D.E. Karn Units 1 & 2 Utility + Mechanical Package

At a glance

Project Overview:

Ideal Contracting was awarded the contract to furnish and erect a new utility trestle at the Consumers Karn facility in Essexville, MI. As part of this project, Ideal provided all materials, including shop fabricated modular trestle sections, the steel support structure for the utility trestle, as well as piping and cable tray for the AQCS project. The 18 pre-assembled trestle modules were fabricated off-site and transported to the Karn facility where they were erected along with an additional 200 tons of site erected support steel, handrails and grating. Mechanical and electrical subcontractors were used to connect the module utilities on site.

This project presented unique challenges as a portion of the trestle was constructed over an inlet channel from Saginaw Bay. To assemble the trestle over the waterway, the existing bridge structure required reinforcing to support the weight of the trestle and utilities. Additionally, the team faced the challenge of erecting around existing structures, which required careful planning of multiple turns and level changes in the trestle. The completed utility trestle spanned over 800 linear feet and was successfully erected with no incidents.

The Mechanical Package consisted of the installation of 2,500 tons of owner furnished structural and miscellaneous steel to support the mechanical installation of two Spray Dry Absorbers. The scope of work also included the installation of new duct support steel and reinforcing of existing duct support steel. The major challenges for this project were tight scheduling, confined logistics and the harsh weather associated with working off the Saginaw Bay.

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