ohio Assembly Plant (OHAP) for a 2.6 million-square-foot expansion to support a new commercial vehicle line. RLG, chosen for its decades-long partnership with Ford, led the Design-Build effort. The project consolidated the Body Shop and Final Assembly into one structure, saving $64.8 million through redesign and tax strategies.

The project spanned 246 acres across three municipalities, requiring tailored coordination to navigate distinct permitting and payroll systems. RLG installed 18,000 tons of steel and poured 75,000 cubic yards of concrete, with structural trusses engineered for future flexibility. The team overcame supply chain disruptions by identifying material needs early, enabling the building to be energized ahead of schedule. Union labor from across the Midwest supported the effort, reinforcing RLG’s commitment to quality and regional workforce development.

Construction occurred over critical infrastructure—roads, parking lots, and stormwater systems—requiring phased execution and precise coordination to maintain full plant operations. RLG self-performed major scopes including concrete, HVAC, plumbing, and electrical, contributing 1.7 million labor hours with over 2,100 workers.

Safety was paramount. The “Find It. Fix It.” program empowered workers to report hazards, resulting in over 4,200 entries and a safety record far exceeding industry norms. Mental health tokens and weekly standdowns reinforced holistic well-being.

Technology played a vital role. Drone flights, BIM modeling, and digital platforms enabled real-time coordination and progress tracking. Prefabrication of 375 piping racks and restroom modules reduced on-site labor and improved safety.

Despite an eight-month delay in electrical equipment, RLG energized the building two months ahead of schedule. The project was delivered on time, within budget, and with early access for production tooling. It stands as RLG’s largest and most complex project to date, exemplifying innovation, adaptability, and excellence in industrial construction.