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: Mechanical Engineering
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.
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.
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.
Denkai Americas
GSE played a pivotal role in the expansion of Denkai Americas in Camden, South Carolina. Denkai specializes in manufacturing copper foil through an electrodeposition process, achieved by manipulating the chemistry of the mother liquor and adjusting the voltage to produce high-purity copper foil with precise thicknesses. GSE managed all facets of the process, providing essential structural, piping, mechanical, electrical, and instrumentation support.
Toyota
GSE provided the Plumbing, Process, and Dust Collection designs for two 500,000-square-foot buildings for Toyota’s Lithium Ion battery production facility in Liberty, North Carolina. Scope included Domestic water and waste, Non-potable water, Process Waste Water, Chemical Waste Water, Pure Water, Nitrogen (gas), Compressed and Dry Compressed air, Emergency Chemical Waste Water (specialized containment and discharge system), Vacuum, Dry and Wet Dust collection designs (using 99.999% ULPA filtration systems for EPA compliance) and all associated construction assistance. GSE participated in weekly BIM coordination meetings between all disciplines to ensure that the subcontractors received the most accurate model for shop drawing generation.
Trane Technologies
GSE provided mechanical, electrical, plumbing, process piping, sprinkler/alarm/life safety and structural services to Trane Technologies to repair a 180,000-square-foot manufacturing facility following a roof collapse. Recognizing the urgency, we approached the project as a design-build, enabling us to accelerate construction and meet our client’s tight installation timeline within eight months. The successful completion of this project is a testament to our expertise, dedication to excellence, and the collaborative effort of our team and a valued client. Trane invested $76.7 million to construct a new building and assembly lines at the Tyler facility due to the collapse.
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.
