Burns Harbor, Indiana

No. 1 Coke Battery Roof Paving and Collector Main Project

Client / Owner





Graycor Industrial

Project Scope

Graycor Industrial’s team demolished and replaced the No. 1 Coke Battery top paving refractories in 82 ovens including tie rods, lintel and parapet plates, stand pipes and charge holes, larry car running rails and hot rails, U-tube car running rails and hot rails, door machine hot rails. In addition, Graycor removed and replaced the collector main and cross-overs (four each) including the existing flare stacks and miscellaneous walkways, platforms, piping systems and instrumentation. The project scope also included structural repairs and revisions being made to the battery’s north end structure, as well as installation of new pump/electrical room which consisted of demolishing the existing concrete, excavating, placing new concrete and installing structural steel, masonry and doors.

Self-perform work included: ironworkers, pipefitters, boilermakers, carpenters, laborers, millwrights, bricklayers, operators and Teamsters.

Subcontracted work included: Painting, electrical installation grading/backfilling, HVAC, insulation, heavy haul/lift equipment, hydro-cutting, concrete demolition, running rails thermite welding, surveying, weld testing, air monitoring control, hot tap/stop plug installation and scaffolding.

Graycor’s team successfully completed the outage seven days ahead of schedule and 18 percent under budget, which resulted in time and cost savings for the client.