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: Structural 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.
Nucor Plate Mill
GSE provided structural design for the entire mill, including the major melt shop ductwork and refractory. The mill structure encloses over 1.5 million square feet and costs over $150 million. GSE worked closely with Nucor to optimize the structure, coordinate crane configuration, and develop means and methods to improve constructability. This led to GSE being chosen as the structural engineer for their new mill in West Virginia.
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.
Steel Warehouse – Slitter Addition
GSE provided the equipment foundation design in support of Steel Warehouse’s new slitter and cut-to-length line installed in their existing Calvert facility. The design accounted for low head clearance and existing foundation obstructions.
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.
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.
