RTP played a pivotal role in the successful installation of a cutting-edge "Greenfield" stainless steel melt shop in Calvert, Alabama, boosting the production capacity to an impressive 900,000 tons of high-quality steel slabs. This transformative project significantly enhanced Outokumpu Stainless USA's competitive edge in the market. As a trusted partner, RTP brought together a multidisciplinary team, delivering comprehensive engineering and project management services. Employing advanced technology, we crafted a precise 3D model, ensuring seamless execution and fostering a seamless collaboration between all stakeholders. Our commitment to excellence drives our mission to provide the utmost value to our esteemed client.

Recognized as the "Industrial Project of the Year," RTP led the way in providing comprehensive design and engineering services for an Electric Arc Furnace (EAF) Melt shop at a prominent steel plant. Our innovative solutions included cutting-edge scrap preheating and environmental control technology, a powerful 250-ton AC electric arc furnace, and a state-of-the-art 250-ton ladle furnace equipped with a twin station swinging gantry.

To ensure optimal performance, we integrated a high-capacity fume collection system, boasting a 1,200,000 ACFM baghouse system. Additionally, we streamlined alloy and flux handling systems and auxiliary equipment to facilitate seamless operations.

From conducting a thorough field investigation to preparing detailed specifications and drawings, RTP's expertise played a pivotal role throughout the project's lifecycle. Our diligent efforts encompassed purchasing, vendor drawing review, and filing of construction drawings.

The successful completion of this transformative project significantly boosted our client's operational efficiency, setting new standards in the steel industry. At RTP, we take pride in our ability to deliver unparalleled value and excellence to our esteemed clients.

At Worthington Steel Co in Decatur, Alabama, RTP undertook the ambitious task of designing and constructing a cutting-edge Cold Mill Facility, encompassing a sprawling 750,000 square foot steel processing center on a Greenfield site. This state-of-the-art facility, serviced by rail and truck deliveries, features advanced equipment, including a new Pickle Line, Four Stand Tandem Cold Mill, Batch Hydrogen Annealing, Temper Mill, Hot Rolled Slitter, Cold Rolled Slitter, and packaging capabilities to cater to each area's unique requirements. The facility showcases an impressive production capacity, capable of producing over 900,000 tons of steel annually.

To expedite the project's completion, we employed separate contracts for site improvements, building shell construction, and major process equipment supply. Subsequently, Worthington entered into a Target Price Agreement with a Joint Venture consisting of The Industrial Company (TIC) and R.T. Patterson Co., Inc., specifically focusing on design engineering, construction, and construction management for the installation of major process lines and support equipment.

RTP's unwavering commitment to innovation, precision, and efficiency enabled the successful realization of Worthington Steel Co's Cold Mill Facility. This cutting-edge facility marks a significant milestone in the steel processing industry, demonstrating Worthington's commitment to delivering high-quality products on a large scale. The seamless integration of advanced equipment and state-of-the-art processes in the facility ensures enhanced productivity and a prominent position as a leader in the steel manufacturing industry.

RTP designed and executed a New Melt Shop for Gerdau in Jacksonville, Florida. This ambitious project involved the installation of a Steel Making Facility, designed to replace the existing steel making shop at Gerdau AmeriSteel.

The new Electric Arc Furnace Facility was strategically constructed while the existing melt shop remained in operation. After successful commissioning, the old melt shop was gracefully idled, allowing for a seamless transition to the advanced production capabilities of the new Melt Shop, designed for an impressive annual production of 1,045,600 tons.

Key components of the New Melt Shop included:

1. New Electric Arc Furnace: Equipped with a remarkable tap weight capacity of 110 tons and a 20-ton hot heel. The furnace featured cutting-edge technologies, such as EBT, AC power, and a comprehensive injection system for side wall, oxygen, gas, and carbon.
2. New Alloy Additive System: A crucial component to enhance the quality and properties of the steel produced.
3. New Water Treatment Facilities: Ensuring optimal water quality and efficient cooling processes.
4. New Fume Emissions System: Comprising a roof canopy, duct system, drop-out box, quench tower, and a powerful 1,000,000 cfm baghouse to efficiently handle emissions.

RTP's expertise played a pivotal role in this transformative project. Our dedicated team provided comprehensive installation engineering services, conducting meticulous field investigations, and creating detailed general arrangement and layout drawings. 

At LTV Tubular's Marion facility, RTP embarked on an ambitious project to construct a cutting-edge ERW Tube Mill from the ground up. The state-of-the-art mill was designed to produce high-quality As-Welded Tubes, primarily catering to the automotive industry.

RTP's scope of work encompassed comprehensive construction engineering and management services, including site development and infrastructure to accommodate the Greenfield Site ERW Tube Mill. The mill building, along with an administration office and lab, was meticulously designed, with architectural development and artist renderings. The foundation, structural, electrical lighting, and power distribution were carefully integrated into the facility to ensure seamless operations. As part of the project, RTP also oversaw the installation of essential equipment, implementing robust foundations and interconnecting piping and electrical systems for efficiency and reliability.

Throughout the project, RTP's dedication to excellence and innovative solutions paved the way for the successful completion of the New Tube Mill Facility. With a commitment to modernization and efficiency, the facility now stands as a testament to RTP's expertise in delivering state-of-the-art manufacturing solutions for our esteemed client, LTV Tubular.

At Armco's Mansfield facility, RTP embarked on a transformative journey to modernize their Hot Strip Mill and boost operational efficiency. The comprehensive scope of work included essential modifications to achieve improved strip gage, crown, shape, and additional PIW rolling capabilities.

The project encompassed various key upgrades across the mill. This included introducing table covers from the reversing rougher to the finishing mill, enhancing the descaling system, upgrading roll cooling, and incorporating X-ray profile gage and width gage. The bottom strip runout table cooling was replaced, and Strip Loopers were added for smoother operations.

RTP also redesigned and upgraded the strip cooling water and roll cooling water systems, ensuring optimal performance and improved quality. The roll shop witnessed a significant transformation, with the roll grinder being replaced by a remanufactured grinder to ensure precision and quality control.

Electrical and controls received a major boost with the replacement of CP drives, MG sets, and rototrols for select table and sideguide drives. The implementation of a PLC for mill automation and scheduling further enhanced the mill's operational efficiency.

Throughout the project, RTP extended expert construction assistance, management, and project oversight, ensuring a successful and efficient execution.

In partnership with LS-II Electro-Galvanizing Company, RTP embarked on an ambitious project to establish a 300,000 ton/year continuous Electrolytic Galvanizing & Coating Facility on a Greenfield site in Columbus, Ohio. The scope of work entailed the installation of a comprehensive array of facilities and systems to facilitate seamless steel processing.

The project encompassed numerous critical components, including the construction of a pre-engineered building and a building services & support facility. The heart of the facility was the Continuous Electrolytic Galvanizing & Coating Line, which featured coil handling, entry coil preparation, coil cleaning, vertical looping towers, plating cells & polishers, prime & finish coaters & ovens, and inspection facilities.

RTP's expertise extended to the development of a fully automated control system with three levels of computer control, ensuring efficient and precise operations. Other essential components comprised the Electrolyte Supply System (Chemical Plant), Water Treatment Facility, Cooling Water Distribution System with Cooling Tower, Power Distribution System, and various supporting facilities, including roadways, railway, lab, and administration building.

RTP played a crucial role in the construction engineering and design for the majority of the project. Comprehensive engineering services, such as feasibility studies, permit engineering, project engineering, and design engineering (civil, electrical & piping), were meticulously executed to guarantee seamless project execution.

The successful collaboration between RTP and LS-II Electro-Galvanizing Company has led to the establishment of a state-of-the-art facility, positioned to revolutionize steel production in Columbus, Ohio, and beyond. The Electrolytic Galvanizing & Coating Facility stands as a testament to RTP's engineering prowess and commitment to empowering steel manufacturing with innovative solutions.

In collaboration with UHDE Corp of America and US Steel at the Clairton Plant, RTP engineered the transformative "C" Battery project, valued at an impressive $700 Million. This monumental endeavor aimed to enhance the USS - Mon Valley Works, specifically the Clairton Plant, by providing engineering and design services for critical components.

The scope of work encompassed various vital elements, including the design and implementation of Quench Towers, Control Rooms, Locker Rooms, General Rooms, Fire Detection Systems, Communication Systems, and modifications to the existing "B" Battery Oven Quench Locomotive and Coal Charge Car.

RTP's installation engineering services played a pivotal role in the project's success. The team conducted thorough field investigations and expertly managed the project, maintaining a detailed engineering schedule to ensure timely delivery. General Arrangements and Layout Drawings provided an optimized blueprint for the development, while Dismantling and Relocation Drawings and specifications facilitated seamless transitions.

Structural Steel Design Drawings, Architectural Design Drawings, and Process and Utility Piping Design, HVAC Design, and Installation Drawings laid the groundwork for robust infrastructure. The project's electrical aspects were skillfully handled with Electrical Design and Installation Drawings, complemented by Instrumentation Design Drawings and Data Sheets to ensure comprehensive control and monitoring.

RTP's expertise in preparing Installation Specification Packages and providing Construction Assistance ensured efficient implementation. With dedication and precision, RTP's engineering prowess transformed the "C" Battery project into a resounding success.

The project's outstanding achievements were further recognized when it received the prestigious "Industrial Project of the Year" award from The Engineers' Society of Western Pennsylvania. This accolade stands as a testament to the excellence and innovation RTP brought to the steel production industry through its remarkable engineering in the Clairton Plant's "C" Battery Project.

RTP took on the challenge of installing a state-of-the-art Billet Reheat Furnace for our client. The project encompassed the installation of new equipment to efficiently receive, transfer, rotate, and deliver billets into and out of the new furnace, as well as seamlessly integrate with existing rolling mills. This endeavor aimed to replace the aging billet furnace, a vital component of the plant's operations.

Working diligently to minimize disruptions, RTP meticulously planned the project to ensure the installation could take place without hampering ongoing plant operations. A planned 21-day outage in 2021 was strategically scheduled to facilitate a smooth transition to the new furnace. Limited available space posed a challenge, and RTP presented several options for installing the equipment, ultimately selecting a new building located between the existing mill building and a high voltage substation.

This location required careful reworking of electrical equipment and underground utilities. Additionally, one end of the Billet Yard, responsible for storing and moving billets using an overhead crane on an outside runway, had to be removed to accommodate the installation. Transition and equipment spanning sections of the Billet Crane Runway were skillfully engineered to ensure seamless operations.

Throughout the project, RTP played a pivotal role in providing cost estimates to secure funding from Sterling Steel Company's parent company. We meticulously maintained a total project schedule and offered construction assistance for all disciplines. RTP played a critical role in evaluating and selecting the furnace equipment while producing comprehensive installation drawings and specifications for procuring and installing support equipment and structures.

The project also involved the design of a closed-loop cooling system for the furnace, and RTP carefully evaluated quotes from equipment suppliers and integrators to ensure the highest standards of efficiency and performance were met.

By collaborating closely with Sterling Steel Company, LC, RTP's team ensured the successful implementation of this vital Billet Reheat Furnace, contributing to enhanced steel production capabilities and positioning Sterling Steel for continued success in the industry.

Gerdau Special Steel Facility in Monroe, MI embarked on an impressive capacity expansion program spanning 24 months. The comprehensive program encompassed the installation of several crucial components to optimize their steel mill melt shop, including a twin station ladle furnace, alloy material handling system, and upgrades to the water treatment plant and argon delivery.

RTP played a pivotal role in this groundbreaking project by providing a wide array of engineering services. We conducted facility planning, ensuring optimal crane clearances, and developing a detailed Molten Metal Path with Cooling Water Emergency Shut-off locations using advanced 3D modeling techniques. Our team also handled structural engineering services, including the design of the LMF Vault Structure and access, as well as the EAF Vault Removable Roof and Tap Hole maintenance platform.

Our Civil/Architectural Engineering Services ensured the successful extension of the LMF Transformer Vault and the development of the two-story LMF Vault Structure with transformer oil containment. Our foundation engineering expertise was applied to the design of two LMF Ladle Transfer Car Tracks, complete with cable drum and ladle car festoon systems.

Our Electrical Engineering Services were instrumental in lighting, weld receptacle, and convenience receptacle drawings for various rooms, as well as the design of the Communications and Data System, featuring fiber optic and Ethernet connections for seamless communication throughout the LMF, EAF, and Material Handling System.

Furthermore, we expertly handled Mechanical Piping and HVAC Engineering Services, ensuring efficient HVAC systems for the LMF Transformer Vault and EAF Transformer Vault, along with interconnecting process piping designs for the LMF, Material Handling System, EAF, and Ladle Pre-heaters.

RTP's contributions significantly enhanced Gerdau's steel production capabilities, revolutionizing their operations and reinforcing their position as an industry leader. Our commitment to innovation and excellence shines through in each aspect of this project, ensuring exceptional results and utmost client satisfaction.