When the nation’s largest steel producer, Nucor, decided to build a new mill in Convent, LA, they turned to Phoenix to help design and build their DRI (direct reduced iron) storage tanks. These six massive structures each have a capacity of 7,000 metric tons and contain internal rock ladders to safely distribute the product into the structure. Coming from an elevated structure background, Phoenix Engineering took on this new task with great detail and precise layout to ensure this product could handle the task at hand and would be easily field-erected in the safest, timeliest manner possible.

Phoenix shop fabricated almost 5.4 million pounds of steel for these structures between the Avon, IN, and Sebree, KY facilities. The fabricated materials were loaded on barges in Henderson, KY, and shipped down the Mississippi River channels to Louisiana for field erection. The storage bins were completed in approximately six months and on budget for Nucor to commence with the production of the fine steel products they continue to produce today.

Coming off of the success of the project in Convent, LA, Nucor once again turned to Phoenix to provide the DRI (direct reduced iron) storage structures at their facility in Ghent, KY. This facility required two structures, each with a capacity of 6,000 metric tons of DRI. Although similar in purpose, the design of the Ghent structures required all support members to be bolted in lieu of welded. Phoenix exhibited versatility in the design, layout, and fabrication of these parts, and our erectors fit all members up in the field without issue or need for modification.

Phoenix shop fabricated approximately 1.95 million pounds of steel for these two structures at the Sebree, KY, facility and transported the fabricated materials across northwest Kentucky to Ghent. Phoenix completed the project on time and within budget for this valuable customer.

Phoenix, known for our world-class elevated water tower construction, also has a wide range of steel fabrication experience and know-how as exhibited by this unique, scrubber-tower ductwork. In order to keep downtime to a minimum, Phoenix management and engineering visited the site and made exact field measurements to ensure the duct fit right the first time. Upon completion of shop fabrication and finish coating, Phoenix worked closely with AMG to remove the existing duct and install the new duct. We performed the work during a short weekend maintenance shutdown to ensure the plant could resume production Monday morning. All of the bolted, flanged connections met up to their exact counterpart, greatly minimizing crane time and field-erection hours. The duct was also fabricated with an access manway and rescue davit for AMG to utilize during their regular maintenance intervals to protect their investment for years to come.