WALBRIDGE, Ohio — The Rudolph Libbe Group (RLG) is being recognized on a national and statewide stage for its work on Ford Motor Co.’s massive 2.7 million-square-foot expansion at the Ohio Assembly Plant. The project, completed earlier this year, has now earned two major construction awards.
RLG secured the Build Ohio Award in the Industrial/Heavy category from the Ohio Association of General Contractors, and Engineering News-Record (ENR) named it the Best Manufacturing Construction Project in the Midwest. Company leaders accepted the honors at separate events on Nov. 14 in Columbus and Nov. 18 in Chicago.
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“This team’s collaboration, expertise and dedication produced an excellent result in which budget and schedule goals were met with an outstanding safety performance that was 50% better than the industry average,” said Jeff Schaller, President of Rudolph Libbe Inc.
The expansion supports Ford’s push to scale production of a new electric commercial vehicle. The project spanned 246 acres, crossing three Northern Ohio municipalities, and included advanced integration with the existing facility. Instead of constructing two separate buildings, RLG redesigned the plan into a single connected structure tied into the paint shop via automated conveyor bridges.
The complexity of the work was significant. The building’s steel frame includes 13-foot trusses, 50x100-foot bays, and structural capacity to support 13,000 pounds anywhere in the facility. Electrical power was routed through a nearly one-mile trestle atop the existing plant.
RLG’s ability to self-perform major work such as concrete, steel erection, plumbing, HVAC and electrical played a major role in meeting timelines and cost goals. The company partnered with 57 trade groups, and more than 2,100 workers completed site orientation, contributing to 1.7 million work hours.
By incorporating early value-engineering, RLG saved Ford more than $60 million, and through its development arm, Rudolph Libbe Properties, an additional $15 million in incentives was secured.
Prefab capabilities were also central to project success. GEM Inc., part of RLG, assembled 375 prefabricated piping racks at its Northeast Ohio shop and delivered them fully ready for installation.
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“Our ability to prefabricate piping racks off-site and ship them to the jobsite saved time, improved accuracy and meant a safer work environment because less work had to be performed alongside the customer’s ongoing operations,” said GEM Inc. President Scott Kepp. “Our prefabrication capacity… helps to deliver excellent results for our customers.”
The awards mark the Rudolph Libbe Group’s 14th Build Ohio Award since 1993, underscoring its industry leadership as it continues delivering major industrial, energy, and manufacturing projects across more than 30 U.S. states.
The Ford expansion contributes to Ohio’s positioning in the EV manufacturing market, supporting supply chain growth and positioning the region as a competitive hub for advanced automotive production.
RLG’s safety performance being “50% better than the industry average” is notable amid ongoing national concerns about rising construction incident rates.
With over 2,100 workers involved, the project served as a catalyst for skilled trades employment and training opportunities in Ohio.
Prefabrication and self-performance, showcased in this project, reflect growing national trends in industrial construction aimed at reducing risk, improving consistency, and controlling project delivery times.
Originally reported by PR Newswire in The Malysian Reserve.
