SDI Columbus, formerly SeverCorr, is a mini-mill plant that recycles steel into new products servicing the automobile industry. GSE was responsible for the Cold Rolling Works and tasked with operationalizing the first process line in less than 12 months from the beginning of construction. GSE provided design services for the pickle line, cold rolling mill, hot galvanizing line, skin pass mill, batch annealing area and offline temper mill. Additionally, GSE was chosen to study the need for and later provided electrical and structural design services for a new slitter and inspection line.
Service: Civil Engineering
Aurubis
GSE provided complete engineering services for the first secondary smelter for multimetal recycling in the United States. Secondary smelting recycles circuit boards, copper cables, and other metal-containing materials. The 300,000-square-foot plant will have the capacity to process over 180,000 tons of complex recycling materials annually. In addition to producing blister copper, Aurubis will further process the intermediate product in its overseas facilities to recover silver, gold and other precious metals. This project represents Aurubis’ first greenfield project outside the EU with an investment of $800 million.
Kloeckner Metals
GSE partnered with Brasfield & Gorrie to provide design-build services for the 87,500-square-foot slitting line and coil storage bay. Constructed on a 16-acre greenfield site in Calvert, Alabama, the steel service center includes slitting, cut-to-length, blanking, and multi-blanking.
GSE provided all structural, architectural, life safety and civil/site design including the addition of a new rail spur through the facility. Equipment foundations included a 45 foot deep pit – most of which was below the watertable and required significant dewatering, waterproofing and special design to sustain high hydrostatic pressures.
Borusan Berg Pipe
GSE provided full-service construction engineering in concert with our construction partner GA West to provide for a new spiral pipe welding line at Berg’s Mobile site. This project entailed an addition to the existing building, new utilities, and crane and equipment foundations. Of note was the modification of the existing building structure to provide for a pass-through that impacted multiple column lines and modifications to the operational traffic flow on the site.
SSAB-VTD Platform
SSAB, formally IPSCO, is an existing steel manufacturing facility in Axis, AL. In an effort to provide more control over their steelmaking process, SSAB installed a Vacuum Tank Degasser (VTD) at their melt shop. The VTD project involved placing equipment within a 20,000-square-foot footprint, 80 feet high, with three working levels. Structural Engineering services included the design to support a 300 Ton overhead crane. Electrical and Piping design included rerouting existing utilities to allow the VTD process area to be added at the existing facility. The addition was required to be implemented with only minor disruption to the operations of the facility.
TF Kabel
GSE partnered with Evans General Contractors to provide complete design services for a 500,000-square-foot facility. TF Kabel produces cables for Utilities, Mining, Alternative Energy, Portable Power Generation, and other Heavy Industries, and this will be their first facility in the United States. GSE’s scope included Mechanical, Electrical, Plumbing, Structural, Civil, and Fire Protection design for retrofitting an existing warehouse facility into a new production facility.
Technip Spoolbase
GSE partnered with design-build contractor GA West for Technip USA’s new 75,000-square-foot spoolbase facility. The facility fabricates and welds mile-long pipe lengths that are spooled and transported by large ships to be laid offshore for the oil and gas industry. GSE’s scope of work included life safety, mechanical, electrical, structural, and civil engineering design for the new pipe storage, assembly, spooling and loading facilities.
Mobile County
GSE provided survey and civil engineering services for Mobile County’s Pay-As-You-Go roadway projects. Survey services include right of way, map and deed preparation and field monumentation. The civil design included roadway centerline alignment, profile, cross sections, drainage facilities, intersection design, pavement sections, erosion and sediment control, traffic control, utility coordination and cost estimate development. Construction services included bid evaluation, full-time on-site monitoring, review of geotechnical tests, monthly pay estimate preparation and as-built documentation.
Airbus Final Assembly Line
GSE partnered with The Austin Company for the main design package awarded for Airbus’ first assembly line in the Western Hemisphere. The design package included the Final Assembly Line building (FAL), the Service Building and the Logistics Center. The FAL comprises 209,000 square feet of manufacturing and 27,000 square feet of office space. The Service Building is a multi-story 125,000-square-foot office building, while the Logistics Center is a 59,000-square-foot warehouse and office building. GSE’s scope included all foundations, industrial systems, medium voltage distribution and fire protection system design.
Centennial Plaza
Centennial Plaza, a historical site that once housed a Veterans Administration facility, was converted to a traditional neighborhood development. GSE provided topographic and tree surveying services to aid in the design of the improvements to the development. Additionally, GSE’s civil design included infrastructure improvements for the overall site. GSE has also provided civil engineering services for the Holiday Inn resort, the first anchor tenant for this development. GSE will continue to provide services as the development expands.
