Each diffuser casting features seven fi ns that taper from 4 in. to 1 in. The casting required 24 cores.
2009), so it used the early contractor involvement (ECI) method during the design, bid and build phases to push the project forward. With just 20% of its plans and specifi cations in place, it began soliciting interest from potential builders to join the project and help with the design. “I use the term miraculous when I think of all the eff ort and entities involved [to meet the timeframe],” Connell said. “T e interesting thing with the ECI method is you don’t have to wait for complete designs to start work. As soon as we had a site plan package ready, the contractor was issued the site package and could start clearing the land without having the foundation package fi nished or fi nal pump station design.” Because the pumping equipment
required a long lead time, the Army Corps of Engineers listed pump pro- curement as a separate contract, which was issued before a notice to proceed on the rest of the project. Each of the 11 pumps, produced
by Fairbanks Morse/Pentair Water, Kansas City, Kan., contain around 100,000-lbs. of castings, supplied by a handful of metalcasters throughout the U.S. Bay Cast Inc., Bay City, Mich., produced 20,000-lb., 120-in. diameter stainless steel propellers, as well as 11,500-lb. housings for each pump. High on the list of qualifi cations for the casting supplier was the ability to meet the delivery date. “We were qualifi ed to do the job, and the customer liked knowing that this would be a big project for our business, so we would be responsive to their needs,” said Max Holman, presi- dent and part owner of Bay Cast. “It was a benefi t to be a family business.” When Decatur Foundry Inc., De-
catur, Ill., took on the job to produce 11 inlet castings, it was committing to providing one 10,000-lb. casting a week to meet Fairbanks Morse’s machining pump assembly require- ments, starting in the spring of 2010, according to Terry Young, president of
38 | METAL CASTING DESIGN & PURCHASING | May/Jun 2012
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