ThyssenKrupp

2009 Design Award Winner

Project Team

Structural Engineer: Giffels-IBI Group and Gulf States Engineering
Owner: ThyssenKrupp Stainless USA
Architect: Giffels-IBI Group and Gulf States Engineering 
General Contractor: Hargrove (Construction Manager)
Steel Joist Manufacturer: Vulcraft
Steel Detailer: Computer Detailing Incorporated, Southern Detailing, Protheous, Apel Structural and C.H. Potter & Company Steel Fabricator: Cives Steel
Steel Erector: Steel City Erecting

Project Type: Industrial

Project Description

ThyssenKrupp committed to building a $4 billion world class, state-of-the-art steel and stainless steel processing facility in Southern Alabama. The facility was a cooperative effort between two ThyssenKrupp segments, Steel and Stainless, and is an important part of ThyssenKrupp’s NAFTA growth strategy. The plant is expected to begin operation in 2010 and when fully operational will create 2,700 jobs. The facility will manufacture and process carbon steel and stainless steel for high-value applications by manufacturers in the United States and throughout North America. The plant will serve industries including automotive, packaging, construction, electrical and utility, in addition to serving manufacturers of appliances, precision machinery and engineered products.

What Makes This Project Interesting

One of the most interesting facts of the project was the sheer size. Steel tonnage totals are as follows: Roof Joists = 1,227 tons; joist girders = 2,668 tons; wall joist = 1,045 tons; and joist bridging = 540 tons. In addition, 142,000 bolts were used for the joists and joist girders alone. Overall, 22,000 tons of structural steel were used on the project with the largest piece of steel weighing in at just over 44 tons. In addition, 86,000 gallons of paint and 385,000 bolts were used. The project utilized 12m long joists, 40m long joist girders, up to 40 MT rated capacity top-running bridge cranes and joist girders used in combination with building columns for moment frames to resist lateral crane loads and wind/seismic forces. Panelized erection methods were used for both roof and wall framing. Also, horizontal joists used as girts to support the metal siding enclosure eliminated the need for intermediate wind columns. Finally, due to the sophisticated paint system requirements, bolted connections were used to minimize touch-up. On past heavy industrial projects conventional framing would generally have been used. However, on this particular project, the structural design team proved that joist and joist girder construction could be utilized in a very effective and efficient manner to resist all imposed loads and load combinations and to meet all project requirements.

Advantages Of The Chosen Structural System

What were the advantages of the chosen structural system? The joist and joist girder framing enabled fast track design, fabrication and erection. The joist and joist girder elements were cost effective compared to conventional fabricated steel purlins and trusses used on previous industrial projects. Joists were used for the wall framing which resulted in the elimination of wind columns and associated foundations. Furthermore, the erection process was streamlined by used panelized construction methods for both the roof and wall framing system.

Project Scope

The scope of the project included the foundations, superstructures, equipment foundations and slabs for the Stainless Steel Cold Rolling Works portion of the site. Superstructures for new buildings included 1.27 million square feet and of that total, 1.24 million square feet are under joist and joist girder roof. Structures included high bay areas with multiple top-running bridge cranes. Joist girder and column frames were designed for lateral crane impact forces as well as 120 MPH hurricane-force winds.

Project Details

Project Construction Cost: $280,000,000 for CRW (total project investment $4 billion including all areas and process equipment)
Joist cost, including fabrication and erection: $24,000,000
Size (square ft.): 1,270,000
Roof area using joists (square ft.): 1,240,000 square feet
Joist area (square ft.): 1,240,000
Joist engineering to delivery (# days): Approx 90 days
Joist erection (# days): Approx 270 days

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