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SunCoke Energy

RailWorks constructed five crane rail systems at the new coke-manufacturing plant.
Project Highlights 
  • Installed 17,400 linear feet of crane rail
  • Welded into place 4,400 No. 175 rail clips
  • Met all accelerated schedule deadlines
Granite City, Illinois
Gateway Energy and Coke Company, a subsidiary of SunCoke Energy
Business Unit 
RailWorks Track Services
Project Description 

RailWorks crews constructed five crane rail systems in a new coke-manufacturing plant operated by Gateway Energy and Coke Company.

Project Scope 

RailWorks served as subcontractor to Kokosing Construction Company, installing 17,400 linear feet of crane rail as part of the construction of a new Gateway Energy and Coke plant supporting the US Steel manufacturing facility in Granite City, Ill. Crews built five rail systems to carry tripper cars, quench cars and other machinery used along the plant’s conveyor system for transferring coke from one processing phase to the next. Besides installing rail and welding 4,400 No. 175 rail clips, the crew met accelerated schedule deadlines through diligent coordination with the prime and subcontractors in a highly congested construction site.

Unique Features 

Equipment traveling on the rail installed by RailWorks serves 120 heat-recovery ovens that have the capacity to provide 650,000 tons of coke annually for U.S. Steel’s neighboring Granite City Works facility. In addition to producing metallurgical coke, the ovens generate energy; their waste steam is captured and converted to electricity also used at Granite City Works.

The Railworks crews had to modify their standard railroad construction methods, and specialized materials were required to meet the job’s unique construction specifications. For example, shortened and lengthened gauge rods were necessary to accommodate the unique gauge of the tracks.

Other participants 
RailWorks served as a subcontractor to Ohio-based Kokosing Construction Company Inc.