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KAISER ENGINEERS, INC. MIDDLETOWN, OHIO
FINAL PROJECT REPORT ARMCO STEEL CORPORATION
SITE DEVELOPMENT - STEPS I, II, & III PROJECT NO. 7112
NOVEMBER 3, 1969
Distribution: Armco
R. F. Boschert V. J. Curtis T. R. Foley A. M. Greco C. G. Kramer D. C. Osborne P. R. Smith J. M. Thomas Kaiser* S. D. C. Anderson D. A. Daly V. L. Frankson B. P. Franceschi R. C. Hulseman S. G. Imherr E. D. Lowell D. R. McSparrin R. J. Wolf Central File
Prepared by: D. C. Anderson
Date
Approved:
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KAISER ENGINEERS, INC. MIDDLETOWN, OHIO
FINAL PROJECT REPORT ARMCO STEEL CORPORATION
SITE DEVELOPMENT - STEPS I, II, & III PROJECT NO. 7112
CONTENTS
Project Summary General Description Project Authorization Project Personnel Project Progress
Project Schedule
Fmal Summary Cost andComparison
General Arrangement Drawings & Photographs
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FINAL PROJECT REPORT SITE DEVELOPMENT - STEPS 3, II, & III
PROJECT NO. 7112
1. 0 GENERAL DESCRIPTION* 1 * 3 4 This project was concerned with the entire scope of Site Development work for the Middletown Expansion Program. Step I dealt primarily with preparation of the site in the South Area where the new Hot Strip Mill is located. A final report has been submitted covering this step of the work. See Final Project Report for South Area Site Development, Project 7112-1.
The general scope of work accomplished by project 7112 Steps II and III was as follows:
(1) Demolition, removal and relocation of existing facilities in the Steelmaking Area.
{2) Site development of the Steelmaking Area. (3) Grading for roadways, railroads, ditches and
surface drainage in the South and Steelmaking Areas. (4) Storm drainage system including all sewers and
culverts in the South and Steelmaking Areas.
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(5) Paving of roads and parking lots in the South and Steelmaking Areas.
(6) Yard lighting in the South and Steelmaking Areas. (7) Two (2) permanent guard houses. One in the South
Area at Oxford State Road. The other is located at Lefferson Road near Highland Street.
As a result of the earthwork study conducted as a part of this t: project, the floor elevation of 107. 50 was established for the r-
Basic Oxygen Plant and Continuous Casting Facilities.
A more detailed description of this project may be found in Engineering Report 7112 - Steps I, 11, and III, dated June 1, 1967.
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2. 0 PROJECT AUTHORIZATION An Engineering Report for 7112 - Step II was issued September 24, 1965 and the "Request for Appropriation" was submitted September 24, 1965. Armco Corporate Management approved the request for $4, 696, 000 on December 28, 1965. On June 1, 1967, a final Engineering Report, 7112 - Steps I, II, and III, was issued combining the previous reports and included the final stage of Site Development, Step III. Armco management approved the consolidated appropriation request of $7, 706, 200 on July 25, 1967.
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3. 0 PROJECT PERSONNEL Armco Program Engineers
Armco Project Engineer Armco Project Engineer Electrical
Mr. T. R. Foley Mr. J. M. Thomas Mr. R. F. Boschert
Mr. J. J. Delaney
Kaiser Project Engineers
Mr. R. C. Hulseman Mr. D. E. Ernst Mr. D. C. Anderson
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4. 0 PROJECT PROGRESS Feasibility studies and scoping drawings for 7112 - Step 11 were started in mid-1965, and completed with the issuance of the engineering' report September 24, 1965. The 7112 Step III scoping information was completed with the issuance of the consolidated 7112 - Steps I, II, and III report June 1, 1967. The "Requests for Appropriation" were approved as outlined in Section 2. 0.
Detail design for Step II began in August, 1965. All steps of the 7112 site development design program were completed in January, 1968. A total of 168 drawings and five (5) sets of specifications were issued for construction for Steps I, II, and III of this project.
Stripping and grubbing of the Steelmaking Area site was started in November, 1965. The South Area storm sewers and drainage system was started by Kaiser Engineers in March of 1966.
Earth and slag embankment in the steelmaking area was completed to approximate design grade during the first quarter of 1967. Completion of this work provided a working grade for the Basic Oxygen Shop, Continuous Casting, Mold
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Yard, Stripper Building, Trackwork, Roads and other miscellaneous facilities located within the Steelmaking area.
Several subcontracts were awarded in connection with Step II
and III of this project. The following is a list of the major
subcontracts:
S/C Number
Type of Work
Subcontractor
7112-1965 -2084
Roadway Paving
Armrel Construction Co.
7112-1730
Roadway Paving
John R. Jurgensen Co.
7112-1768
Roadway Paving
Triasco Corporation
7112-1109
Slag Removal and Embankment
W. L. Harper Construction Company
7112-1629
Storm Sewers Steelmaking Area
Delta Pipeline Construction
7112-1667
Yard Lighting
Westinghouse Electric
7112-2276
Lefferson Road Guard House
S K Construction Co.
7112-1077
Fencing
Davis & Siehl
The final completion inspection of the Steelmaking Area was held
on August 6, 1969. The final inspection of the South Area was held
August 13, 196 9.
Punch list items, clean up, and additional work items extended the final completion date to the end of October, 1969.
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5. 0 PROJECT SCHEDULE The schedule outlining the theoretical and actual project progress is attached. This schedule shows the combined progress for all steps of the site development work.
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PROJECT NO. 7 1 1 2 -1 & 2 & 3
*, DENOTES RESCHEDULE
KAISER ENGINEERS, INC.
REPORT DATE F IN A L
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FINAL COST & COMPARISON TO ENGINEERING REPORT
BUDGET _____
_________
___ ___________
Appropriations
The following is the chronological history of appropriations
for the Site Development Project from the inception of
Phase I to the present:
September 30, 1 964
$ 10,000
January 13, 1965
1,816,000
September 24, 1965
4, 696, 000
June 16, 1967
1, 184, 200
February 9, 1968
150, 000
May 20, 1968
(679, 296)
$7, 176, 904
Costs The final costs of the project shows an underrun of $1, 04 9, 823, reflecting a savings of $352,430 in direct costs, $30, 393 in indirect costs, and the entire contingency of $667, 000.
A summary of final costs as compared to the engineering report budget follows.
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Costs
Project Section Description
Budget Estimate
101 102 103 104 105 106 107 110 111 112 113 115 116 117 118 119 120 131 151 152 153 154 155 156 161 163 172 173 176 179 180 181 201 202 203 252 253 880
Demolition Remove & Salvage Clearing & Grubbing Seal Exist. Wells &. Cisterns Earthwork Slag Culverts Perimeter Fencing Gen. Site Clear. -So. Area Roadways - South Area Parking Lots - South Area Coil Conv. Overpass Bridge Fencing - South Area Culverts - South Area Storm Sewers - South Area Yard Right - South Area Park. Lot at No. 2 O. H. Traffic Signal - South Area Demolition &. Removal Alter Middletown Sewer Gen. Site Clear. - SM Area Culverts - S. M. Area Storm Sewers - S. M. Area Clean Out & Fill Exist. Oil Ponds Refuse Dump Roadways Oil Recovery Area Roadways - S. M. Area Parking Lots - S. M. Area Fencing - S. M. Area Yard Lighting - S. M. Area Yard Light. Crawford St. Ent. Traffic Signal - S. M. Area Interplant Signs Flag Pole at New Guard House Guard House - So. Area Fabricating Shop Guard House - S. M, Area Elect. Sub Ovhd & Fee
3, 500 20, 000 25, 000
600 653,600 821,000
48, 400 50, 900 559, 400 313,300 77, 700 47, 700 14,200 70, 300 1, 405, 100 139, 700
9, 100 5, 000 89, 400 17,000 800, 700 272.000 424,400 22,500 2, 800 17, 700 158,800 37, 600 9, 200 138,700
6, 800
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172,100 9, 300
23,000
$6, 483, 900
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Estimate at Completion
3, 476 20, 000 25, 000
600 653,563 820, 927
48, 332 50, 818 687, 450 282, 206 35,856 42, 218
7, 885 53,708 1, 172, 029 118, 880
9, 064 8, 762 85,763 2, 774 74 3, 34 9 233,041 356, 887 20, 377 2, 74 3 17, 437 189, 046 10, 463 17, 055 125,038 26, 118
1, 787
881 65, 874 172, 073 17, 600
2, 390
$6, 131, 470
(Over) Under Budget
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37 73 68 82 (128, 050) 31,094 41,844 5, 482 6, 315 16,592 233,071 20, 820 36 (3, 762) 3, 637 14,226 57,351 38, 959 67,513 2, 123 57 263 (30, 246) 27,137 (7, 855) 13,662 (26, 118) 6, 800 (1, 787) (881) (48, 474) 27 (B, 300) 20, 610
$352,430
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7. 0 GENERAL ARRANGEMENT DRAWINGS & PHOTOGRAPHS
The following project general arrangement drawings are attached:
625167 625168
625169
625171 625170
Roads and Roadway Lighting South Area
Roads and Roadway Lighting Steelmaking Area
Roads and Roadway Lighting Steelmaking Area
Storm Sewers South Area
Storm Sewers Steelmaking Area
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PHOTO NO. 1 - SOUTH ALFA WORMS SOUTHEAST, SHOVIIHG INITIAL STAPFS
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PHOTO NO. 2 - AERIAL VIS'/ LOOKING NORTH, SHOWING INITIAL CONSTRUCTION
STAGES OF THE HOT STRIP MILL AND ROUGH GRADING OF THE SOUTH AREA, OCTOBER 1965.
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AERIAL VIEW LOOKING NORTHWEST, SHOWING THE SOUTH AND STEELMAKING AREA SITES. THE ROADS, DRAINAGE, AND SITEWORK ARE IN THE FINAL STAGE OF CONSTRUCTION, FEBRUARY 1969.
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AERIAL VIEW LOOKING NORTHEAST, SHOWING STEELMAKING AREA SITE IN THE FINAL STAGE OF CONSTRUCTION.
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