Phase 1 – new construction of mill

Rudolph Libbe Group was the first partner selected to manage this design/build¬†project for North Star BlueScope Steel’s massive 593,360-square-foot mini-mill in Delta, Ohio. ¬†It was completed on a¬†fast-track schedule over 16 months.

The initial project site consisted of 515 acres where over one million cubic yards of dirt was moved with the scale pit excavation measuring 400’ x 150’ x 50’ deep. Over 100,000 cubic yards of concrete were placed, making this the largest concrete project in northwest Ohio at the time with over 400 tradespeople employed. Five different concrete producers in the area were needed to complete the massive foundations.

The site and concrete work were followed by an award of the pre-engineered heavy structure erection package for the rolling mill.  Numerous additional work packages were awarded including mechanical and process piping, and electrical including instrumentation for the building and process.

The RLG fabrication shop was heavily utilized with two shifts per day supporting the re-work of pipe fabricated overseas which had been rejected due to quality issues. Outside of the direct contracts, RLG teams worked with vendors on the BOC oxygen plant and wastewater treatment facility, both key components for the mill.

PHASE 2 – $700 Million expansion

For Bluescope’s largest capital investment to date, the Rudolph Libbe Group was selected as the construction manager for a $700 million total program investment to expand North Star’s Delta facility. The expansion, known as Project Aristotle, increases hot-rolled coil production at the facility by 850,000 tons annually. Project scope included the addition of a third electric arc furnace, second slab caster and new shuttle facility, with spare capacity on the existing hot-strip mill.

Over 600 tradespeople worked on the site Рduring the 2020/2021 pandemic Рwhile the existing plant continued in full production mode.  RLG self-performed all major trade activities for the facility and a significant portion of the process work.  Construction also included:

  • A new tunnel furnace and slab transfer shuttle
  • New scrap building, bag house, and water treatment systems
  • New administration building and demolition of the existing
  • Multiple other site improvements

More than 600 total projects completed throughout the partnership

The relationship that began during the preconstruction phase of the original project has now spanned 27 years with continuous support at the plant. RLG’s Site Management team has an¬†in-house presence for on-going maintenance, down-day outages as well as small construction and larger capital projects. The Site Management team has managed emergency facility services as needed as well.


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