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: Life Safety
Steel Warehouse
Steel Warehouse Alabama features a state-of-the-art push-pull pickler capable of pickling hot-rolled coils up to one inch thick and up to 72” in width. The new facility has rail and truck access and barge access nearby. The line can produce pickled dry, pickled and oiled, Mil-Bond and dry lubed strip. GSE provided complete engineering services for Steel Warehouse’s heavy gage Push/Pull Pickle Line, which was constructed at the Calvert Industrial Park. The scope of this work included engineering for all buildings and equipment support for the approximately 106,000-square-foot facility.
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.
CMC Steel Alabama
CMC chose GSE to provide engineering, planning, alignment surveying and construction management services to upgrade their merchant bar mill in Birmingham, AL. This included installing a new state-of-the-art rolling mill provided by Danieli and associated utility upgrades to support the equipment. The new line was installed during a 45-day shutdown, during which the project team worked around the clock. This project represented a $68 million investment by CMC.
ArcelorMittal Calvert HSM Upgrade
GSE collaborated with ArcelorMittal Calvert (formerly AM/NS) to modify the cooling system in their hot strip mill. The project involved developing the initial scope and providing an AFE-level estimate for approval. Utilizing a laser scanner, GSE worked with AM Calvert to create as-built drawings to integrate and coordinate with SMS equipment to develop comprehensive equipment arrangements, serving as the foundation for the detailed design. GSE coordinated with SMS and AM Calvert, utilizing the shutdown schedules to create the system’s detailed design and develop the contracting strategy and construction packages for bid and installation. GSE supplied engineering support and pre-bid and bid evaluation assistance throughout construction and start-up.
Colson Group USA
As a design partner to Brasfield & Gorrie, GSE provided the Architectural, Life Safety, and Structural design for Colson’s new 184,000 square foot caster facility constructed in Jonesboro, AR. Constructed on a Greenfield site, the new facility includes manufacturing, storage and shipping areas. The project includes an administrative office building with a 250 mph tornado shelter.
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.
Samuel, Son & Co.
Constructed on a 30-acre Greenfield site, this facility houses a world-class hybrid automotive blanking line with a width capability of up to 2050 mm. Other enhancements include the ability to inspect, clean, level and lubricate sheet as well as produce rectangular, chevron and custom shapes. GSE provided civil, rail, architectural, life safety, and foundation design for Phase 1 and 2 of this project. Phase 1 was completed as a design-build partnership with Brasfield & Gorrie. The facility comprises over 200,000 square feet of environmentally controlled process and coil storage, an administrative office building, a tornado shelter and pallet storage. Phase 2 includes a new 2133 mm wide slitter.
