CCI Industrial Constructors (CCI) has been at the forefront of the bulk handling conveyor industry since 1997, delivering high-quality, comprehensive conveyor services. Our experience spans across multiple market sectors including – automotive, aerospace, power & energy, manufacturing, industrial process and water infrastructure. CCI specializes in turnkey industrial conveyor installation, maintenance and repair services.
With our self-perform divisions, CCI can control critical path construction disciplines which includes – civil and site utilities, concrete foundations, structural steel erection, machinery installation, heavy rigging operations, specialty welding and selective demolition. With a strong local presence and national strategic partners, CCI can mobilize high-performing teams where ever our clients need us to be.
Since its inception, CCI has built long-standing relationships with key industry partners, providing tailored construction solutions to meet evolving industry demands. What started as a local welding business has grown into a recognized leader in bulk material handling construction and maintenance.
In the early years, there were two key projects that were monumental in the expansion of CCI’s conveyor capabilities. The first project dates back to the late 90’s, where CCI received our first automotive project. Located at the Ford Flatrock Assembly plant, CCI was contracted to perform conveyor modifications and retrofits during a July shutdown. The project was performed working two shifts around the clock in order to achieve the shutdown timeline. The project team successfully performed on schedule with zero incidents. Earning the trust of our client and a long-term partnership. The second project was located at the DTE Monroe Power Plant dating back to 2012. Our team was contracted to install a new state-of-the-art Refined Emissions Fuel (REF) conveyor system. CCI’s self-perform team installed all conveyor trusses, components, hoppers, bins and structural steel. Critical to plant operations, this upgrade was a defining moment in CCI’s history that positioned us as a preferred contractor of choice within the industry. Not only did our teams execute these projects safely and within budget, we built lasting relationships through our leadership, problem solving and value engineering capabilities.
With a simple goal of delivering a higher standard of service for our clients, we have become a trusted partner for several facility owners and OEM’s supporting critical projects throughout Michigan as well as nationally.
CCI has played a significant role in major critical infrastructure projects, working with some of the most respected names in the industry. Our teams have executed projects ranging from large-scale material handling system installations and facility expansions to routine/forced outages.
Key Projects Include:
CCI served as the turnkey machinery and conveyor erectors for a new state-of-the-art shredding and conveyor separation system. Our client procured the new equipment in order to optimize scrap aluminum production operations. CCI has contributed to this groundbreaking endeavor with upfront detailed preconstruction efforts and self-perform conveyor installation services.
The system consists of over 30 oscillating conveyors, vibrators, separators and a main shredding mill. Raw scrap is loaded onto the conveyors which feeds the shredder. The shredded product is then emptied onto another conveyor equipped with a screen to remove dust and other foreign materials. From there, another conveyor takes the processed scrap to magnetic separators which deposit the finished product for quick and easy removal and storage.
“Our installation team has over two decades of experience constructing and maintaining conveyor systems across multiple industries” said Gary Garcia, Director of Projects.” “We have some of the top Millwrights and Ironworkers in the industry working for us. This project was a big win for our team and for the success of our client’s production operations. We’re honored that our client trusted us to take lead and look forward to continuing our relationship.”
CCI provided self-perform construction services for the Detroit Metropolitan Wayne County Airport (DTW) McNamara Baggage Handling System (BHS) Upgrade. The terminal upgrade included 11 domestic and 7 international baggage reclaim conveyor systems. The DTW airport has six runways, four concourses and 129 in-service gates. At nearly 1 mile in length, Concourse A in McNamara Terminal is the second-longest airport concourse in the world.
The project was completed in six separate phases. Removing and replacing two domestic and one international carousel’s per phase. CCI’s millwright division performed the demolition, layout, and installation. In addition, CCI provided warehousing and logistics services for each system. Our location to the airport, indoor storage and trucking capabilities offered our client just-in-time delivery and overall project control.
The terminal is now equipped with the latest technology along with improved capacity to support the high-density traffic throughout DTW. The energy-efficient drives are designed to optimize the overall life span of the system with the lowest practical maintenance frequency.
CCI was contracted to erect a new cogeneration power plant, a type of plant that produces both heat and power. This plant’s purpose is to help the Veterans Affairs Medical Center in Battle Creek, Michigan diversify its power & energy fuel mix with the goal of cutting the carbon footprint.
CCI’s scope of work included the installation of all mechanical equipment, heavy rigging and steel erection. This included numerous critical lifts that needed to be properly rigged, erected and commissioned for operation.
Unique to this project was the fuel source. The plant used recycled wood chips providing clean, renewable energy. The result was a reduction in greenhouse gases by approximately 14,000 tons per year (cutting 80% of the carbon footprint of the prior solution). The wood chips were placed in the storage basin where conveyors transferred the chips to the incinerator. As industry leaders in the bulk handling and power & energy sectors, our client selected our team for our industry expertise and past work history.
Through the high-quality and timely provision of our services, we helped our client and the VA to achieve their power & energy goals for the project. In addition, our team earned the trust and repeat business from both our client and the EPC.
Our industrial maintenance team has supported several shutdowns and outages for Cleveland Cliffs (Previously Severstal & AK Steel) over the years. The majority of the work performed took place at Dearborn Works in the Hot-Dipped Galvanizing Line (HDGL) and Basic Oxygen Furnace (BOF) sections of the plant.
CCI was awarded multiple scope packages on the HDGL, which included removal and replacement of furnace rolls, inspection, removal and replacement of bearings, replacement of down chute baffles, replacement of heat shields and fluid refill.
In addition, our team was awarded the BOF Electrostatic Precipitator (ESP) conveyor repairs and upgrades. The scope included removal and replacement of the drive motor, inspection, removal and replacement of bearings, removal and replacement of rollers and structural steel weld repairs. With specialty equipment, tools, and conveyor specialists, we offered our client a turnkey solution and responsive services.
Precision leveling and alignments were a critical component for the projects. CCI’s precision millwrights performed the leveling and aligning with our specialty precision instruments along with our senior millwright leadership.
The outages were all completed on schedule allowing plant operations to resume production as planned. In addition, all crew members performed the work without any near misses, incidents, or rework.
In 2012, CCI completed our first capital project, constructing the Refined Emissions Fuel (REF) Facility at the Monroe Power Plant. The first-of-its-kind facility provided a clean coal solution for the existing fuel handling operations. The project consisted of mechanical process equipment installation and structural steel erection. CCI’s self-perform divisions managed the installation of all conveyor galleries, hoppers, chutes, components and structural steel.
CCI provided self-perform construction services for the Charlotte Douglas International Airport terminal lobby expansion. The airport has 3 operating runways and one passenger terminal with 124 gates across five concourses. The scope of work consisted of upgrading outbound BHS belts associated with the Ticket Counter, Oversize, Curbside & FIS re-check / re-accommodation conveyor lines. In addition, upgrades to inbound systems were performed including – installation of new BHS incline plate claim devices, installation of (2) roller-bed conveyors for oversized baggage and installation of lower-level header steel, hanger supports and catwalks.
The entire project was completed on night shift to reduce the overall impact to the public. In addition, CCI provided warehousing and logistics management services for each system. Due to the project requirements, demolished and new material could not be staged within the airport. Our team worked closely with our partner to create a just-in-time delivery approach.
The terminal is now equipped with the latest technology along with improved capacity to support the high-density traffic throughout the airport. The state-of-the-art devices and components are designed to optimize the overall life span of the system with the lowest practical maintenance frequency.
CCI was contracted by our client to provide self-perform installation services for the Springwells Water Treatment Flocculator Replacement project. The Springwells facility is the systems second-oldest water treatment facility. At the time of its dedication in 1935, it was the largest water treatment facility in the world.
Due to the overall age of the system, a significant overhaul was required to achieve optimal efficiency and long-term reliability. The existing flocculation system, which provides critical functions in removing suspended solids in the basins, needed to be replaced due to significant operational inefficiencies. CCI’s success in securing the project award was due to a detailed means and methods execution plan. Due to the precise alignment requirements, traditional instruments could not be utilized. CCI’s plan included procuring specialty alignment and leveling instruments and producing third party engineered verification readings.
The scope of work included removal of the existing systems in Basins 5-8 and installation of new direct-drive variable speed paddle wheel flocculation systems. Each basin consisted of 5 stages with independent systems including, motors, shafts, bearings, arms, paddles, baffles and slide gates. Critical to the project success was precision layout, leveling and alignment. With extremely tight tolerances, a comprehensive execution plan was developed and approved by the GLWA engineers and OEM.
In addition to the alignment requirement, schedule was critical to the overall plan. In order to maintain commissioning dates, the field team adjusted to the site demands through constant manpower coordination and strict task planning. Our expertise working around live equipment and various trades enabled our team to complete the work safely without disrupting plant operations or other subcontract trades.
With specialty equipment, tools and millwright specialists, we offered our client a turnkey solution with proven performance. Our crew adapted to daily requests and delivered the project ahead of schedule allowing contractors to fully optimize the scheduled durations.
“Our installation team has a strong background in constructing and maintaining complex conveyor systems across multiple industries” said Gary J. Garcia, Principal & Director of Estimating. “We have top industry leaders that have been working for us 20+ years. The result is our clients receive high performing teams and the confidence that the project will get done right the first time.”
Safety remains at the core of CCI’s operations. Our organization has maintained a five-year average Total Recordable Incident Rate (TRIR) of ZERO, which is five times lower than the industry average. We’re also recognized for our outstanding safety performance, with an Experience Modification Rate (EMR) of 0.76.
Certifications and Safety Programs:
Awards & Accolades:
CCI continues to innovate and expand its footprint into existing and new market sectors. With a growing focus on new technology and advanced infrastructure projects, CCI is positioned to continue leading rewarding construction projects and deliver high-performance results.
As CCI moves forward, our strategy remains the same – to deliver high-performance construction services, maintain the highest standards of safety and quality, and support the industries that keep America moving.
