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Kaiser Alumina Refinery, Gramercy, LA
Forensic Analysis
Rebuild and Upgrade
$300,000,000
A 1999 explosion at the Kaiser Aluminum & Chemical Corporation (KACC) Alumina Refinery in Gramercy, LA destroyed substantial areas of the plant. Alumina production halted an extensive rebuild was necessary before production could resume. KACC saw this as an opportunity to update the refinery from its original 1950s technology. The upgrades would allow a higher percentage of alumina to be extracted from the bauxite.
KACC specified a fast-track design system (i.e., construction and procurement begin before the design is completed). Because it was imperative that alumina processing resume as quickly as possible, they also selected a multi-phase construction process so that parts of the refinery could remain operational.
Several disputes arose between KACC and the engineer, Hatch Associates, regarding the completion time and certain design issues. KACC asserted a claim against Hatch for damages arising from alleged delay and additional costs. Hatch engaged GREYHAWK to review the project record and to respond to KACC’s claim.
GREYHAWK utilized an electronic document database system to manage the massive quantity of project and discovery files. As a result of GREYHAWK’s discrete delay analyses, cost assessments and document management, our client achieved a favorable settlement through mediation.
- The KACC Gramercy plant site is 300 acres, and refines approximately 3,000 tons of alumina per day.
- GREYHAWK’s use of an electronic document database reduced the project file physical size from 400 banker’s boxes to a computer hard-drive.
- The electronic database was instrumental in providing immediate results for searching, sorting and reviewing project documents.
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