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.
Service: Process Engineering
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.
Burg Vinegar Plant
GSE took on a key role in the realization of Burg Vinegar Jefferson, an integral part of the Burg Group and heralded as the world’s foremost sustainable producer of natural vinegar. The cutting-edge facility, Burg Vinegar Jefferson, epitomizes excellence in bulk vinegar production, boasting state-of-the-art automation to streamline operations for optimal workforce efficiency. GSE delivered comprehensive mechanical, electrical, plumbing, fire protection, and structural engineering services for the Burg Vinegar facility, with a focus on systems within the building envelope and underground drainage containment. Our team designed HVAC and plumbing systems, developed detailed electrical power and lighting plans, including emergency generator specifications, engineered structural foundations and steel frameworks, and implemented fire protection systems in accordance with NFPA standards.
NASA: Michoud Assembly Facility Tornado Repair
GSE was contracted to assist in repairing and renovating multiple buildings damaged by a tornado in mid-2017. The buildings ranged from mission-critical to office spaces and storage PEMBs.
In Building 102, the roof replacement was part of the S3 contract to maintain and replace MAF utilities and infrastructure that was deemed necessary. The roofing system was aged and damaged, so GSE was contracted to provide a design for its replacement. Included in this design was an investigation into the extent of damage caused by years of water intrusion and termite infestation. GSE’s scope was to provide the design, drawings, and specifications and cost estimation for the removal and replacement of the current roof membrane and provide repair of the structural elements as required. There were also multiple penetrations and pieces of equipment that were noted as unnecessary and marked for removal to ensure minimal impact on the new membrane.
In Building 110, mission-critical 3D welding machines that assemble rocket engine tank sections required a new TPO roofing system and a complete siding replacement. GSE performed inspections of the existing structural systems, reviewed against the as-built documents, and developed the securing system to ensure the new siding panels connected cleanly to the structure. The building has tight Foreign Object & Debris (FOD) guidelines that had to be maintained. GSE also worked closely with the Historic Committee as Building 110 is a historic building and its overall appearance had to be maintained.
In Building 114, an aging control room that oversees the application of foam insulation to the rocket shells was damaged along with the entire roof. GSE provided a new TPO roofing system, renovation, repairs to the control room that brought it up to current standards, and a new exhaust system for the open facility.
In Building 131, one cell of a three-cell building was renovated from a painting booth to a new storage area with a new HVAC system that used HVLS fans and heat pumps instead of the dated and inefficient equipment. The roofing system was repaired, and a new maintenance hatch was provided for the replacement of existing dehumidifiers in another cell.
In Building 159, the chemical storage area’s metal building was damaged, and it was determined to be cheaper to provide a new PEMB design rather than abate the lead-painted structure. GSE provided a new PEMB design with a security gate and additional storm drainage.
Building 350 is a 533,000-square-foot, two-story structure that provides office space to multiple personnel from different federal agencies. Due to the tornado damage and the presence of asbestos-containing materials (ACM), the Owner decided to demolish the building. GSE provided plans and specifications that detailed the facility’s demolition, including the handling of the asbestos.
In Building 420, provided design for removing the damaged rocket sled track and the associated control shed. The area was turned into parking for the adjacent building leased to General Electric.
NASA: Stennis Space Center Building 9322
Building 9322 – HVAC and Compressed Air System Upgrades
In 2015, GSE was contracted to provide a total HVAC replacement and upgrade for the 60,000 sq. ft. Naval Oceanographic Office. The existing HVAC system was of an aged design and well oversized for the use of the building. GSE performed load calculations on the building to ensure the proper tonnage was specified in the new system to reduce energy consumption. As a result, newer high-efficiency equipment was specified (air handlers, chiller, boiler, and VAV boxes), and a redundant system was provided to ensure the building could operate should the primary heating or cooling source go down. GSE coordinated closely with the US Navy representative and multiple site visits to collect and address all concerns and requests.
Shortly after completing the HVAC upgrade for Building 9322, the client engaged GSE to analyze their current compressed air system and provide a new design. Building 9322’s open warehouse areas utilized compressed air for sensitive mission work. The workers raised concerns regarding the quality and capacity of air they received from the existing system. GSE walked through the entire system, collected the concerns, and reviewed what each station did with the compressed air. Using this data, GSE provided a new system (oil-less compressors, filters, dryers, and non-metallic quick-connect piping) to deliver instrument-quality air to each drop.
