Project Scope:

Cleveland Cliffs is the dominant player and sole supplier of merchant iron units to integrated blast furnace clients in the Great Lakes. In June 2017, Cliffs announced that Toledo, Ohio would be the location of their first hot-briquetted iron (HBI) production plant, a crucial first step in their strategic plan to become the sole producer of high-quality HBI for the EAF steel market in the Great Lakes region. The Toledo, OH HBI plant will extend Cliffs’ market reach towards EAF steelmakers.

IPS was awarded one of the first construction packages on site – the installation of the underground site process natural gas, a vital system crucial to the success of Cliff’s $1.1 billion
investment. The piping ranges from 2” to 24” with the system operating at 175 PSI.

Following the successful installation of the natural gas system, Cliffs then awarded IPS package 4B covering the reformer and heat recovery units, reformed-gas duct bridge, seal gas compressor building, and syn-gas compressor building. IPS performed equipment setting and process piping fabrication and installation for the flare gas including top gas fuel and natural gas.

Cliff’s partnership with the IPS mechanical team then continued with the award of package 4E where they installed process piping and performed equipment setting in the vapor removal building (VRB) and dust collection building. IPS was next awarded the completion packages of 4A where the IPS team finished work within the furnace tower, firewater pump house, machinery water pump house, and cooling conveyer classifier building.

$1.1BIL. Total Construction
$30MIL. Project Cost
72ACRES Facility Size
2020 Completion Date
18 Project Duration
Bid Build Delivery Method

Project Scope:

North Star BlueScope Steel is a 50-50 joint venture between BlueScope Steel (Melbourne, Australia) and Cargill, Inc. (Minneapolis, MN). The partnership brings together expertise in electric furnace steel making, slab casting and hot rolling technology in a synchronous flat rolled mini-mill. The steel mill is designed with a unique combination of proven technology to provide our customers a superior hot rolled product.

IPS was the mechanical contractor for installation of a new rolling steel mill at the Delta, Ohio facility. IPS self-performed all piping work and some electrical work.

Additional work in the Wastewater Treatment Building required IPS to install: 3 chillers, 12 large sand filter units, 2 circulating pumps, 2 filtration pumps, drag skimmers, weir pit, gravity settle tank, and associated piping.

Challenges:

The initial design was conceptual only, requiring IPS to work closely with Lockwood Greene, an engineering firm headquartered in North Carolina, to complete the final design. Throughout the design process IPS provided valuable engineering and constructability reviews for all above‑ground and underground piping.

1996 Delivery Method
18 Delivery Method
Design-Build Delivery Method
$900MIL. Total Construction
$58MIL. Project Cost
1,500,000SF Facility Size
1996 Completion Date
18 Project Duration
Design-Build Delivery Method

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