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E5 at YKTA

At the Mazda-Toyota campus in Madison, Alabama, YKTA needed properly cured, abrasion-resistant production floors without slowing a fast industrial build. E5® Internal Cure + Catalyst met the schedule while elevating performance.

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Project Snapshot

    • Location: Madison, Alabama

    • Owner/Client: Y-tec Keylex Toyotetsu Alabama (YKTA)

    • General Contractor: Gray Construction

    • Ready-Mix: Bama Concrete

    • Finisher: Jay-Ton

    • Products Used: E5® Internal Cure, E5® Catalyst

    • Total Concrete Placed: 16,000 yd³

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About YKTA

YKTA is an on-site Tier-1 automotive supplier at the Mazda Toyota Manufacturing (MTM) campus in Huntsville/Madison, AL. The 700k+ sq-ft facility produces stamped body parts and assemblies, with stamping, welding, assembly, and paint operations, and was formed as a joint venture of Y-TEC, Keylex, and Toyotetsu to serve MTM directly.

The Challenge

Deliver a highly durable, abrasion-resistant floor for a high-throughput stamping/assembly environment—without adding curing steps or delaying downstream trades. With heavy material handling, traffic lanes, and tight commissioning timelines, the slab needed predictable finishing, strong early performance, and long-term resistance to wear.

The E5 Solution

A combined system of E5® Internal Cure and E5® Catalyst addressed curing and surface performance. Internal Cure improved hydration from within, reducing permeability and shrinkage stress, while Catalyst formed a dense, hard surface “micro-grout” that reduced drag during troweling and boosted abrasion resistance—helping crews finish faster and gain earlier access.

Products Used

Built-In Performance: The E5® System Behind the Results. This project’s outcomes weren’t accidental—they were engineered into the slab. By pairing the right admixtures and surface systems, we delivered internal curing, faster access, and a harder, more resilient finish that stands up to real-world demands.

 
 

E5® Internal Cure

Internally cures the slab, increasing hydration efficiency and density while removing wet-curing steps and topical curing compounds—ideal for schedule-critical healthcare projects.



E5® Internal Cure

E5® Liquid Fly Ash

Engineered pozzolan to tighten the matrix, improve cohesiveness, and reduce permeability.

 

E5® Liquid Fly Ash

16,000 yd³

Total concrete placed for production floors and support areas.

2019

Year constructed; floors placed and finished during the build.

220M

Capital investment for the Madison, AL stamping/assembly plant.

Schedule/Mix Process

The project team sought a curing approach that wouldn’t slow placement or add extra steps. Liquid dosing of E5® Internal Cure at the plant and in-place application of Catalyst allowed Jay-Ton to maintain pace and finish efficiently, supporting Gray Construction’s aggressive industrial schedule while meeting durability goals.

Performance Needs

Production floors adjacent to stamping and assembly demanded high abrasion resistance, dense paste, and moisture-aware behavior for line striping and future coverings. The mix also needed to limit shrinkage-related movement and maintain flatness under forklift and tug traffic typical of automotive plants.

Project Overview

The $220M+ YKTA program required fast, clean, repeatable slab placements that could be finished consistently and opened to trades on an accelerated path. By pairing E5® Internal Cure with E5® Catalyst, the team produced dense, abrasion-resistant floors while eliminating wet curing and minimizing schedule risk—an ideal fit for a modern automotive supplier ramping to volume.

How E5 Elevated Performance

  • Accelerated access: Eliminated wet curing/curing compounds, helping keep commissioning on track.

  • Finishing control: Reduced drag and extended workable window for consistent trowel passes.

  • Durable surface: Dense, hard paste resists abrasion in high-traffic production aisles.

  • Moisture aware: Internal moisture management supports coatings/markings and lowers permeability.

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