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Metal
Industry Projects
Steel Mills and Steel Industry Construction and Maintenance Projects are
a speciality of McGraw/Kokosing, a general contractor for Ohio, Kentucky
and Indiana. Typical project descriptions include: Steel Mills, Steel
Rolling Mills, Blast Furnaces, Basic Oxygen Furnaces (BOF), Baghouses and
Steel Mill Ladles. The following are some examples of our latest projects.
Greenfield
Coke Plant
Haverhill, Ohio
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Turning a cornfield that was under a foot of water into a
state-of-the-art coke manufacturing plant in only 15 months is about as
fast as fast-track construction can get. Such was the mission for 600 (at
peak) skilled craftsmen of the affiliated unions of the Tri-State
Building and Construction Trades Council to make this coke plant a
reality.
Located in Haverhill, Ohio, the $150 million design-build project,
built under the direction of the Kokosing Construction Company, had the
first of its more than 100 ovens fired up at high noon on March 1—the
exact target date set before work began. And in a world where the new
demand for steel relies on the production of processed coke—every day
counts.
As if the time frame between project start and completion wasn't
impressive enough, craftsmen had to overcome the wettest year on record
in southern Ohio, which makes the job all the more remarkable.
The tripartite involvement between owner, contractor and labor has
been a popular approach for some time in the Appalachian region, and
proved itself again as Kokosing and the Tri-State Building Trades used
the NMAPC streamlined system to turn up the heat in Haverhill.
The facility is expected to create 64 jobs in the Appalachian region,
and at capacity the coke plant will purchase 800 thousand tons of coal
annually and produce 550 thousand tons of coke per year.
The above information is from "The Construction User
Magazine", Summer 2005.
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Turbo Blower
Rebuild
Middletown, Ohio
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The No. 1 Turboblower system, which supplies 110,000 SCFM compressed
air to the blast furnace, was in need of a complete overhaul. The blower
is powered by a 10,000HP steam turbine that runs off of 400 PSI steam.
Due to internal damage to the steam turbine, the resulting vibrations
caused considerable damage to the turbo blower concrete pedestal. The
steam turbine rotor, stator wheel cases, nozzle block and casings were
removed and then refurbished in a shop environment while the concrete
pedestal was repaired. The cast iron turbo blower shell also sustained
damaging cracks which were repaired as well. New levelers and sole plates
were installed for the turbo blower, steam turbine and bearing blocks.
All turbo-machinery components were then reinstalled.
Once testing verified that the unit performed successfully, Phase II
of the rebuild continued by replacing the lube oil coolers and associated
lube oil and cooling water piping. Additional instruments and controls
were also added as part of the Human Machine Interface (HMI).
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Ductwork
Installation and Control Buildings
Middletown, Ohio
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McGraw/Kokosing was chosen to install the ductwork inside the shop as
well as install the control buildings for the new emission system all
while the shop maintained full operation. During the seven-month
installation process, M/K installed the following:
- Three (3) vertical
uptake duct routes consisting of thirty-three (33) pieces, in and
around the two Basic Oxygen Furnaces
- Charge Aisle duct
consisting of twenty-two (22) pieces
- Tap Side duct
consisting of twenty-eight (28) pieces
- Total of
eighty-three (83) pieces of duct in and around the vessels
- Computer Room – a
five (5) module prefabricated building
- Elevated Pulpit –
a two (2) module prefabricated building supported over the Hot Metal
Car Track
- Foundations and
support steel
- Power and fiber
optic cables for the control buildings
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Turnkey
Foundations, Electrical Buildings and Grounding
Middletown, Ohio
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This project included the installation of the foundations for a
830,000 SCFM baghouse, three 250,000 SCFM/1250 HP ID Fans and a 110’
exhaust stack. The foundations involved the installation of one hundred
30" diameter caissons to depths from 15’ to 40’ as part of the seven
main foundations for the baghouse, three fans, stack and the two
electrical buildings. The foundations included 2000 cubic yards of
concrete, 50 tons of rebar and 500 anchor bolts. Grounding of all
foundations and buildings included the installation of 2000 feet of
ground cable and a single ground well approximately 140’ deep.
Also part of the scope were two turnkey buildings that housed the
electrical equipment for the facility. The electrical buildings were
approximately 2300 total square feet to accommodate the 13.8kv
switchgear, MCC and PLC’s. The two buildings included the design and
installation of all building HVAC , electrical and grounding systems.
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Electrical
& Instrumentation
Middletown, Ohio
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This project included the installation of the underground conduit
banks as well as the installation, electrical hookup, construction
checkout, testing and energizing the Electrical Control Building power
distribution equipment, Electrical Substation Building power distribution
equipment, baghouse ID Fans, automation equipment, and lighting systems.
This project also included the grounding, exposed cable tray and conduit
systems, electrical equipment installation, cabling and termination of
electrical and instrumentation devices and motors.
Scope of work included the installation of 8000 feet of underground
conduit, 4200 feet of cable tray, 3500 feet of above ground conduit and
45,000 feet of various size cable.
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500,000 SCFM
Baghouse Installation
Middletown, Ohio
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Erected a 14 module baghouse plus spark box and (2) 250,000 SCFM ID
Fans, each coupled to 1250 HP motors. This project also included
installation of the associated structural steel and ductwork connecting
the ID Fans to a 11’ diameter, 100’ tall exhaust stack. M/K also designed
and erected the 3,000 SF Electrical Control Building and installed all
electrical, instrumentation and mechanical components for the baghouse.
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Structural
Steel & Duct Installation
Middletown, Ohio
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M/K was selected to install the structural steel and ductwork on an
operating blast furnace. All of the work was closely coordinated with
operations and maintenance during operating turns, down turns and through
a major outage. During the 10 month schedule, M/K’s scope included the
following:
- Furnishing and
installing 180 tons of structural steel supports, platforms,
walkways
- Furnishing and
installing 650 linear feet of 8 to 11 foot diameter duct,
transitions and hoods in the Cast Houses and under the Skip Hoist
- Numerous structural,
pipe and electrical relocations
- Installing the
main 450 ft long 11 ft diameter duct run at an elevation of 70 ft
from the cast house to the new baghouse facility
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Cast House
Extension with Access Ramp
Middletown, Ohio
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Blast Furnace Cast House Extension project was completed without
interruption of iron making operations. This was accomplished by
pre-fabricating the foundation forms complete with rebar and embedded
anchor bolts at an offsite location. Excavating, form setting, concrete
pouring and backfilling was performed during scheduled 8 hour windows.
204 tons of building steel and ramp sections were prefabricated off site
in large sections and erected between iron casts minimizing impact to
operations.
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Hot Metal
Crane Upgrade Project
Middletown, Ohio
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- Upgrade four 300
ton hot metal cranes to 400 ton capacity
- Modify building
structure to accommodate heavier loads and higher capacity ladles
- Install 12,000 new
bolts from inside the main runway box girders
- Install
reinforcement plates on the main hoist trolley frames
- Install new
lifting beams
- Installation of
new main hoist equipment (replaced during a five day scheduled
outage)
- Replace the bridge
and trolley drive systems, bridge and trolley idler wheel and bumper
- Load testing to
certify capacity
- Building
modifications completed without interruption to operations
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Ladle Lift
Car Replacement
Middletown, Ohio
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Modifications to the Caster Facility
- Assembly of
structural, piping and electrical components for a 240 ton ladle
index car with a 500 ton hydraulic lifting capacity
- Design of a 300
ton lifting beam
- Seven day outage
duration
- Replacement of
fifty support beams for the 1000 ton bridge car
- Installation of
the new ladle index car
- Replacement of
three sets of rails for the bridge and tundish cars
- Modification to
the bridge car to increase capacity
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Clay Guns
& Taphole Drills
Middletown, Ohio
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McGraw/Kokosing was commissioned to install two new Clay Guns and
Taphole Drills on a blast furnace. During the seven day outage, M/K
removed the old guns, drills, control desk, piping and electrical, and installed
two new clay guns, drills and a control desk. The success of this project
yielded M/K a similar project at an Ashland, Kentucky facility.
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#2 Mill
West Virginia
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The project included installation of a new 34.5KV Feeder and
Distribution Switchgear. The high voltage distribution included the
installation of an overhead 34.5KV line to three new pole mounted high
voltage switches. Seven new sections of 34.5KV Switchgear were tied to
the switches via 400' of cable tray and Armored cable. Four new
transformers were installed to feed new Roughing Mill Stand Drives and
Motors. M/K performed all high voltage terminations and checked out the
system. The upgrade also included installation of new 600V Feeders,
Switchgear and Motor Control Centers. The 600V distribution consisted of
a new transformer with Armored cable feeders and cable tray system. The
installation included one new four section switch gear feeding a Motor
Control Center and new KC drives for the Roughing Mill Motors, all
motors, controls and instrumentation for Furnace exit conveyors, Rough
Mill approach conveyors, and Roughing Mill exit conveyors. The Exit end
of the #2 Mill consisted of installing new Motor Control Centers, DC and
AC drive cabinets to power the new Cooling Bed equipment and Conveyors.
Over 90% of the new installation was completed while the existing Mill
was fully operational. The balance of the work was completed and the new
Mill was in operation after a 14-day shutdown.
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Closed Loop
Cooling Water
Middletown, Ohio
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The installation included mechanical and electrical work to install
the process control instrumentation. The system consisted of a PLC based
system connected via Ethernet to a blast furnace control system. M/K was
responsible for the instruments from bench test through commissioning.
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Cold Strip
Mill
Middletown, Ohio
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Installation
of new equipment on five Cold Mill Stands simultaneously. For each of the
five stands, the work rolls, tracks, support beams and cylinders were
removed. Using special drills, the cold mill machine housings were then
drilled to accept the equipment mounts for the re-installation of the
tracks and cylinders. The project was successfully completed during a
four day outage.
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Latest News
Greenfield Coke
Plant
Haverhill, Ohio
McGraw/Kokosing and the Kokosing Group's self performance
capability for all trades on-site streamlined communication and improved
quality.
Read More »
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Heat Recovery
Steam Generators
Lawrenceburg, Indiana
Installation of four HRSG's. Also installed pipe racks and
foundations for racks and miscellaneous equipment. This was a greenfield
project.
Read More »
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