In collaboration with US Steel and Lexicon, Inc., RTP undertook a series of critical EAF support activities as part of the installation of the new EAF project at the Fairfield, AL Works facility. After the facility's idleness for around three years, RTP was contracted to provide comprehensive engineering services, while Lexicon, Inc. handled the installation.

The scope of work included various vital projects, such as the Electrical Power Distribution, Lighting, Truck Scale Arrangements & Radiation Detectors for the Scrap Yard, the EAF Alloy Dust Collection System, LMF/VTD Off-Gas System, EAF Dust Loadout System, EAF Baghouse Air Compressor System, EAF Off-Gas Radiation Detection System, EAF Slag Spray System, ASU Plant Utility Coordination, EAF E-Stop Design Modifications and Panel Designs, Level I & Business Network Design, and Ladle Tracking System.

To ensure seamless project execution, RTP provided a wide array of engineering services, starting with comprehensive project engineering and field investigation. Our team meticulously developed process designs, demolition drawings, and general arrangement and layout drawings. Foundation designs and drawings, as well as structural designs and drawings, were carefully crafted to ensure structural integrity.

The project also included the development of a new network diagram, equipment specifications, bid packages, proposal evaluations, and purchasing recommendations. Ensuring smooth coordination, RTP managed vendor designs and deliveries, guaranteeing timely and efficient project progress.

In close collaboration with US Steel and Lexicon, Inc., RTP took part in an ambitious project to upgrade the existing 4-Stand Rounds Caster at the Fairfield, AL Works facility. After being idled for around three years, the facility was poised for a restart and the implementation of new capital equipment improvements by SMS Concast. 

The extensive list of improvements included the installation of New Cartridge Molds, Mold Level Detection System, Mold Electro-Magnetic Stirring System (MEMS), Hydraulic Oscillator, Modified Secondary Cooling System, updated Hydraulic Controls for Withdrawal Straightener, and New Withdrawal Straightener Units with Multi-Point Unbending, among other crucial enhancements.

RTP's role in this project involved providing meticulous installation engineering services to ensure the successful integration of the upgrades. From field investigation and inspection to demolition drawings and general arrangement and layout drawings, our team covered every aspect of the project. We developed foundation modifications and new foundation drawings, conducted structural repair drawings, and created new structural drawings to ensure structural integrity. To enhance operational efficiency and safety, RTP also designed a new Turret Loadside Platform and Ladle Slide Gate Hydraulic Control System.

Throughout the project, RTP provided comprehensive construction assistance, ensuring seamless project execution and adherence to quality standards. The successful Rounds Caster Restart and Capital Equipment Improvements project stand as a testament to RTP's commitment to excellence in engineering and customer satisfaction.

R.T. Patterson provided engineering services to CMC Jacksonville for the installation and modification of equipment in their Rod Mill operations. Our scope of work included creating a 3D model to design equipment foundations and showcase modifications such as a replacement Rod Block Entry Cropping Shear, a new High-Speed Pinch Roll and High-Speed Shear, and the relocation of a Laying Head Pinch Roll. We also conducted detailed structural design for new support structures and modifications to existing platforms and stairwells. Additionally, we prepared interconnecting piping drawings, including plans, sections, and detailed drawings up to the take-over points. Our engineering expertise ensured the seamless integration and efficiency of the equipment in the Rod Mill.

R.T. Patterson led the installation of a new Steelmaking Facility at an existing steel mill, enabling the production of 1.5 million metric tons of carbon steel slabs. Our engineering services encompassed site layout, 3D modeling, and comprehensive design of foundations, structures, piping, and electrical systems. We provided equipment procurement and turnkey packages, ensuring seamless integration of OEM equipment. With our project management expertise, we oversaw the successful execution of the facility, which includes a DC Powered Electric Arc Furnace, water treatment facility, gas plant, and river terminal.

RTP played a crucial role in the transformation of an existing Electric Arc Furnace (EAF) Shop, implementing a series of significant upgrades and modifications. This comprehensive project involved replacing the existing No. 8 Furnace, introducing hydraulic electrode positioning and bottom tapping capabilities, and implementing a new off-gas duct system and cooling water system modifications. RTP's expertise in various engineering disciplines ensured the successful implementation of these transformative changes.

The project entailed several key elements, including field investigations, layout drawings, dismantling and relocation, foundation and structural design, cooling water system and instrumentation design, process and utility piping design, electrical design and installation, off-gas ductwork analysis and design, and construction assistance.

The implementation of the new furnace with hydraulic electrode positioning, bottom tapping capabilities, and the accompanying modifications to the off-gas duct system and cooling water system resulted in enhanced productivity and operational efficiency.

RTP led a groundbreaking project to transform Mansfield Steel Operations into a state-of-the-art mini-mill facility, with the aim of becoming a low-cost producer of carbon hot bands while also enabling the production of stainless and silicon steels. The project involved the replacement of existing ingot teeming, ingot soaking, and primary ingot rolling facilities with advanced slab casting and direct hot charging technologies.

The scope of work encompassed a wide range of critical tasks and services. Our team conducted thorough field investigations to assess the existing infrastructure and determine the feasibility of the modernization project. We developed comprehensive general arrangement and layout drawings to optimize facility design and streamline operations, ensuring the efficient flow of materials and resources. Maintaining a critical path method (CPM) schedule, RTP meticulously managed the project timeline and facilitated its smooth execution.

RTP provided dismantling and relocation drawings and specifications, ensuring a seamless transition from the existing facilities to the modernized setup. Our team designed foundations, structural steel, and architectural elements through detailed drawings, guaranteeing the integrity and functionality of the new infrastructure. Process and utility piping design and installation drawings were developed to optimize material flow within the facility, while precise electrical system designs ensured safe and efficient power distribution. Additionally, RTP prepared installation specification packages and building permit drawings, adhering to regulatory requirements, and facilitating a smooth approval process. 

Throughout the project, our team provided comprehensive construction assistance, construction management services, and project management services to oversee and ensure the successful execution of the modernization project. The transformation of Mansfield Steel Operations into a cutting-edge mini-mill facility was successfully realized, and resulted in improved cost-efficiency, expanded product capabilities, and enhanced operational performance.

RTP undertook an impressive project involving the installation of a state-of-the-art 250,000 ton/year Hot Dip Galvanizing Line, expanding the existing 270,000 ton/year facility to meet market demands and enhance production capabilities.

The scope of work encompassed various crucial tasks and components. This included constructing a pre-engineered building to house the new galvanizing line and wastewater treatment facilities. RTP designed and constructed building services and support facilities to ensure smooth operations. The installation of the Hot Dip Galvanizing Line involved integrating essential components such as coil handling equipment, a welder, horizontal looper, continuous annealing furnace, aluminum/zinc pot, air wiping system, cooling tower, skin pass mill, tension leveler, chemical treatment & printer, exit looper, electrostatic oiler, tension reel, and bander.

To optimize operational efficiency, RTP implemented an advanced automated control system. They also established a comprehensive water distribution system, power distribution system, and chemical system to support the galvanizing line's operations. The project included the construction of pulpits, offices, and sanitary stations to create a productive and comfortable working environment.

RTP's expertise spanned across various engineering disciplines, including civil, electrical, mechanical, piping, and instrumentation, to develop a facility installation design. Our team provided design engineering services, including detailed specifications, bid reviews, estimating, and scheduling. Throughout the project, RTP offered comprehensive construction assistance to ensure seamless execution.

The project significantly increased production capacity, advanced galvanizing capabilities, and streamlined operations for our client.

RTP spearheaded a comprehensive project to install two independent continuous slab casting machines, accompanied by associated support facilities, achieving an impressive annual production capacity of 3.3 million tons. Additionally, this endeavor involved integrating an LMF (Ladle Metallurgy Furnace) facility into an existing complex and modifying the existing Q-BOP (Quenching and Self-Tempering of Bars and Rods) facility to enhance its average heat size.

The scope of work encompassed a wide range of activities and services, including demolition, relocation, and site preparation, renovation of existing mill buildings, construction of new mill buildings, modifications to the Q-BOP Shop, and the installation of various essential facilities and equipment. These included slab skimming stations, ladle preparation facilities, LMF facilities, crane upgrades, new crane girders, slab casters, cranes, power distribution system upgrades, a fully automated control system, a metallurgical lab, tundish repair, slab slitting, shipping, and water treatment facilities. The project also involved the construction of computer and control rooms, auxiliary buildings, roadways, and a building ventilation system.

RTP's involvement in this ambitious project extended to project management, construction engineering, and design. We provided a comprehensive range of engineering services, such as feasibility studies, appropriation cost estimates, project engineering, design engineering (civil, electrical, piping & instrumentation), specification writing, expediting, cost control, construction management, and check-out and start-up assistance.

This project resulted in the installation of advanced continuous slab casting machines and facility upgrades. The transformed production facility now boasts increased capacity, improved operational capabilities, and enhanced technological efficiency, positioning the client for greater success in their industry.

RTP  executed a project to modify an existing pickle line, incorporating mechanical and electrical upgrades to optimize productivity and quality control. The project involved various enhancements, including increased line speed, expanded looper car capacity, improved tracking and tension control, upgraded drive packages, control systems, and diagnostics. Quality control measures necessitated the replacement of pickle tanks and the implementation of a new solution control system.

Due to the line's critical role in supplying products to other mills within the corporation, a narrow outage window necessitated innovative methods for replacing pickle tanks, increasing looping car capacity, and minimizing electrical work on the critical path.

RTP's scope encompassed developing a comprehensive feasibility study, including preliminary cost estimates, construction schedules, and outage schedules. Project management was a key aspect, involving structural inspection, repair recommendations, specification development, technical evaluations, scheduling, and cost estimation.

Our multi-disciplinary approach included installation engineering for various aspects such as single line diagrams, conduit layouts, lighting, general arrangements, motor sensor lists, cable tray layouts, demolition plans, and staging drawings. Extensive field documentation supported the staging drawings. Additionally, mechanical piping, machine design, structural, foundation, and architectural disciplines were involved, providing comprehensive construction and start-up assistance.

The engineering phase of the project spanned approximately 12 months, during which RTP ensured meticulous planning, coordination, and execution. The result was a highly optimized pickle line, driving increased productivity and superior quality control.

RTP provided engineering services to install a new Electric Arc Furnace and replace an existing EAF servicing the melt shop. The new larger furnace was installed during a 47-day outage. Demolition and installation scope of work for the new, replacement equipment includes furnace foundations, mezzanine floor at the charging floor elevation, modification of the existing Slag tunnel for more direct access, 4th hole, drop-out box and water-cooled duct replacement, non-contact cooling water system, electrical distribution upgrades, alloy system addition, and wire feeder relocation.

In addition, RTP replaced (3) existing interconnecting cooling water systems facilitating to the melt shop, with (1) new, unified cooling water system to satisfy current needs and future expansion. The new cooling water system consisted of a built-in-place, fiberglass, counterflow cooling tower capable of supplying a 32,000 GPM service requirement.

Comprehensive services provided by RTP included project and detailed engineering services; preparation of estimates to assist with budget funding; structural, foundation, and electrical drawings; and coordination with various OEM’s and CMCST’s.