The Senior Engineering Manager of a major cement producing plant called with a dilemma. He needed new, hot gas ducting fabricated within six weeks, but engineering drawings were still being drafted. The challenge: to build from final drawings as they became available, maintain product integrity and still complete the project in the allotted time.

We had worked with this client on previous projects, but this was the largest and most complicated to date. Based on our past performance, our client was confident we were up to the challenge.

Following our estimating procedure, we reviewed the preliminary drawings with our engineering and estimating staff and calculated the materials for purchase, including hardware requirements. We quoted a price for 100,000 lbs of steel to get the job started.

Next we held a production review meeting with the Plant Manager, Shop Foreman and Estimating Manager to review the project and schedule. As always, one person was placed in charge of the contract from start to finish; in this case, our Estimating Manager.

Our purchasing agent bought enough steel to complete the work for which we had received drawings. We obtained mill certification so the client would know the origin of each piece of steel, its exact composition, grade and stresses. The client's Senior Engineering Manager dropped by our facility frequently and attended in-process quality control tests and inspections.

We worked with their engineering group as design changes were completed. In some cases, we supplied "as built" drawings for problems that were solved on the shop room floor and approved by the Senior Engineering Manager during his visits.

Experience told us that typically, as final drawings came in, the project would mushroom in size. In the end the job grew to four times its original size, using 400,000 lbs of stainless and mild steel. To handle the added shop workload and stay on schedule, we implemented an additional weekend shift. We purchased more steel as required, and did the finishing touches in house, including sand blasting and painting in our paint shop.

Although we weren't contracted to install the ducting, our staff did a trial fit in our yard to ensure that the on-site assembly would go smoothly. Our client was impressed that despite the challenges and growth of this project, all ducting was completed and delivered on schedule.