Suncoke & Gateway Energy | New Coke Plant
Mechanical subcontractor for SunCoke and Gateway Energy's $290 million coke plant serving US Steel, with 120 heat-recovery ovens and steam systems.
- Owner
- US Steel - Granite City Works
- Value
- $2,500,000
- Construction Manager
- MC Industrial
- Industries
- Industrial
- Power
- icon's role
- Engineering
- Fabrication & Modular
- Mechanical Construction
- HVAC & Sheet Metal
icon Mechanical served as the mechanical contractor for this U.S. Steel plant in Southwestern Illinois, executing large-bore process piping and supporting HVAC inside a fully operational facility. The centerpiece was the installation of 96"-diameter piping—set in 40' to 80' sections and guided by a critical lift plan covering 14 individual sections. Working amid live plant operations and alongside icon's other ongoing projects at the location, the team completed the project in 9 months with zero injuries.
Scope of Work
Large-Bore Process Piping
- 700' of 96"-diameter steel pipe, installed in 40'–80' sections
- Critical lift plan — design and execution of 14 sections
- (4) 36"-diameter boiler-feed knife gate valves
HVAC & Natural Gas
- Design-build 15-ton positive-pressure HVAC unit and ductwork for the switchgear room, bathrooms, and operator control room
- Design-build of (12) natural gas unit heaters
- ~800' of natural gas piping
Testing, Quality & Safety
- Final low-pressure piping test using solar heat and a small standby compressor to build internal pressure (natural pneumatic testing) plus wall-suction testing
- Quality control plan and implementation
- Site safety with AWS-CWI certification
Project Insights
- 9-month completion · zero injuries
- 700' of 96"-dia. steel pipe · 14 critical-lift sections
- (4) 36" knife gate valves
- 15-ton positive-pressure HVAC system for the control/switchgear suite
- (12) gas unit heaters · ~800' natural gas piping
Related Projects
Ultium Cells – Electric Vehicle Battery Plant
Delivering mechanical systems for the $2.64 billion, 2.8-million-square-foot Ultium Cells EV battery plant in Spring Hill, TN, a GM and LG Energy joint venture.
Nissan Production Facility
Design/build mechanical contractor delivering utility services across a half-million-square-foot Nissan facility, with over 40,000 feet of modularized pipe on 54 racks.
Express Scripts Innovation & Technology Center
Design/build mechanical for a fast-track office and 200,000-square-foot pharmaceutical production facility built in 82 days, with 27 rooftop units set by helicopter.
De-Sulfurization Project, US Steel
Mechanical contractor for a de-sulfurization project at US Steel's Granite City plant in Southwestern Illinois, completed on time in 13 months with zero injuries.
DartPoints Data Center
Mechanical systems for a 9,600-square-foot data center using a hot-aisle/cold-aisle design, with eight AHUs and four 200-ton air-cooled chillers on variable drives.