Lehigh Heavy Forge

Bethlehem, PA

Client: Alvin H. Butz Inc.
Owner: Lehigh Heavy Forge Corporation

Lehigh Heavy Forge is a producer of a full range of custom open die forgings for the metalworking, pressure vessel, power generation, industrial equipment and machining industries -- in addition to manufacturing propulsion shafts for the military. Their 40-foot high, 10,000-ton press, which is capable of forming ingots of 600,000 pounds, is the largest open die forge in the Western Hemisphere. In June 2001, a fire broke out in the hydraulic forging press area. Immediately after it was extinguished, BIA was called in to provide a structural evaluation of the 100-by-80-foot building. Working in close association over the next week with the facilities manager at Lehigh Heavy Forge and Alvin H. Butz, Inc., the construction manager, BIA developed a plan for repair. The repair and reconstruction continued throughout the summer, with the BIA project manager spending many hours at the site. Part of the plan included keeping the smaller forge, which was undamaged, in production throughout the construction that restored the 10,000-ton forge to operation. BIA is proud to be part of the project team that put the forge back into operation in time to meet a multi-million dollar government contract.

Design Dates: Summer 2001
Construction Dates: Summer 2001
Service Dates: Fall 2001