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.


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 time-frame. 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.

$215MIL. Total Construction
$5.8MIL. Project Cost
135,000SF Facility Size
2013 Completion Date
6 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.


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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