Esskay Structures Projects: Quality Steel Detailing Portfolio

GSR Arena

5100 Tons, 2025

The GSR Arena is a 10,000+ seat, 300,000 sq ft facility designed for concerts, basketball and multi-event loads. Such arenas require long-span roof structures and raker beams to support steep seating bowls. A roof system of this span typically requires long-span trusses or space frames, deep connections and sequencing that keeps the erection stable during construction. Structural expansion joints must accommodate differential movement between the new arena and older structures.

SL Bees Stadium

1000 tons, 2024

The Salt Lake Bees is a modern baseball stadium with a capacity of 6500 seats and stunning views of the Wasatch. This stadium consists of Roof structures with concession areas.

Stadium (Confidential)

5400 tons, 2020

Louisville City Stadium

1200 tons, 2018

Stadium (Confidential)

13500 tons, 2018

Tulsa Gateway - Williams Crossing Pedestrian Bridge

1200 tons, 2021

The pedestrian bridge provides a safe and modern crossing between the east and west sides of the Arkansas River. It is located 45 ft (13.7 m) above the Arkansas River.

This bridge is 1,440 ft long and is supported by eleven 120 ft-long arch spans and an approach span. The semi-integral bridge was designed with extremely slender deck-stiffened arches built from a 3-1/4″ plate of weathering steel and is curved in plan.

It is the longest arch-type pedestrian bridge in the United States and the first multi-span, plate arch bridge built in the US.

Red Purple Bridge, Chicago

1255 tons, 2020

The Chicago Transit Authority (CTA) completely rebuilt the northern portion of the Red Line from Belmont station to Howard station and the Purple Line from Belmont station to Linden station. The Red and Purple Modernization (RPM) Program replaces the old, deteriorating infrastructure and stations along Chicago’s busiest rail line, paving the way for CTA to significantly increase train capacity and improve service for generations to come. Esskay executed the detailing of this prestigious project and delivered it ahead of schedule.

Lakefront Trail Phase 3

400 tons, 2018

41st street Pedestrian Bridge

680 tons, 2018

The 973.5 ft. long, $28.7 million “41st Street Bridge” received the AISC award for the best bridge under the Special Purpose Bridges category for 2020.

It features double-curved arch mono trusses to form large, graceful S-curves. The bridge contains three segments in its total span. The segments are called East & West Approaches at the ends and the Main span in the middle.

Main Span

The main span has two spans with a length of 239 ft 5 inches and is supported at both ends & middle. It is suspended on both sides of the middle support by using the Arches and suspended Hangers.

The Arch is fabricated from a 48-inch diameter steel pipe with 1 inch thick and mounted over the Thrust block. The Main Rib 48 inches & Arch location are changed to follow the S-curve. The suspended hangers are connected from the Arch to the Main span Ribs.

East West Approach Spans

The bridge’s central Rib is fabricated from a 30-inch diameter steel pipe, either 1 ¼ inch or 1 ¾ inch thick depending upon span and strength requirements. At the top of the pipe, shear studs are added, which enable composite action between the steel and the path’s 8-inch thick, 17 ft wide concrete deck.

Lakefront Trail Phase 1

450 tons, 2018
The 1,750 ft. long, $60 million “Navy Pier Flyover” is a popular cycling, walking and running venue.

With many site constraints and limited clearances, a meander (bend or curve or spine rib or roller coaster) form was essentially the only option for the grade-separated pathway. A dramatic steel spine-rib superstructure support achieved the objectives of both form and function. The longitudinal spine-rib support system accommodates the complex bridge’s need to curve both horizontally and vertically and provides the desired aesthetics.

The bridge’s central spine is fabricated from 30 inch diameter steel pipe, either 1 ¼ inch or 1 ¾ inch thick depending upon span and strength requirements. A T-shaped web and flange are welded on top of the pipe to provide added strength and a surface for shear studs, which enable composite action between the steel and the path’s 6 inch thick, 17 ft. 10 inch wide concrete deck. Rib elements, fabricated from steel plates, are connected to each side of the steel spine on 8 ft. centres, tapering in depth from approximately 2 ft. 2 inch at the central spine to less than 5 inch at the outer deck edge to create a sleek, graceful appearance. A longitudinal steel channel, running parallel to the steel pipe spine, is supported by steel columns created from 1 ¼ inch steel plate bent into a 30 inch by 22inch elliptical shape. The elliptical column extends 2 ft. below the bottom of the spine before separating into two half-elliptical column legs that splay apart to create a wider base for additional stability.

Confidential Airport Concourse

7450 Tons, 2026

Constructing a large, modern unified headhouse spanning T4 and T5. Terminal 5 must meet modern California building code and airport seismic criteria, which are stricter than many U.S. regions. Long-span terminal roofs must incorporate seismic drift management and flexible joints. Construction must comply with CalGreen and high energy‑efficiency mandates, impacting mechanical and structural coordination.

Confidential - Phase II

1808 tons, 2025

The project included partial demolition and renovation of the Concourse, renovation of the interiors of the West Ticketing Building, realignment of Taxilane C9, and providing seismic resilience and structural safety. The entire work was done in accordance with the California Building Standards Code and American Society of Civil Engineers (ASCE) standards.

Confidential Terminal 3 -Modernization

6550 tons, 2024

This project entails the Extension of Terminal 3 in Arrival, Departure, Mezzanine and Roof Levels for the East and West Addition. In this project new steel structures, retrofitting the existing structures, the Superhighway, skylight and penthouse structures were in our scope.

Midfield Satellite Concourse

1300 tons, 2023

This will add approximately 150,000 square feet and eight gates for narrow-body aircraft. Used a first-of-its-kind construction technique called Offsite Construction and Relocation (OCR). This OCR technique is both innovative and adaptive. Our detailing team supported the project and completed it in record time.

Confidential Airport - Phase 4

3,800 Tons, 2023
Salt Lake City

The expansion, Phase 4 of the new Airport Redevelopment Program, will feature new gates, flexibly designed to accommodate both narrow- and wide-body aircraft. The Concourse B-east addition will add 317,000 square feet on three levels and bring the total number of gates to 94. The steel structure of this project weighs over 3,800 tons. The planned public spaces include passenger amenities, airline gates and hold rooms, public restrooms, and a variety of lease spaces totaling 39,500 square feet of new concessions space.

TESLA GFTX DAT-202 Data Center

8750 tons, 2025

This is a unique, state-of-the-art data center. The steel structure weighs over 8750 tons. The building is covered with IMP panels supported by girt structures running around the perimeter.

IAD 350 Data Center

2200 tons, 2025

This six-sector data center building features a steel structure weighing over 2,200 tons. It is covered with panels, supported by embeds, with beams running around the perimeter. The building is separated by expansion joints. The exterior includes a substantial amount of galvanized steel to support the generator, which is enclosed by a screen wall with posts and beams.

Iron Mountain VA8 & VA9

1649 Tons, 2025

Iron Mountain Data Centers operates a global colocation platform that enables customers to build tailored, sustainable, carrier and cloud-neutral data solutions.

The project is a two-story data center and office building with an approximate 339,744 sf gross
Area. Construction will include the core and shell of the building; (2) data halls at level 1 and (2) data
Halls at level 2 with supporting electrical and mechanical rooms, exterior service yard, and
Roof equipment platform to support the 60 MW critical load planned, and admin areas
Including lobby, security, loading dock, conference rooms, break areas, office areas, and
Restrooms with supporting mechanical/electrical and network spaces.

The building structure is precast concrete. The data center envelope is an insulated precast
Concrete and the office envelope is a combination of an insulated metal panel and a curtain wall.

Prime Data Center

3000 tons, 2023

This project is a Seismic structure with complicated SLRS connections, BRB braces, and heavy beams and columns. All the mechanical structures are situated on the roof of the building, so the joist is avoided.

Stellantis/LG Energy Windsor Battery Plant

20750 tons, 2023

This is a Stellantis group’s Battery Plant. There are Channel girts all around the building. Trestle arrangement is a unique requirement in this project.

S-JV Hyundai Formation Building

9300 tons, 2023

Project Star

20,000 tons, 2022

This is a large Battery plant. It is the first large-scale, domestic electric vehicle battery manufacturing facility on a 70-acre property. The steel structure weighs over 20,000 tons. The building is covered with IMP panels supported by girt structures running around the perimeters. It’s a complex job with heavy structural braces and parapet support steels, with a bridge connecting the intermediate buildings. It is a state-of-the-art plant and a challenging project.

FORD TEVC Paint Shop

7500 tons, 2023

Ford TEVC paint shop is situated in Stanton, Tennessee. This project weighs over 7,500 tons and this new building was constructed for the painting of automobile components.

HMGMA WORKS PACKAGE

8000 tons, 2022

This is an assembly shop for an auto major in Georgia, on a floor area of about 1.2 million Sq.ft. The workshop comprises various types of structural roof trusses, supporting columns, and miscellaneous steel. The total steel is around 8,000 tons.

MICRON TRITON - PROBE

8000 tons, 2024

This is a $15 billion project to expand its fabrication plant and increase research and development space. It will combine 8,000 tons of steel to build 15 new buildings. The new plant would have one of the state’s largest-ever office buildings, a 2,800-space parking garage, a water treatment plant, and more.

MICRON TRITON - HPM

5000 tons, 2024

The project will combine 5,000 tons of steel to build a portion of the 15 new buildings. This consists of office buildings, a parking garage, and a water treatment plant.

Texas Instruments

34370 tons, 2024

TI is a new 300-millimeter semiconductor wafer fabrication plant in Lehi, Utah. The new fab (LFAB2), currently under construction, will connect to the existing fab (LFAB1) in the heart of the Silicon Slopes. The 2 plants will manufacture tens of millions of analog and embedded processing chips every day that will go into electronics everywhere.

ALPHA

20000 tons, 2023

This fast-track project was issued for approval within a period of two months. Despite many amendments, the project was delivered on time with quality drawings. Fieldwork drawings (due to continuous revision of contract drawings after approval) were well coordinated and delivered successfully.

UNICORN

14,500 Tons, 2026

Project Unicorn building represents industrial steel structure designed to support high-precision data center. Total structural steel weights approximately 14,500 tonnes and the building incorporates 484 side plate connection . Due to the massive footprint and heavy operational loads, the building utilizes a complex structural steel framing system that ensures stability, load distribution, and support for equipment and mechanical infrastructure.

VMS4 TransLink OMC4

900 Tons, 2025

TransLink’s OMC4 is a major new Operations and Maintenance Centre designed to support the growth of Metro Vancouver’s SkyTrain network. It is located at 225 North Road, Coquitlam and will support the incoming Mark V trains.

Key Technical / Steel-Structure Information

Large steel-frame structures form the vehicle maintenance shop, inspection bays, and a flyover track connection to the guideway.
A 55,000 sq ft steel-framed building is part of the overall system upgrades. [buzzer.translink.ca]
Construction involves:
- New guideway built adjacent to the existing line
- Steel-framed building
- Structural capacity for 145–170 railcars

Saronic Gator Bay Shipyard

3300 Tons, 2025

Saronic Gator Bay Shipyard is an autonomous shipbuilding facility comprising four buildings—one standalone structure and three interconnected buildings—utilizing approximately 3,300 tons of structural steel. The project features braced connections in intermediate bays, integrated office mezzanine floors, an observation deck area, and crane monorail systems spanning across the building bays to support operational efficiency and heavy industrial functionality.

Aligned Energy

3300 tons, 2023

It included seismic BRB bracings. complicated tilt-up wall panels, hung panels, and expansion joint coordination. It also involved various mechanical equipment, and a chiller plant above the Roof structure. This project was completed before schedule with high-quality drawings.

K+S Potash

8000 tons, 2016

This $4.1 billion Legacy green field mega-project is the first new potash mine in Saskatchewan in over 40 years. The project was commissioned in 2016. The scope of this project included the main process buildings, which comprise nine major industrial structures. In addition to the steel structure, the project included rough-setting approximately 515 pieces of equipment and ninety large pipe/electrical modules.

Our scope consisting of four buildings weighing 8000 tons, was received in July 2014 and completed in 6 months, including 15% change orders. These equipment support structures typically included main steel, complex miscellaneous steel, Handrails, Stairs, Cage ladders, Safety gates, Removable gates, Checker plates, etc. All connections were fatigue-critical connections and therefore exceptional care had to be taken to meet this requirement.

Northwood Long-Term Care

710 Tons, 2025

This four-storey long-term care facility is organized around a central core with four extending wings, forming a highly distinctive and non-conventional architectural geometry. The design moves beyond traditional institutional models, establishing a strong identity while supporting clarity of movement, access to daylight, and a human-scaled environment.
The building’s geometry is fundamental to its design and directly informs its structural strategy. Steel construction is pushed to its limits, requiring exceptional precision in design, fabrication, and assembly to achieve the intended form. Structure and architecture work as a single system, where accuracy and performance are essential to realizing the project’s vision.

Convention Center Confidential

22,500 Tons, 2025

This expansion is designed to become an architectural showpiece when completed. Two areas in particular present significant design challenges:
Skynode Atrium and Multipurpose Level – A visually striking architectural feature that requires advanced coordination due to its geometry, glazing, and structural integration
Being in a high‑seismic zone adds another layer of complexity, requires robust structural detailing and enhanced coordination between architectural, structural and MEP disciplines.

Hard Rock Hotel and Casino

4295 tons, 2024

The iconic Mirage Hotel & Casino is rebranded and renovated into the new Hard Rock Hotel & Casino. This new venue will offer luxury accommodations, gaming, dining, and entertainment.

COLBURN HIGH SCHOOL CAMPUS

1,800 Tons, 2024
Los Angeles

Colburn School campus expansion is a new 100,000-square-foot addition to Colburn’s existing campus in downtown Los Angeles. The building includes built-up box columns, box beams, brace frames, and moment frames. The building features a series of four radial frames with raker beams, enabling gallery seating arrangements. Built-up balconies and cloud-hanger coordination are examples of architecture. Aside from that, the building consists of the following coordination: safety anchor, curtain walls, elevators, and staircase.

Peninsula Innovation Point

2000 tons, 2023

Peninsula Innovation Point is a new eight-storey, high-rise, steel-framed commercial building. The building has a rooftop mechanical penthouse, roof screen, loading dock, and terraces at multiple levels. The parking structure has a partial exterior cladding that complementing the office building.

Missouri Botanical Garden (MOBOT)

2100 tons, 2020

MOBOT is the oldest Botanical Garden in St. Louis, USA. It has a long history in Plant Science Research. In 2020, Esskay was entrusted with the complete Detailing of the New Visitor Center, the gateway for more than one million visitors annually. The design reflects the bold, transformative vision of MOBOT. The project had a lot of challenging architectural designs and has won many awards. Esskay is proud to be associated with this Iconic Project.

W&M Fine and Performing Arts Center

1800 tons, 2020

Detailing for this project was awarded in 2020. It comprised of the renovation of an existing Theater and a new Music Building, in Virginia. The existing theatre was converted from a 750-seat capacity to a 500-seat capacity. The new music building is a 450-seat Concert Hall and a 125-seat Recital Hall. It was a challenging project with a lot of site coordination and architectural and miscellaneous detailing.

Rainbow

4250 Tons, 2025

Fedex Indianopolis Facility

18500 tons, 2024

AMAZON FULFILLMENT CENTER PROJECTS

111674 tons

PROJECT DIAMOND (SEISMIC)
PROJECT DIANA
PROJECT BIG BIRD (SEISMIC)
PROJECT BOLTS
PROJECT BAICY (SEISMIC)
PROJECT SUGAR
PROJECT ALICE

5 floors & Mezz
Composite joists
Tilt-up wall panels
Scope includes ALL misc. steel
Scope includes connection design
Top-down erection

STACK: SVY 01D, SVY01F & SVY01C

10,000 Tons, 2024,
San Jose, CA

This is a Data Center and has 3 buildings named as SVY01D, SVY01C, and SVY01F. The buildings SVY01D and 01C has a 4-storey structure with SLRS members, BRB framings, and an equipment platform at the roof and are surrounded by Screen wall frames. The exterior of the building is covered with EIFS/Metal panels and Glazing walls. Also, these are structures with SLRS members with BRB connections and have a loading dock and Generator yard, supported by steel framings.

Fedex Outbound Sort Facility

5000 tons, 2022

All moment connections were SidePlate connections type.

Advance Manufacturing Facility

520 tons, 2020

This is a Warehouse project. It comprised a little over 600 tons of Steel. Esskay did the Structural & Miscellaneous steel. Yet another project was completed on time.

Cedars-sinai Medical Center

5200 tons, 2025

The new Cedars-Sinai Marina building will replace the existing two-story hospital that has served the community for over 50 years, with a modern eight-story tower rising prominently above the street.

BJC Institute of Health

2000 Tons, 2021

The vertical expansion of the BJC Institute of Health, involved the addition of six steel-framed floors above the existing structure.
The project presented several structural challenges, including complex connections at existing column splice locations and the integration of a newly added elevator shaft extending from the ground level through the expanded structure. These conditions required careful coordination between detailing, fabrication, and field erection to ensure accurate alignment and successful integration with the existing building framework.

Mercy hospital

1700 tons, 2019

Mercy Hospital is one of the largest groups of multi-speciality hospitals serving low-income groups across 4 States in the US. Esskay took up the detailing of the complete project expansion at the St. Louis facility in the year 2021. This included about 1700 tons of Structural and Miscellaneous Steel. This included some challenging miscellaneous work with a long-span camber truss. The Project was completed on schedule, despite a lot of challenges.

HCA Plaza Medical Center

1000 tons, 2017

The 3-storey building had over 2000+ drawings. This project involved lots of coordination work with the back-feed area steel and with an adjacent existing building.

SSM SLU HOSPITAL

5000 tons, 2017

SSM Health Saint Louis University Hospital, is a $550 million academic medical centre in the City of St. Louis. It is a 316-bed, 802,000-square-foot replacement hospital and an outpatient care centre.

The total tonnage of the steel structure is 4,700 tons. The columns & beam in the tower buildings are defined as heavy sections with CVN requirement. Some of the base plates are 4” to 6”thick.

The complexity of the job lies in the wall systems with bump out slabs. The walls are different type with glass mullions, terracotta walls & stone walls around the podium level with steel hanging supports.

This design and build project consist of three separate buildings:

Patient tower building (Total nine floors with roof, penthouse & penthouse Roof.)
Commons Building (Two floors with Roof & a monumental stair)
Addition Clinical Care building (Three floors & a roof)

We have delivered

2000+ Projectsin the USA

Our Projects

Esskay Structures Inc.

2950, Short Court, Vienna, VA 22181 USA

Contact Us

GSR Arena

5100 Tons, 2025

SL Bees Stadium

1000 tons, 2024

Stadium (Confidential)

5400 tons, 2020

Louisville City Stadium

1200 tons, 2018

Stadium (Confidential)

13500 tons, 2018

Tulsa Gateway - Williams Crossing Pedestrian Bridge

1200 tons, 2021

Red Purple Bridge, Chicago

1255 tons, 2020

Lakefront Trail Phase 3

400 tons, 2018

41st street Pedestrian Bridge

680 tons, 2018

Main Span

East West Approach Spans

Lakefront Trail Phase 1

450 tons, 2018 The 1,750 ft. long, $60 million “Navy Pier Flyover” is a popular cycling, walking and running venue.

Confidential Airport Concourse

7450 Tons, 2026

Confidential - Phase II

1808 tons, 2025

Confidential Terminal 3 -Modernization

6550 tons, 2024

Midfield Satellite Concourse

1300 tons, 2023

Confidential Airport - Phase 4

3,800 Tons, 2023 Salt Lake City

TESLA GFTX DAT-202 Data Center

8750 tons, 2025

IAD 350 Data Center

2200 tons, 2025

Iron Mountain VA8 & VA9

1649 Tons, 2025

Prime Data Center

3000 tons, 2023

Stellantis/LG Energy Windsor Battery Plant

20750 tons, 2023

S-JV Hyundai Formation Building

9300 tons, 2023

Project Star

20,000 tons, 2022

FORD TEVC Paint Shop

7500 tons, 2023

HMGMA WORKS PACKAGE

8000 tons, 2022

MICRON TRITON - PROBE

8000 tons, 2024

MICRON TRITON - HPM

5000 tons, 2024

Texas Instruments

34370 tons, 2024

ALPHA

20000 tons, 2023

UNICORN

14,500 Tons, 2026

VMS4 TransLink OMC4

900 Tons, 2025

Saronic Gator Bay Shipyard

3300 Tons, 2025

Aligned Energy

3300 tons, 2023

K+S Potash

8000 tons, 2016

Northwood Long-Term Care

710 Tons, 2025

Convention Center Confidential

22,500 Tons, 2025

Hard Rock Hotel and Casino

4295 tons, 2024

2000+ Projects
in the USA

2950, Short Court,
Vienna, VA 22181
USA

450 tons, 2018
The 1,750 ft. long, $60 million “Navy Pier Flyover” is a popular cycling, walking and running venue.

3,800 Tons, 2023
Salt Lake City

1,800 Tons, 2024
Los Angeles

10,000 Tons, 2024,
San Jose, CA