Calvert, Alabama

Hot Strip Mill – Project Management Services

Client / Owner

ThyssenKrupp Steel USA




Graycor Industrial

Project Scope

Graycor Industrial Constructors and Siemens VAI Services teamed together to provide project management services to ThyssenKrupp Steel and Stainless Steel USA, LLC, at its new facility in Calvert, Alabama. The new facility – which operates continuously and is situated on a site covering approximately 3,500 acres with 7 million square feet of building space – processes carbon steel and stainless steel for high-value applications by manufacturers in the NAFTA market.

The Graycor Industrial/SVAIS management team provided management services on the carbon area of the new mill, which managed construction of the hot strip mill where more than 10 million cubic yards of earth was moved, more than 300 miles of piles were driven, and in excess of 150 pieces of large equipment were utilized on site.

Specifically, Graycor coordinated the erection of the Laminar cooling, down coiler and coil conveyor sections of the hot strip mill. Coordination included direct construction interfacing between ThyssenKrupp Steel USA, the ISG/SMS Consortium Equipment supervisors, and the installation contractors including mechanical, piping, electrical and miscellaneous utility contractors. The team was primarily responsible for scheduling work activities, monitoring daily work activities, observing work and task practices, and making continuous improvement suggestions, along with providing estimations to assist in the evaluation of Earned Value tracking, applications for payment, change order evaluations and claims resolution.