Project Scope:

Gerdau Special Steel North America is an engineered steel bar manufacturer that produces special bar quality (SBQ) carbon and alloy hot-rolled and bright cold finished steel bar products for a variety of applications, including the auto industry. As part of a multi-year, $215 million expansion of the Monroe facility, IPS was contracted to replace the reheating furnace and rolling mill in an effort to boost product quality and productivity.

The scope of work involved installation of:  walking beams, cooling water, CA, natural gas, combustion air, hydraulics, valve benches, pumps, tanks, grease piping, nitrogen, scale water piping, and gas vent piping. In addition, IPS extended the plant utility mains.

Challenges:

Materials and equipment to be installed was purchased directly from the customer, and delivery delays threatened to put the project behind schedule. IPS worked multiple shifts and on weekends in order to meet the aggressive timeframe. Multiple trades were scheduled to complete work concurrently throughout the facility. IPS coordinated work with other trade contractors in order to avoid any interference or equipment relocation that might be caused by overlapping work areas.

IPS
$215mil. Total Construction
$5.8mil. Project Cost
135,000SF Facility Size
9/2013 Completion Date
6 Project Duration
bid build Delivery Method

Project Scope:

Fenner Dunlop is the world’s leader in the field of conveyor belting, manufacturing the most comprehensive range of conveyor systems for many industries and applications.

IPS was contracted to provide setting, aligning, and installation services for five (5) process equipment lines: calendar line; steel cord press line; fabric belt press line; inspection line; and laminating line. Scope of work include process piping, process electrical, and equipment installation.

The preplanning for the equipment moves began while the building was being erected. Provisions had to be made for the process piping runs to be integrated within the building and the process electrical runs that had to be embedded within the concrete. Additionally, alignment plates were strategically placed in order to ensure that each individual process line was precisely installed to meet the required tolerances.

IPS was also responsible for the installation of all electrical work in the new building to support the expansion. Planning and pre-work was completed prior to the substation retrofit, which took place during a 72-hour shutdown over Thanksgiving. IPS worked around-the-clock to ensure the substation was available to the customer a full day earlier than required.

2/2013 Delivery Method
9 Delivery Method
design build Delivery Method
$38mil. Total Construction
$3mil. Project Cost
2/2013 Completion Date
9 Project Duration
design build Delivery Method

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