West Olive, Michigan

Air Quality Control System (AQCS) Project

Client / Owner

Consumers Energy

Architect / Engineer

Black & Veatch Limited of Michigan




Graycor Industrial

Project Scope

As part of Consumers Energy’s program for achieving EPA air quality standards, this 22-month AQCS project includes structural, mechanical and architectural work on Unit 1 located on Consumers’ 2,000-acre site. Major components of Graycor Industrial’s work scope include erection of structural steel, a pulse jet fabric filter (PJFF) baghouse, ductwork, ID fans, blower building, and performing demolition and a critical tie-in outage in 2016.

Along with erection components, the scope includes barge unloading and transporting over a public road of prefabricated baghouse modules and fabricated and insulated ductwork modules. Adding to the project’s complexity are multi-contractor coordination challenges combined with limited site access. As a solution, Graycor Industrial’s team is working closely with Consumers to carefully plan, schedule and execute work with overall project objectives as the driving criteria. The small project site-with portions such as the baghouse construction located directly over a circulating water inlet/outlet channel-has also dictated careful planning of crane maneuvers and placement of construction equipment. The design-build project requires just-in-time deliveries for all major elements and pieces of equipment.

Because a strong focus on safety has been key to the ongoing success of the project, there are several important safety measures being used to help keep workers safe from project-specific hazards. The proactive measures include a stringently enforced barricade procedure to prevent unauthorized personnel into active work areas, a radar speed sign to deter speeding on a public road through the laydown areas and a portable fall-arrest system for safely unloading materials.

Graycor’s self-perform trades being used on the project include ironworkers, boilermakers, pipefitters, carpenters, laborers, operators, cement finishers and masons. Subcontracted work includes scaffolding, large cranes, duct insulation and lagging, and siding.