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 Consumer’s 2,000-acre site. Major components of Graycor’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.

Along with erection components, the scope included barge unloading and transporting over a public road of prefabricated baghouse modules and fabricated and insulated ductwork modules. Adding to the project’s complexity were multi-contractor coordination challenges combined with limited site access. As a solution, Graycor’s team is worked closely with Consumers Energy 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 also dictated careful planning of crane maneuvers and placement of construction equipment. The design-build project required just-in-time deliveries for all major elements and pieces of equipment.

Because a strong focus on safety was key to the success of the project, there were several important safety measures used to keep workers safe from project-specific hazards. The proactive measures included 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 used on the project include ironworkers, boilermakers, pipefitters, carpenters, laborers, operators, cement finishers and masons. Subcontracted work included scaffolding, large cranes, duct insulation and lagging, and siding.