Gresham Smith was retained to provide Stage 1 and 2 design for a $240 million expansion to melting and casting operations of a world-class metal production client. The project began with an overall site analysis and master planning effort. A series of working sessions with plant engineering and production were held to review different options for the expansion. Location, overall site process flow and material flow balance were reviewed to determine the best solutions.

The expansion project will be undertaken while the existing plant remains fully operational. When all three phases are complete, the plant’s capacity will have increased by 1.2 billion pounds per year.




, KY


million expansion




billion pounds of future capacity

A Phased Approach

A Phased Approach

The master plan resulted in a three-phase approach that ultimately will double the capacity of the scrap yard and allow for the addition of four shredding lines, a scrap conveying system, four sidewall furnaces, two rotary furnaces, multiple reservoir furnaces and two eight-bay casting beds.

In addition, the master plan simplified material flow for this portion of the plant, eliminating bottlenecks and opening space for future modifications to existing casting operations. An upcoming expansion of the plant’s hot mill also was accounted for during master planning.

A new dross house will be built and the existing dross house will be relocated. New bag houses and two new decoating lines also were part of the project, while site infrastructure improvements include a new water tower and electrical substation.

Project Contact

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John Wharton, P.E.
John Wharton, P.E.
Senior Vice President