A large producer of long steel turned to Lee Industrial Contracting to upgrade multiple system components during their 30-day shutdown in June 2021.

THE CHALLENGE

A large producer of long steel turned to Lee Industrial Contracting to perform several upgrades to their systems during a 30-day shutdown. Some of the notable projects during the shutdown included:

• Removal of an old cooling tower and reinstallation of a larger one. This allowed for better temperature control throughout the plant.
• Upgrades to stairways, structural steel and foundations.
• Upgrades to rolling mill saws, which involved removing the existing outdated equipment and replacing and reinstalling with new machinery.
• Assembly, installation and integration of a brand-new controls and material handling system on the client’s conveyors.
• Upgrading the plant’s cooling system.
• Removal of the client’s old caster spray chamber and the installation of a new one.

One major challenge the Lee Contracting team faced with this large-scale project took place during the removal and installation of the caster machine. Due to the location of the equipment in the plant, moving this large piece of machinery was nearly impossible without the quick thinking of Lee Contracting’s team to cut open the wall to safely remove the large piece of equipment. The teams then pre-assembled the new caster machine and rigged it through the same opening. After the machine was installed, Lee’s teams worked to weld the wall opening shut with galvanized steel plates.

THE RESULTS

Because Lee Contracting has all trades, equipment and tools in-house, they were able to meet the 30-day deadline. Not only did this save the customer time, but helped to get them back up-and-running by their deadline.

Remove and replace nearly 600, 90 pound interior cement kiln chains through a 26-inch manway in only 9 days? This is how we achieve the unthinkable.

THE CHALLENGE

Lafarge Holcim, which specializes in cement, construction aggregates and concrete, operates two cement kilns out of their Paulding, Ohio location. Each kiln measures 800-feet long and 12-feet in diameter, and the inside contains over a thousand chains weighing over 90 pounds each.
Each chain is hung by tombstones welded into the steel walls of the kiln. When turned on, the chains slowly rotate, crushing the mined rock, which is then heated to 1,500 degrees Celsius and continues to rotate until the rocks are crushed into fine dust.

Over time, the chains on the interior of the kilns become worn and need to be replaced. Lafarge Holcim contacted Lee Contracting to remove and replace nearly 600 chains in a nine-day window – which is no small feat. The kilns had uneven flooring, the chains created a trip hazard, limited space, no lighting and the dusty conditions.

THE RESULTS

To remove the heavy chains from the cement kiln, Lee Contracting’s teams attached them to a crane and raised the chains through a 26-inch manway on the side of the kiln. The team was also tasked with removing any worn tombstones and welding new ones in place in a precise pattern. The Lee Contracting rigging team then lowered new chains into the kiln, which were reattached to the tombstones.

At the end of the project, the client was pleased with the crew’s teamwork and for Lee providing a cost-effective and timely solution for this project.

When a heavy industry client in Indiana needed a Steel Slitter Line installed, Lee Industrial Contracting was called to put their “turn-key solutions” tagline to good use.

THE CHALLENGE

When a heavy industry client in Indiana needed a steel slitting line installed, they called on Lee Industrial Contracting’s Power of One. Lee Contracting needed to construct new foundations for the machinery, while the building remained partially open.

Since the project was taking place in the middle of winter, the Lee Contracting team had to take extra measures to ensure the project was done safely and without delays.

THE RESULTS

To minimize disruption to the customer, Lee Contracting installed installed temporary walls with panel doors to keep in the heat and to allow access for construction equipment and concrete trucks. This allowed Lee Contracting’s team to easily excavate, install underfloor conduits and set reinforcement steel.

Next, Lee Contracting’s in-house fabrication department constructed and installed embedded structural steel beams, entry and exit turnstile anchor bolt frames, coil car rails with support channels, utility trenches with cover plates, as well as stairs and handrails.

Once the foundations were finished and the concrete cured, Lee Contracting’s rigging crew offloaded, set in place, aligned, leveled and anchored the new equipment onto the new foundations.

Following the installation of the equipment, the Lee Contracting electrical team installed new wiring, from the equipment to the main control cabinet.

Designing and pouring foundations for 8 large milling machines is a pretty straightforward project. Doing it on frozen ground while buildings are being constructed around it took Lee’s Power of One.

THE CHALLENGE

Visioneering, a leading aerospace designer, manufacturer and installer of assembly systems for the aerospace, defense and space industries, began building a new facility with a goal of consolidating their buildings and machinery under one roof. They contacted Lee Industrial Contracting to perform a design/build project, which included pouring foundations for eight large milling machines during the development of the new facility.

It was essential to begin planning with the Visioneering facilities team to ensure the layout resulted in a good process flow. Because these new foundations would be poured while the new facility was under construction, the Lee Contracting team had to plan around various timelines and other work being done at the site.

THE RESULTS

To meet the project timeline of the customer, Lee Contracting had between eight and 12 workers on the site at any one time during this year long project. As a testament of the Lee Contracting team’s experience, they were able to complete the machinery foundations in under 10 months, exceeding timeline expectations.

After the foundations were finished, Lee Contracting transported and installed the machinery in the new location. The foundations were completed with such precision that there were no problems installing the eight milling machines.

Due to Lee Contracting’s quality work, ability to offer multiple trades under one roof and the company’s skill of completing projects ahead of schedule, the team has returned to the Visioneering facility to complete a variety of other projects.