Faurecia, one of the largest automotive parts manufacturers in the world, needed to expand a building that housed a production office at its Dayton, Ohio plant. The nearby lunch area was cramped and open to the factory floor.
The company turned to McCormick Equipment Co. In Cincinnati, Ohio, an independent Starrco dealer and partner, to explore what they could do. A modular solution, pre-engineered off-site and fast to install, was the best choice.
Picking the right partner
From the start, Cole Wesley from McCormick could see this project was going to be complicated. His company had not handled a modular enclosure project of this scope before. He knew putting together the right team would be critical.
He called one of his best vendors — Starrco. McCormick had represented Starrco for many years and Cole knew their modular buildings were high quality.
Scope of work
The new building is 60 feet long by 32 feet wide. Faurecia saved money by using the factory’s exterior concrete wall as the fourth wall of their new Starrco building.
The ground floor houses the modular cafeteria, which has a modern market-style café and vending machine area, along with some HR offices. Supervisors and managers have spacious office facilities on the floor above.
Large window panels wrap both floors and make what could have been a box-like building into a translucent showpiece.
Custom engineering solutions
All Starrco buildings are custom designed and manufactured, but this project presented Starrco designers with some unique challenges.
• Removable wall panel
Because Faurecia would need to move furniture or equipment into the second floor after completion, they asked for a big door. But, as it would be for infrequent use, Starrco designers suggested a removable wall panel would be less expensive and a more attractive option. The panel looks just like the rest of the 60-ft wall, so it does not distract from the building’s aesthetics. It can be removed or replaced in just 15 minutes.
• Open plan spaces
Faurecia needed the break room to be completely open on the lower level with no interior columns to interfere with furniture or block sight lines. Starrco’s heavy-duty, load-bearing wall system was able to accommodate this request. The wall structure allowed for support steel to clear span the entire 32-foot width of the lower level.
• Protecting the HVAC equipment
The new building uses every inch of available floor space, so there was no good location for HVAC equipment. Starrco solved the problem by fabricating an extra-large, eight-foot by four-foot landing at the top of the staircase. The equipment fits neatly in the space below.
Five weeks after installation began, the building was completed. During installation, all Faurecia’s daily operations continued unaffected, the installation took up virtually no more floor space than the Starrco building itself, and it produced almost no debris.