Client: Golden Aluminum
Location: Fort Lupton, Colorado
Completion: July 2025
Project Value: $1.2 Million
Project Overview
Industrial Constructors/Managers, Inc. (ICM) played a critical role in one of the most significant modernization efforts in Golden Aluminum’s 40-year history: the replacement of the plant’s original block caster with the innovative Nexcast™ system, which transforms molten aluminum into coil that’s used to produce lids for food and beverage containers. SMS group, a global leader in metals processing equipment, developed Nexcast™ as a next-generation casting technology designed to improve efficiency, reliability and long-term performance.
ICM was responsible for the complete removal of the plant’s original aging block caster and the installation of the new custom-designed system during a full production shutdown. With the caster serving as the foundation of the facility’s operations, the successful execution of this project was vital to securing the future of the plant and its workforce.
The Challenge
Golden Aluminum compressed the planned outage from three weeks to just two weeks, creating an aggressive schedule that demanded around-the-clock operations. Working alongside SMS group and Golden Aluminum personnel, ICM managed demolition, equipment installation, piping, structural modifications and mechanical integration within a highly active industrial environment.
The installation involved a first-of-its-kind equipment weighing more than 100,000 pounds and built to tolerances as tight as one to two millimeters. The project required meticulous planning, precision rigging and carefully coordinated crane operations within confined plant spaces. Adding to the complexity, the existing caster equipment had to be preserved and stored in the event the new system required modifications.
Innovative Solutions
To maximize efficiency and minimize downtime, ICM worked closely with project partners to complete extensive prefabrication and pre-assembly work before the shutdown began. Hydraulic and pneumatic systems were installed in advance, piping was pre-run, and assemblies were fabricated off-site whenever possible.
ICM also implemented several innovative construction techniques, including:
- Oxypropylene torch cutting to accelerate demolition while delivering clean, mill-quality cuts.
- Laser alignment technology to position structural steel beams within half a millimeter of required tolerances.
- Strategic preplanning and phased installation sequencing to maintain continuous productivity throughout the outage.
These efforts helped recover valuable schedule time and ensured the project remained on track despite the compressed timeline.
ICM Services Utilized:
Lasting Impact
Golden Aluminum has been a cornerstone employer in Fort Lupton for more than four decades, supporting approximately 200 local jobs. The successful completion of the Nexcast™ modernization ensures the facility can continue operating for another generation while advancing manufacturing innovation in the United States.
As one of only 33 companies nationwide selected to receive Inflation Reduction Act funding for the project, Golden Aluminum is now positioned to introduce its groundbreaking Nexcast™ technology to aluminum producers around the world, improving efficiency and productivity across the industry.
Client Testimonial
“From start to finish, ICM demonstrated the highest level of professionalism, skill and commitment on this project. The demolition of our old caster and the installation of our new Nexcast™ system were executed on schedule and to the highest standard of workmanship. Safety is always our top priority, and we are pleased to acknowledge ICM’s impeccable safety record throughout the project. Achieving this while working in such a complex and demanding environment is a testament to the team’s planning, discipline and safety culture.”
Jeff Frim, CEO & President, Golden Aluminum
