FLINT – General Motors’ next generation of paint shop technology is taking shape at its Flint Assembly plant on Van Slyke Rd.

And it’s no small undertaking: the 560,000 square-foot addition will require 10,000 tons of structural steel, the placement of 1.3 million square-feet of concrete, and about 600 Hardhats on the job at peak employment. Gallagher-Kaiser is managing the paint process portion of the project, while Walbridge has been contracted by G-K to design-build the structure.

“It’s always a challenge putting things together in the time allotted, but the job is going very well,” said Frederick Hench III, project controls coordinator for Walbridge. “We’ve made great progress in a short period of time, considering all the intricacies of what is involved. We’ve had great success on the project with all the trades.”

Similar paint shops have already been installed at GM’s Orion (Michigan) and Fairfax (Virginia) plants. The new technology allows for faster movement of assembled vehicles through the plant, and uses an environmentally friendly wet-coat paint process. The new paint shop will bring about a 90 percent reduction in landfill sludge, usage of 20 percent less natural gas and 40 percent less electricity, as well as improved air management. GM says the new paint will offer improved sealers and increased corrosion resistance for vehicles.

The new paint shop is located on land south of the existing assembly plant, which was built in 1947.  The buildings will be connected by a two-story trestle, which will allow for conveyors to move the vehicle bodies to get their new colors. The new paint shop is being built atop the plant’s old V-8 engine plant, which was demolished more than a decade ago.

The topping out of the structural steel at the plant is expected to take place in early December . Hench said at the same time the steel is being set, the construction team is also using cranes to place the big paint booths on the floor of plant, saving time and money.

Last month the trades were about three-quarters complete with the structural steel, and were setting tanks, enclosing the sides of the building, installing the roof, pouring concrete slabs, installing fire protection, placing drains, and hooking up temporary power.

This project will also include various conservation projects to reduce energy use at the plant, as well as upgrades of the existing conveyor system.

GM’s Flint Assembly Plant currently employs 2,821 salaried and hourly workers. The plant has produced 13 million vehicles (9 million trucks and 4 million cars) since 1947. The new paint shop’s employment impact is “150 new or retained jobs,” according to GM.  The new plant is expected to start applying paint to vehicles in October 2016. The plant’s products include the heavy duty Chevrolet and GMC Sierra Crew and Regular Cab trucks, and it’s capable of producing Light-Duty Chevrolet Silverado Crew and Regular Cab trucks.

“The Walbridge and Gallagher-Kaiser project team have been excellent partners to work with,” said Tom Wickham, the plant communications manager for GM. “Along with the building trades, you can see that there’s a lot of pride by the people working on this job.”

GM’s NEW PAINT SHOP addition at its Flint Assembly Plant takes shape.  Setting a truss section on the high steel are Iron Workers Local 25 members Aaron Bobo and John Tonkovich of Midwest Steel. The Local 324 crane operator of the red Manitowoc 2250 is Richard “Hutch” Hutchinson.

A LUBRICATED power cable is snaked into a section of conduit at the GM-Flint Assembly Plant Paint Shop by John Bond and Nic Garza of IBEW Local 948. They’re employed by Slifco Electric.

UPLOADING SIPHONIC PIPING at the new GM-Flint Paint Shop are (l-r) foreman Wayne “The Ox” Raver,  Luke McKenzie and Richard “The Legend” Young of Plumbers and Pipe Fitters Local 370. They’re employed by Progressive Mechanical.