New Shell Plant Construction Packages

Monaca, PA
Location: Monaca, PA
Owner: Shell
Construction Company: Fay
Project Status: Completed in February 2019

Fay was heavily involved in the construction of Shell’s new ethylene cracker plant in Beaver County, PA for over six years. Construction for this project began with two riverfront docking/bulkhead facilities that allowed for the delivery and unloading of prefabricated modules. Due to Fay’s strong performance working with the client, quality workmanship and ability to hit schedules, we secured the main site works package and substantial additional site work that focused on various concrete and grout scopes, along with site indirect maintenance work. Our services on this project included excavation, backfill operations, and piling at numerous locations—the ethylene cracker unit, cogeneration area, outside battery limit, and polyethylene units one, two and three.

Fay won Bechtel’s global supply chain excellence award two years in a row on this project.  At its peak, Fay employed over 250 personnel, including operators, laborers, teamsters, carpenters, cement masons, iron workers and supervision.

Your scope of work has increased significantly throughout the duration of the project, which is a reflection of your capability and consistently high performance.
- Erin Young, Purchasing and Expediting Manager

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An aerial view of the ongoing construction; according to Governor Tom Wolf, the construction of the Shell ethylene cracker plant was Pennsylvania's largest industrial project since World War II.
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An aerial view of the Shell plant early in its construction.
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Early construction of Fay's marine package; this picture shows the installation of piling for the load on-load off (LOLO) dock.