Hoeganaes Powder Metallurgy Facility Upgrade
icon Mechanical served as general contractor for an $18.7 million process systems upgrade at GKN Hoeganaes' active powder metallurgy manufacturing facility in Gallatin, Tennessee.
- Owner
- Alton Steel
- Value
- $3,000,000
- Industries
- Industrial
- icon's role
- Fabrication & Modular
- Mechanical Construction
- HVAC & Sheet Metal
icon Mechanical served as the prime mechanical contractor for this EPA-mandated dust collection system upgrade, selected as contractor of choice on the strength of proposal completeness, price structure, and commitment to the required schedule. The work was divided into two phases so system performance could be verified as each was completed. When the compliance deadline tightened, icon compressed the second phase from a 26-week schedule to just 11 weeks. icon delivered an accident-free worksite and reached mechanical completion a few hours ahead of schedule, flowing directly into a normal plant start-up.
Scope of Work
- Demolition and replacement of large-bore ductwork
- Fan housings and expansion joints
- Capture hoods above the furnace
Schedule & Execution
- Two-phase delivery to monitor system performance at each stage
- Phase 2 compressed from 26 weeks to 11 weeks to meet the EPA deadline
- Production limited work to Fridays and Saturdays until the scheduled outage — careful planning maximized the two-day work week
- Expanded to two 10-hour shifts, 7 days a week, during the 16-day outage
- Majority of work performed on elevated areas 80'–120' above grade
"A Job of Inches"
A 350-ton truck crane was carefully threaded between existing steel towers to reach every hoist on the project. When a visitor asked how the crane was maneuvered into position, the answer, "This is a job of inches", captured the precision this project demanded at nearly every turn.
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