Southern Industrial Contractors (SIC) is proud to support the successful execution

of a new rolling mill that produces high-quality wire rods, coiled rebar, and billets located in the southern part of the United States. SIC's scope extended from demolition and mass excavation through the equipment foundations and structural steel for the new rolling mill, new FFB with quenching lines and high-speed shears, new cooling beds, new cut-to-length line, new bar counting station, new electrical rooms, new workshop, new cold shear pulpit, new bar counting pulpit, etc.

This scope was completed within an operating steel mill while maintaining full production.

Southern Industrial Contractors self-performed the following scopes of work:

• site work
• sheet pilings as further described below
• piping
• masonry
• cladding and sheeting
• approximately 34,000 cubic yards of structural concrete
• approximately 8.3 million pounds of reinforcing steel
• underground stormwater network
• electrical grounding and conduit
• three buildings totaling nearly 4.94 million pounds of structural steel with a 396-ft finished product bay with a 110-ft clear span carrying full-length top-running bridge cranes

Southern Industrial Contractors installed the following equipment foundations:

• JA01-E1 Rolling Mill Electrical Building Structures
• JA01-E2 Finished Product Electrical Building Structures
• Equipment Foundations and Structures JD41 Finishing Mill
• Equipment Foundations and Structures JD51-F01, JD51-F02, FFB + Quenching + HSS
• Equipment Foundations and Structures JE11 Cooling Bed
• Equipment Foundations and Structures JE21 Cutting to Length
• Equipment Foundations and Structures JE41 Bar Counting Station
• Equipment Foundations and Structures JE61 Tying and Storage

These photos illustrate the JD41, JD51-F01, JD51-F02 area which is the FFB, quenching line,

and high-speed shear area. These equipment foundations were designed as elevated decks which

is up to 168-inches thick at elevation +17. SIC accomplished this work by utilizing a MEVA form system and WACO Hi-Load shoring towers which are capable of 25-kips per leg and EFCO stringer beams known as Z-Beams which are capable of carrying 28 kips placed at 24-inches o/c to support the concrete elevated deck. These concrete decks presented loading challenges in excess of 2,100

pounds per SF. This area also included reinforcing steel quantities in excess of 447-pounds per cubic yard and over 3,034 anchor pockets as well as numerous embeds to facilitate equipment installation.

Southern Industrial Contractors also performed the following work on this project:

• Rolling Mill Pulpit Extension Structures
• Underground Networks / Conduits
• New Workshop building foundations, structural steel erection, cladding, and masonry
• New Finished Product Bay building foundations, structural steel erection, cladding, and masonry
• New Compressor Building foundations, structural steel erection, cladding, and masonry
• New Laboratory Building foundations, structural steel erection, cladding, and masonry

Southern Industrial Contractors also design-built a new sheet piling cofferdam system around a new rolling mill. SIC utilized NZ 26 Sheet Piles which were 78-ft long with 2 rows of horizontal struts and walers that were W12x190's. Below is a snapshot of the conceptual work plan utilized by SIC to install this cofferdam system:

Pre-excavation and grading

• Clear the footprint of the proposed excavation of existing pavement and debris associated with prior to construction.
• Divert surface drainage away from proposed excavation footprint.

Sheet Pile Installation

• Sheet piles should be installed to the minimum required embedment using a driving technique which ensures good verticality and alignment is achieved to minimize the risk of installation difficulties or driving out of interlock.
• Sheet piles should be driven to the final proposed depth without stopping to avoid increased driving resistance due to soil setup.

Dewatering

• Piezometers should be installed to monitor groundwater in the vicinity of the excavation.
• Provide sumps as needed around the perimeter of the pre-excavation area.

Stage 1

• Excavate to a maximum of 5-ft below the centerline of the first brace level (El -5).
• Install H-Piles or other appropriate means to support the struts at the crossing points.

Stage 2

• Install walers and struts comprising the first brace level.
• Rigidly connect crossing struts to limit the unbraced length to 20-ft or less.
• Excavate to a maximum of -25-ft below the centerline of the second brace level (El -20 to -25).

Stage 3

• Install walers and struts comprising the second brace level.
• Rigidly connect crossing struts to limit the unbraced length.
• Excavate to the final excavation depth (El -35).
• Place mudmat in bottom of excavation to assist in maintaining a stable working subgrade.

Working within an active operating steel mill

as well as highly congested work areas with numerous other trades, SIC successfully

completed more than 246,312 man-hours with zero recordable incidents.

Through close and constant collaboration

with the client and fellow trades, the team implemented a comprehensive site-specific safety program that led to this outstanding achievement. SIC is proud to have earned

our latest EMR of .62, reflecting our

unwavering commitment to safety excellence.

Southern Industrial Contractors is also a full-service, AISC-Certified structural steel fabricator specializing in complex medium to heavy industrial projects across the United States. Combined with our design and erection capabilities, SIC has successfully delivered some of the industry’s most intricate and demanding projects for over three decades earning

a reputation for quality, safety, and reliability.