In collaboration with Arconic Corporation in Bettendorf, IA, RTP embarked on a transformative project to upgrade the Ingot Plant's No. 4 Melting Furnace, No. 4 Holding Furnace, and repair the No. 4 Casting Pit Equipment. The project aimed to improve efficiency, reduce maintenance requirements, and incorporate the latest available technologies to optimize operations.

The scope of work encompassed three sets of furnaces in the Ingot Plant, each modified over the years to integrate advancements and enhance functionality. RTP closely collaborated with Arconic personnel, redesigning and detailing the No. 4 Melting Furnace to incorporate improvements derived from other furnace retrofits.

To ensure precision and seamless execution, RTP utilized Autodesk Inventor 3D modeling to create a comprehensive model of the replacement furnace. Detailed drawings of ancillary equipment, such as burner supports, doors, door mechanisms, and piping systems, were also produced. Technical specifications for equipment procurement and installation were meticulously prepared by RTP to meet the project's high standards.

RTP oversaw all aspects of this project from inception to completion. We evaluated bids and provided recommendations for equipment procurement and contracting services. We also developed and maintained a comprehensive project schedule. Throughout the 45-day outage, RTP's expert team provided 24-hour construction assistance coverage, ensuring smooth execution and timely problem-solving.

RTP provided comprehensive electrical engineering services to upgrade green mill controls at a busy aluminum plant in Hawesville, Kentucky. The challenge of this project was to replace the existing relays and PLC-5 racks with a ControlLogix PLC and replace the existing operator desk and graphic panel with new HMI units. Our team provided electrical design drawings which included exposed conduit plans, cable schedules, cabinet layouts, I/O schematics, PLC & HMI programming. We also assisted with start-up. With a focus on efficiency, precision, and user-friendliness, the upgraded control room empowers Century Aluminum to achieve unmatched productivity and quality.

RTP provided comprehensive engineering and design services for a new Rod Mill located at an aluminum facility in Marston, MO. The project’s main parts consisted of one rod mill, two tilt furnaces, a storage area, and an overall rod mill building complex. Our scope of work included field investigation, detailed engineering drawings, preparation of installation specification packages, and project management services. Through close collaboration, innovative engineering, and effective project management, RTP successfully delivered the foundation for Noranda Aluminum's New Rod Mill Facility.

RTP collaborated with Logan Aluminum in Russellville, KY, to execute a comprehensive upgrade of their DC-4 Decoater APC System, a critical component in their aluminum production process. The project aimed to enhance efficiency, improve functionality, and optimize operations for increased productivity.

The scope of work encompassed an array of engineering design services, excluding cooler and bathhouse equipment, to address various aspects of the upgrade. RTP's expert team provided mechanical duct and piping design, civil/structural support, foundation and paving design, and electrical service design to ensure a holistic and seamless solution. RTP also played an instrumental role in designing the area paving layout for maintenance and lime delivery truck access. The layout included roadway sections, revisions to area lighting, and the placement of pipe bollards, optimizing logistical flow and safety.

Our collaborative approach, precision engineering, and effective project management have contributed to the seamless integration of the upgraded system, enabling Logan Aluminum to achieve heightened efficiency and productivity.

RTP collaborated with The Industrial Company (TIC) for the installation engineering, foundation, piping, and electrical construction of the Hi Rolling Mill and Automated Storage Retrieval System (ASRS) at Norandal USA, Inc. Our actions included coordinating with on-site suppliers, constructors, and engineering firms to ensure smooth interfaces between the caster, building, and finishing areas. We received vendor drawings and converted metrics to the customer's US standard preferences, incorporating them into the general arrangement drawings within the overall building plan. Our team designed foundations for various areas such as the mill, roll change area, mezzanine operating area, and coil and scrap handling areas. Structural design drawings were created for supporting structures like the main pulpit and miscellaneous platforms, considering seismic design conditions. We also provided architectural design drawings for walls and doors, separating operating areas beneath the mezzanine floor, and designed the 2-story PLC/computer and switchrooms. Additionally, we developed interconnecting piping design drawings for various systems, including air wash, roll coolant, hydraulics, lubrication, and fire suppressant. Interconnecting electrical design drawings were prepared based on provided schematics and diagrams.

R.T. Patterson successfully completed the replacement of a Aluminum Melting Furnace, the rebuilding of a Holding Furnace, and the repair and/or replacement of Casting Pit equipment as required. Our actions included modifying three sets of furnaces in the Ingot Plant to ensure uniformity and improvements. We utilized Autodesk Inventor 3D modeling to design the replacement furnace and created detailed drawings of all its components, including ancillary equipment. Additionally, we developed technical specifications for equipment procurement and installation. Our team evaluated bids, made recommendations for purchase orders and contracting services, and maintained a comprehensive project schedule. We provided round-the-clock construction assistance during a 45-day outage, ensuring a smooth and efficient process.