The Continuous Cast Facility is approximately 100,000 square feet with multiple levels in the melt furnace / casting area and a cut-off basement. The Maerz furnace is used for the scrap copper process and, as an alternative, the Southwire furnace is used for melting down clean copper wafers. The key components of the facility include the large melt furnaces (which are fed by large bucket elevators) along with refining and induction holding furnaces in preparation for casting. After the melting, a continuous ribbon of copper is cast and then cut off into billets by a flying saw in the basement. Billets are then transported for further processing and extrusions in the adjacent tube mill.
JESCO utilized a Design / Build approach to construct the manufacturing facility including the MEP system’s which entailed: inert gases, compressed air, furnace cooling water, electrical and controls. In addition, JESCO also set most of the casting equipment.