Algoma Steel, a prominent Canadian steel producer since 1902, and Walters Group have been collaborating on the ambitious project of constructing two cutting-edge electric-arc furnaces (EAF) to replace their existing blast furnace and basic oxygen steelmaking operations. This transformation aims to reduce Algoma’s carbon footprint by approximately 70%, making it one of Canada’s largest greenhouse gas reduction initiatives. The new EAF shop will increase Algoma’s capacity by approximately 1 million tons, allowing for a total capacity of 2.4 million – 3.5 million tons.
Initially brought in to provide design assistance services, Walters Group demonstrated exceptional planning and collaboration with partners such as The JNE Group and Danieli, which ultimately expanded the scope of our responsibilities. We worked closely with consulting engineers as design changes evolved.
Walters Group’s efforts solidified our partnership with Algoma and further strengthened our longstanding relationship with The JNE Group and Danieli. We showcased our ability to adapt and deliver comprehensive solutions in complex projects, establishing our role as more than just a steel fabricator but as a full-service solution provider.
Walters Group and Algoma Steel share a vision for progress on constructing Algoma’s EAF building. This vision extends beyond infrastructure upgrades; it embodies a collective commitment to implementing sustainable solutions that address outdated steelmaking operations. Leveraging our expertise in construction, fabrication, and logistics, the new EAF building will lay the foundation for a more sustainable steel industry in Canada.
“We are both delighted and honoured to be selected by Algoma to build their new EAF facility in Sault Ste. Marie. Having served as a stalwart in the steel construction industry for over 65 years, Walters is eager to contribute our expertise to a project that promises to drive tangible carbon reduction in our home province of Ontario”
Peter Kranendonk, CEO of Walters Group
Central to the success of this transformative project lies the collaborative approach to planning adopted by all partners. Collaborating closely with Danieli and JNE was crucial to the structural, mechanical, and civil engineering support required for the construction of the EAF building.
Incorporating as many of Algoma’s steel plate products as possible, Walters Group crafted the heavy structural components required for the project while collaborating closely with local industrial contractor SIS Manufacturing to ensure seamless assembly on-site.
Additionally, Warfab and Nucor contributed their expertise and collaborated with Walters Group to optimize the integration of all structural steel components.
Pinnacle Logistics played an important role in transportation and logistics, ensuring the timely delivery of materials and equipment to the site. Working in collaboration with Pinnacle Logistics, Lopes[JI1] , Mammoet and Burnco, we contributed to the efficient management of on-site operations, facilitating the seamless installation of key components.
From the intricate assembly of structural steel to the operation of heavy machinery, the workforce, consisting of Ironworkers and Crane Operators from multiple local unions, including 786 (Sault Ste. Marie), 721 (Toronto), 736 (Hamilton), 700 (Windsor), 765 (Ottawa), and 759 (Thunder Bay), continues to demonstrate exceptional skill and coordination throughout the project.
Despite the complexities of the job, the collaborative effort between Walters Field Services, Crane Operators and Ironworkers ensures smooth operations in the development of Algoma’s EAF project.
As the project progressed, Walters Group assumed the role of detailing, supplying, and installing structural steel, heavy crane girders, stick steel, and plate modules. Walters has navigated through complex connection engineering challenges, ensuring seamless integration of all project components.
This included overcoming the unique challenges posed by the fabrication of four massive crane girders, each approximately 100 ft long, 16 ft deep, and weighing 120 tons. The fabrication process presented hurdles due to the sheer size limiting movement in the shop. Nevertheless, our planning and collaboration with Warfab enabled us to overcome these obstacles, ensuring the completion of this critical component.
A milestone was achieved with the completion of the main EAF building, signifying a crucial phase in the project’s evolution. This structure, spanning 1000 ft long and 180 ft tall, is comprised of 14,000 tons of structural steel and is a testament to the collaborative efforts and expertise of Walters Group and all partners involved.
Our focus now shifts towards the installation of towering dust hood modules, each standing at 40 ft tall. These modules, crucial for environmental control and safety within the facility, require precision to ensure their seamless integration. Working over the installed base scope in the EAF Building, we will handle duct assemblies weighing up to 60 tons, with preassembly on the ground to reduce the number of lifts. Leveraging our experience and expertise in structural steel and modular construction, Walters Group is eager to tackle the next phase of the project.
Fluid schedules, challenging site access, and the simultaneous operations across multiple locations presented challenges for Walters Group to adapt to. Notably, the design and installation of the EAF dust hood was a monumental task given the weights involved and the need for specialized equipment.
Additionally, the transportation of four massive crane girders, fabricated by Warfab, to the site in Sault Ste. Marie posed significant logistical challenges due to their size and tolerances required for cyclical loading. Pinnacle Logistics orchestrated the planning of the transport, from route surveys and permitting to loading onto specialized trailers and transportation to the port. Despite delays caused by weather conditions, Walters Field Services and Pinnacle Logistics collaborated on navigating the complexities of the offloading process and final placement of the girders on-site.
Our collaborative efforts and extensive planning exemplify the importance of coordination in overcoming challenges in projects of this scale.
As the project advances, Walters Group remains committed to on time delivery and optimizing resources. Leveraging modular construction methods, the team maximizes safety, operational efficiency, and cost savings, setting a precedent for future endeavours in the steel construction industry.
Additional scopes awarded to Walters Group, including the installation of the Water Treatment Plant, Overhead Crane and furnace relining underscore our contributions to this transformative project.
As we continue to drive progress in constructing Algoma’s EAF building, the project moves closer to the goal of reducing carbon emissions in steel production.
Stay tuned for more updates!
Algoma Steel Inc.
JNE Engineering
BURNCO
Warfab
Nucor
Pinnacle Logistics
Lopes
Mammoet
Warren Fabricating & Machining Corporation
SIS Manufacturing Inc.
McKeil Marine Limited
Pioneer Heavy Haul Inc. for sharing the amazing footage.
Ironworkers Local 721 (Toronto)
Ironworkers Local 736 (Hamilton)
Ironworkers Local 700 (Ottawa)
Ironworkers Local 759 (Thunder Bay)
Editorial piece originally published by Oleksandr Slivinskyi on LinkedIn
