Value Delivered
To minimize the number of vendors involved and streamline production and delivery of the completed project, Shambaugh’s in-house prefabrication facility was tapped to fabricate over 30,000 feet of pipe taking significant time out of the project timeline as well as improving quality control and lowering costs.
Client Objectives
Steel Dynamics needed to add additional production capacity at its Columbia City, Indiana, mill that would allow the plant to produce a higher volume of rail products and add lighter-weight structural shapes and merchant bars to its product offerings.
When in full operation, the mill expansion needed to add capacity of 600,000 tons per year and bring Columbia City’s finished steel production capacity to 1.6 million tons per year.
Scope of Services
Shambaugh's mechanical services scope of work included the layout, prefabrication, and installation of piping and equipment for the various piping systems, including hydraulics, compressed air, high-pressure water, grease, oil-air, contact and new contact cooling water, lube oil, and natural gas.
Shambaugh also installed 10 miles of multiple level cable tray and large drive electrical cabinets and pulled 77 miles of cable. Between the commercial mechanical piping and electrical installations there were over 150,000 labor hours used to complete both aspects of the project.
Mechanical Piping & Electrical Services Highlights:
- 80,000 feet of piping installed (10"-16" diameter and wall thickness from .062 to Sch. 160)
- Prefabrication facility fabricated over 30,000 ft. of pipe
- 77 miles cable pulled, including fiber optic cables
- 5,000 feet of 4" conduit for duct banks
- 10 miles of multiple level cable tray
Client Background
Steel Dynamics, Inc. is a steel producer based in Fort Wayne, Indiana, and is the fifth largest producer of carbon steel products in United States. Over sixty percent of the company’s steel shipments are flat-rolled sheet steel and the remainder is long products (bars and beams) and fabricated products.