In the News: Modern Steel Construction

Cardio Construction

WHAT BETTER PLACE for a new heart hospital than the heart of the city?
Upon its completion next year, the $78 million, steel-framed Detroit Medical Center Heart Hospital will house cardiology centers, surgical rooms and clinical offices on a vast hospital complex in the Midtown area of Detroit near the campus of Wayne State University. Read More>

Altering Alerts

On March 26, 2012 OSHA published the first major revision to the 1994 Hazard Communication Standard (HazCom) (OSHA 1910.1200 & OSHA 1926.59) to align it with the Globally Harmonized System (GHS). Read More>

FireKeepers Casino

The drive along the busy I-94 expressway between Detroit and Chicago is about four hours but can sometimes seem even longer. FireKeepers Casino Hotel in Battle Creek, Mich., about halfway between the two cities, hopes to serve as a brief stopping point along the way — and maybe more. Read More>

GM Press Consolidation

Parma Ohio (700 Tons), Marion Ohio (637 Tons) and Flint Michigan (1765 Tons)

Douglas Steel Fabricating Corporation was retained by Ideal Contracting to install new steel and relocate existing steel to support presses being relocated from shuttered GM plants to Parma, Marion and Flint locations. The entire project was done using model review. No shop drawings were issued to the EOR for approval.  Only the 3D model was exchanged back and forth. All connection design was preformed within the modeling software.

Working within the confines of existing press pits, existing steel was reinforced to accommodate the new loading and support point.  Because steel was painted with lead paint and coated with lubricants from press operations, Douglas provided air monitoring and lead abatement so the attachments and reinforcing could be accomplished without exposing employees to hazardous lead fumes.  Existing concrete walls of pits were field measured to be sure that the new steel would be installed in the proper location. Douglas located all new anchors attaching the new steel to the existing concrete walls of the pits.

General Motors Noise & Vibration Test Facility

Milford, Michigan – 2555 Tons

Contracting directly with General Motors, Douglas Steel fabricated and erected 2555 tons of trusses, beams, columns, girts and bracing. General Motors’ new Noise and Vibration Test Facility covers over 170,000 square feet.

All work was completed on schedule and without any time loss injuries after nearly 6200 man hours worked.

General Motors Platinum Plant – Storage/Stamping Building

Lansing, Michigan – 1438 Tons

Delta Township is home to the newest General Motors Assembly Plant currently called the Platinum Plant. Douglas Steel fabricated and erected 1,438 tons of structural steel for the Material Storage Building, Scrap House and Blank Receiving Building, providing a total of 265,000 square feet under roof. Due to the quick schedule demanded by General Motors, Douglas Steel sublet a portion of the truss fabrication to Thomas Steel, Inc. of Bellevue, Ohio. Erection progressed so quickly that the crane and crew had to interrupt their operation and wait for the foundations to progress further resuming operation.

General Motors V-6 Engine Plant

Flint, Michigan – 3.645 Tons

Douglas Steel Fabricating Corporation was selected by Ideal Contracting as a partner in the design and construction of General Motor’s new 400,000 sq. ft. V6 Engine Plant in Flint. Douglas Steel provided a 3D model of the steel frame to the design team, which allowed the MEP contractors the ability to “virtually install” their systems within the allowable free space and avoid conflicts with the structural steel. All shop drawings were electronically submitted for approval to Ghafari, the Engineer of Record. In most instances approval drawings were returned to Douglas Steel in less than one week. Douglas Steel erection crews used 2 cranes to erect the 3,645 ton structure. Each crane started at opposite ends of the building. The manufacturing facility was completed for Owner occupancy within 10 months from the start of design.

BASF – Lithium Ion Battery Plant

Elyria, Ohio – 1,160 Tons

BASF was racing to get their product to market before the competition. Government funding was at stake. Schedule for completion of the steel package – all galvanized steel – was not negotiable. Equipment deliveries drove steel completion.  Numerous platforms and stairs providing access to the equipment were designed  after the main building and had to be integrated into the main structure while it was being fabricated.

Douglas Steel Fabricating Corporation took a proactive approach, meeting on site with the design team to provide innovative framing and connection solutions and assist with scheduling. Our in-house engineering and fabrication capabilities enabled us to stage our work and intensively manage the schedule, reacting to design changes on the fly and completing the project two weeks ahead of schedule.

Lansing Board of Water & Light – REO Town Power Plant

Lansing, Michigan – 2,150 Tons

The Christman Company retained Douglas Steel Fabricating Corporation to provide engineering support, fabrication and erection for this complex 154,000 sq.ft. project.  Working with an extremely tight site, numerous design revisions took place during the shop drawing preparation and fabrication phase.  Douglas provided space in our office for the EOR to come in and review the 3D model and approve the shop drawings on the spot, which streamlined the entire shop drawing review process.  Our in-house engineering and fabrication capabilities enabled us to offer alternate framing and connection solutions, react to numerous design changes, and complete the project on schedule.

MSU T.B. Simon Power Plant – Coal Handling Facility Upgrade

Lansing, Michigan – 45 Tons

This entire project was time driven. Shutdown of the facility was to occur in November and all work including equipment installation was to be completed before January 1st.  Early involvement with the MSU construction team enabled Douglas Steel Fabricating Corporation to offer alternative framing solutions to the EOR that helped to reduce costs and field time.

Our scope included not only detailing, fabricating and erecting the structural steel but also installing the entire conveyor system and other supporting equipment.  Douglas designed, fabricated and installed supplemental framing including many hoisting systems for maintenance.

Douglas also addressed the substantial lead paint in the existing structure. We contracted to have the lead paint abated in all areas requiring reinforcing and areas where equipment was to be attached.

Michigan Army National Guard Aviation Support Facility

Grand Ledge, Michigan – 1237 Tons

The Michigan Army National Guard’s new Army Aviation Support Facility (AASF) will serve to store and maintain their fleet of Apache Helicopters. This modern facility consists of three (3) separate buildings totaling 156,414 square feet. Douglas Steel was contracted by The Christman Company to fabricate and erect 1,237 tons of structural steel and miscellaneous iron for this project.

The first structure is the office and training building. This 56,202 square foot building is a two-story steel structure with a steel truss system for the roof and a 6″ inch deep x 16 ga. metal roof deck. The trusses are 20′-0″ feet apart and braced laterally with struts and the 6″ inch deep metal roof deck. This office building is surrounded by numerous galvanized steel canopies.

The second is a 56,430 square foot primary maintenance hangar standing 54 feet tall. This is a “cable-stayed structure”, supported in the center of the building with four (4) main columns. The front and back walls have a 300 foot clear span door opening framed with 300 foot long trusses. This feature allows the owner to have a long un-obstructed span, thus allowing several helicopters at one time to enter or exit this facility. This was complex structure to erect. Several shoring towers had to be constructed and many high-strength screw anchors had to be drilled in the ground to serve as anchor points for the support cables. These cables stabilize the truss system until horizontal, lateral bracing and the 6″ deep x 16 ga. roof deck is installed. Multiple large cranes had to be employed.

The third building is an un-heated 43,782 square foot aircraft storage facility with an open storage area. The front wall is framed with two (2) 141 foot long trusses allowing for clear span door openings. The structure is approximately 33 feet tall.