Air Separation Unit Facility Expansion
Kelley Construction delivered a high-impact, multi-scope civil construction package for the expansion of an Air Separation Unit (ASU) facility in the Clarksville, TN area, supporting increased industrial gas capacity to meet rising regional demand.
Over the course of nearly a year, Kelley successfully executed critical site development and structural foundation work in a challenging active plant environment. Crews worked through extreme seasonal conditions ranging from summer heat to winter snow, all while operating within a tight jobsite footprint shared by multiple trades and ongoing facility activity.
Kelley self-performed and managed a substantial scope of work that included placement of 10,000 tons of stone, nearly 12,000 cubic yards of soil excavation, installation of 420 tons of rebar, and placement of 3,500 cubic yards of concrete. The project featured a diverse range of complex structural foundations, including Cold Boxes, various Compressors, Skid and Pipe Racks, and Cooling Water Tower Foundations. In addition to the structural scope, Kelley delivered critical site infrastructure improvements such as stormwater piping and catch basins, ductbanks, grounding systems, gas and water line relocations, roads, truck loading scales, laydown areas, bollards, and fencing.
Execution required a high level of technical expertise, particularly in managing complex foundation geometries and monolithic compressor foundation pours within a live, space-constrained facility. Kelley also operated within a client-led just-in-time design framework, coordinating closely with the design team to keep construction moving efficiently by aligning field execution with phased document release. This approach allowed the project to start quickly while later design packages continued to develop.
Through disciplined QA/QC, strong safety leadership, and proactive subcontractor coordination, Kelley delivered seamless execution across every scope. The result was a successful, on-schedule project completed without compromising quality, safety, or performance.
