Follansbee, West Virginia

Coke Battery Rebuild

Client / Owner

Mountain State Carbon LLC

Architect / Engineer

R.T. Patterson Co.




Graycor Industrial

Project Scope

Graycor Industrial completed a coke battery rebuild for Mountain State Carbon, a joint venture between Wheeling-Pittsburgh Steel and Severstal, NA, at the Follansbee, West Virginia plant. Graycor′s scope of work for the project included complete through-wall repairs for 39 oven walls and end-flue repairs for the remaining walls. Structural and collecting-main upgrades, installation of gas collection piping, and replacement of coke side and pusher side benches were also part of the contract.

Throughout construction, the battery had to remain in operation, which required significant coordination with the plant′s operations in order to schedule repair work. During rebuilding, battery walls had to remain hot to ensure no contraction would occur. This made demolition and rebuild activities at adjacent work areas very challenging. So Graycor designed and installed a temporary support bridge over the functioning facilities, to allow simultaneous construction and plant operations.

The Graycor Industrial team self-performed battery brick work and was responsible for heating the repair areas during construction, which required around-the-clock temperature monitoring.