Roncelli was honored to be highlighted as an Outstanding Construction Project of the Year at the 2025 CAM Showcase Awards. This recognition celebrates our role in the historic renovation of the Ford Engineering Laboratory (FEL) in Dearborn, Michigan. While the project was not selected as the final category winner, the acknowledgment reflects the innovation, technical excellence, and collaborative effort behind one of Ford Motor Company’s most significant redevelopment initiatives.

Preserving History and Building the Future

Originally designed in 1924 by architect Albert Kahn, the Ford Engineering Lab stands as a cultural and industrial landmark. For decades, it served as a center of engineering activity for Henry Ford’s expanding enterprise. After its closure in 2003, the building remained dormant until Ford Motor Company initiated a transformative vision to modernize the space while preserving its historic character.

Project team:

• Owner: Ford Motor Company
• Architect / Engineer: DiClemente Siegel Design Inc.
• Construction Manager: Roncelli

This partnership brought new life to the 205,000 square foot structure. More than 1,000 Ford employees now work within a modern, high‑performance environment that still preserves over 60 percent of the building’s original architectural footprint.

A Model of Adaptive Reuse

The FEL renovation demonstrates the potential of adaptive reuse by integrating modern workplace systems into a nearly century‑old building. The project restored historically significant elements while implementing the latest standards in engineering, sustainability, and research facility design.

Key achievements include:

• Preservation of Albert Kahn’s original limestone façade
• Restoration of the steel‑arched windows and vaulted skylights
• Addition of a 20,000 square foot research laboratory
• Installation of new mechanical, electrical, and plumbing systems designed to blend into the historic structure
• Strategic reuse of existing materials to reduce waste
• Preservation of Henry Ford’s original office, maintained as it appeared in 1947

The finished facility now delivers modern functionality, natural light, and improved workplace performance while maintaining the spirit of its early twentieth‑century design.

Navigating the Complexities of a Century‑Old Structure

One of the central challenges of the renovation was the building’s limited documentation and decades of unrecorded changes. Once demolition began, unforeseen conflicts became routine. The project ultimately required more than 1,400 change orders, rerouting of undocumented systems, and structural corrections discovered during floor demolition.

Restoration of Original Structural Steel Columns

Among the most complex challenges was the restoration of structural steel columns from the original design. These columns had been concealed behind drywall for years. Initial attempts to encapsulate lead‑based paint in place were unsuccessful. To resolve the issue, Roncelli engaged a bridge blasting crew equipped to perform industrial steel media blasting operations. This solution required environmental controls, specialized oversight, and tight coordination with all surrounding trades. The result was a complete restoration of the historic columns without sacrificing safety or quality.

Overcoming Hazardous and Confined Conditions

Additional obstacles included:

• Utility crawl space required extensive abatement of hazardous materials and demolition of abandoned utilities to allow space for new MEP installations.
• Remediation of all lead painted surfaces throughout the main floor.
• Structural instability required shoring the main floor for both demolition and construction activities.

Despite the difficult conditions, the team maintained strict safety standards and protected the architectural integrity of the building. Success was driven by coordination, adaptability, and a shared commitment to delivering long‑term value.

Community and Campus Impact

The impact of the FEL renovation extends well beyond the building itself. The project:

• Reenergized a major portion of Dearborn’s engineering corridor
• Created significant construction employment opportunities
• Preserved an important architectural and cultural asset
• Demonstrated the long‑term value of sustainable renovation and adaptive reuse

The Ford Engineering Lab is now a forward‑looking workplace within a historically significant structure. It supports Ford’s continued investment in engineering research and workplace modernization.

Roncelli is proud to have been highlighted at the 2025 CAM Showcase Awards for our role as Construction Manager. The FEL renovation represents the best of what can be achieved through collaboration, craftsmanship, and respect for both the past and the future. Our partnership with Ford Motor Company and DiClemente Siegel Design Inc. created a transformative project that will serve generations of innovators.