REHAU Manufacturing Plant Expansion

The REHAU manufacturing plant expansion project, located in Cullman, Alabama, involved the addition of 115,000 square feet to the existing REHAU facility. This significant undertaking had a contract value of $11,628,022, and the primary objective was to substantially increase the plant’s capacity, supporting a new contract with Mercedes-Benz to produce bumper assemblies for the C-Class and M-Class vehicle lines. This expansion was projected to create 200 new jobs and boost bumper production from 90,000 to 540,000 units per year, incorporating new warehouse space, offices, and an employee locker room.

The project presented several complex challenges, the most significant of which was integrating the new pre-engineered building with the existing operational plant. Robins & Morton implemented strategic solutions, carefully coordinating MEP tie-ins and cooling tower replacements during late-night hours and on Sundays to minimize disruption to the plant’s 24/7 operations. Accuracy issues with the pre-engineered building were resolved through constant communication with trade contractors and Inland Buildings, the manufacturers, who maintained an onsite presence. Additionally, the team rerouted traffic, opened new exits, and enforced strict safety zones to ensure the safe coexistence of construction and plant operations. Hazardous waste materials were also carefully and safely relocated.

Robins & Morton’s leadership was instrumental in the project’s success, demonstrating a strong commitment to safety, quality, and client satisfaction. The proactive approach included comprehensive preconstruction efforts, such as detailed project staffing and budget reviews. Furthermore, Robins & Morton’s diligent cost controls and self-performance of certain tasks, like concrete, ensured the project remained within budget and delivered overall savings for the client, culminating in a highly successful expansion that met REHAU’s operational and production goals.