For the most recent expansion of Mercedes-Benz’s North American manufacturing facility, located in Alabama, USA, CEMEX supplied more than 60,000 cubic meters of custom-designed concrete, tailored to meet the specific structural needs of this massive, challenging project.

The project consisted of expanding the existing Mercedes-Benz plant, which manufactures four vehicle models for the North American market, to approximately 4.5 million square meters (around 5 million square feet), including two large body shops, a paint shop, two assembly shops, and a logistics center.

To better understand the unique set of challenges presented by each area of the expansion project, a pre-construction planning meeting was held, in which CEMEX provided a cost-saving solution that overcame the biggest requirement of the expansion: Reduce the probability and severity of random concrete floor cracking. Considering the dimension of the facilities, CEMEX supplied over 25,000 cubic meters of low-shrinkage concrete that avoids interim cracking within the slabs.

Additionally, the robots used by Mercedes-Benz to assemble the vehicles called for a smooth surface made of a different solution than traditional steel reinforced concrete, which would interfere with the machines’ signals. CEMEX provided a special concrete mix that includes steel fibers added like an aggregate; a solution that not only allows the robotics to operate without interference, but also saves time when compared to pouring concrete with reinforced steel.

To meet the demanding production schedule, CEMEX poured approximately 10,000 cubic meters of concrete, which required 16 tankers of cement, six tankers of fly ash, approximately 70 loads of stone, 45 loads of sand, and about 2,000 gallons of admixtures.

“First and foremost, we were able to supply a project of this magnitude because of our quality people. Everyone played a crucial role in making this project a success and providing a superior experience for our customers,” said CEMEX USA Mid-South Region President, Marc Tyson. “We are proud to supply cutting-edge specialty concrete mixes that make projects like Mercedes-Benz’s North American manufacturing facility possible.”  

CEMEX is a global building materials company that provides high-quality products and reliable services to customers and communities in more than 50 countries. CEMEX has a rich history of improving the well-being of those it serves through innovative building solutions, efficiency advancements, and efforts to promote a sustainable future.