Turnkey EPC & OEM Solutions for Industrial Metals Processing
The metals and materials industries are the backbone of global manufacturing and infrastructure, driving everything from construction and automotive production to renewable energy and advanced technologies. Yet these operations face mounting challenges—tightening emissions standards, the push for energy efficiency, and the urgent shift toward sustainable practices such as Green Steel and Direct Reduced Iron (DRI).
For over 35 years, IAC has partnered with iron and steel producers, foundries, smelters, and nonferrous processors to engineer, build, and maintain high-performance systems that keep plants compliant, productive, and future-ready. As a vertically integrated EPC contractor and OEM, we bring together engineering, equipment, construction, and lifecycle services under one roof, ensuring seamless execution and long-term reliability.
Whether supporting a greenfield melt shop, retrofitting smelting operations for better emissions control, or integrating advanced material handling systems, IAC delivers the solutions metals producers need to meet today’s demands while preparing for tomorrow’s sustainability goals.
Core Challenges in Metals Processing
Producers in the metals and material processing industries operate in some of the most demanding environments in the world. From iron and steel mills to foundries and smelters, facilities must balance high throughput demands with stringent regulatory compliance and evolving sustainability goals.
High-Temperature Emissions Control
Melt shop operations – including electric arc furnaces (EAFs), basic oxygen furnaces (BOFs), and ladle metallurgy furnaces (LMFs)- generate extreme-volume, high-temperature exhaust. Controlling particulate, VOCs, and acid gases at this scale requires large-capacity, high-efficiency baghouses and ducting systems capable of sustained operation under heat, abrasion, and chemical exposure.
Fugitive Dust and Material Handling
Ore, scrap, fluxes, and alloy additives must be moved efficiently while preventing dust escape at every transfer point. Pneumatic and mechanical conveying systems, integrated with dust collection, keep production flowing while protecting worker safety and air quality.Energy and Throughput Optimization
With volatile energy prices and ambitious output targets, producers need thermal and process systems that reduce kWh/ton and BTU/ton. Retrofit programs for dryers, baghouses, and handling systems can deliver double-digit throughput gains without additional fuel consumption.
Regulatory Compliance and ESG Pressures
Metals plants must meet increasingly stringent environmental standards, from NESHAP and OSHA in the U.S. to global ESG reporting requirements. Compliance is no longer limited to stack emissions—it includes fugitive dust, noise, and lifecycle energy use.
Transition to Green Steel
Emerging hydrogen DRI and renewable-powered EAF projects bring new engineering demands. Heat recovery, biomass integration, and closed-loop materials handling must be designed from the outset to meet carbon reduction goals without sacrificing reliability.
IAC Core Capabilities for Steel Mills, Foundries, and Metal Processors
IAC delivers engineered systems and field-proven technologies that address the demanding conditions of metal production and processing. Our solutions support clean air compliance, reliable material movement, and stable furnace and dryer performance across primary steelmaking, secondary metals, and non-ferrous operations.
Melt Shop and Furnace Ventilation Systems
Designed for EAF, BOF, ladle metallurgy, and casting areas. Our team integrates canopy hoods, fourth-hole capture, and building ventilation with high-capacity baghouse systems to control fume and heat effectively.
High-Temperature Baghouse and APC Systems
Engineered for metal fume, slag dust, and abrasive particulates. IAC supplies M-Pulse and reverse air baghouses, cyclone pre-cleaners, and complete ductwork and stack systems sized for large-volume gas handling.
Pneumatic and Mechanical Conveying
For fluxes, alloy additives, mill scale, dust, pellets, and recycled metals. Systems include dilute phase, dense phase, screw conveyors, bucket elevators, and rail or truck loadout.
Thermal Processing Equipment
Including rotary dryers, coolers, and calcining systems for ore concentrates, pellets, recycled by-products, and other heat-sensitive materials.
Automated Control Systems
That integrate furnace, baghouse, dryer, and material handling operations for consistent performance and improved safety. Remote monitoring options provide real-time diagnostics and alerts.
IAC’s integrated capabilities give metal producers a single source for clean air systems, thermal processing, material handling, and long-term service support. Our engineering depth and field experience help steel mills, foundries, and non-ferrous facilities improve reliability, control emissions, and keep critical production assets running safely and efficiently.
IAC Solutions for Industrial Metals
IAC delivers end-to-end engineered systems that address the most demanding operational and compliance requirements in metals production and processing. As both a turnkey EPC contractor and OEM manufacturer, we combine in-house engineering, fabrication, construction, and commissioning to deliver integrated solutions built for performance and longevity.
Iron & Steel (Including Green Steel & DRI)
- Melt Shop Ventilation – Reverse air and pulse-jet baghouses, canopy hoods, and building ventilation to control emissions from EAFs, BOFs, and ladle metallurgy.
- DRI and Green Steel Support – Pneumatic dust handling, railcar loadout, and alloy additive systems designed for hydrogen-ready and decarbonized operations.
- Proven EPC Execution – Experience delivering some of the world’s largest melt shop baghouses and ventilation systems for leading steelmakers like Nucor and Steel Dynamics
Foundries
- Dust Collection – Custom baghouses sized for melting, pouring, shakeout, and sand handling processes.
- Material Handling Integration – Pneumatic conveying and silo systems for sand, additives, and raw feed.
- Worker Safety & Compliance – Capture and filtration systems engineered to protect operators and meet stringent OSHA and EPA standards.
Primary & Secondary Smelting
- High-Temperature Filtration – Baghouse and DSI systems capable of capturing dust and pollutants from ferrous and nonferrous smelting furnaces.
- Material Transport & Storage – Domes, silos, and dense phase conveying systems for ores, fluxes, and byproducts.
- Recycling Applications – Emissions control and material handling for secondary smelting, refining, and metal recovery plants.
Aluminum & Nonferrous Metals
- Anode Bake Furnace Ventilation – High-temp baghouse solutions tailored for aluminum operations.
- Dust & Fume Capture – Proven APC systems for copper, nickel, ferronickel, and other nonferrous processes.
- Integrated EPC Services – Turnkey delivery of conveying, storage, emissions control, and automation systems across nonferrous markets.
Field Services & Aftermarket Support
Metal production facilities depend on critical equipment that must operate reliably under extreme dust loads, high temperatures, and continuous throughput. IAC provides comprehensive lifecycle support that helps steel mills, foundries, and non-ferrous processors maintain compliance, extend asset life, and prevent costly downtime.
Maintenance & Repair
- Scheduled bag change-outs, cage replacements, and leak testing for all baghouse brands
- Mechanical repairs including valve, damper, and fan replacement
- Equipment conversions to upgrade older reverse-air or shaker systems to modern pulse-jet technology
System Optimization
- Burner tuning and dryer flighting analysis to improve efficiency
- Airflow balancing and ductwork inspections to reduce emissions and wear
- Dust control retrofits for improved compliance and product recovery
Parts & Components
- 55,000+ stocked parts for baghouses, dryers, conveying systems, and controls
- Rapid shipment from strategically located warehouses to minimize downtime
- OEM and compatible parts available for multi-brand systems
Training
- On-site or virtual seminars covering baghouse operation, troubleshooting, and maintenance scheduling
- Hands-on instruction from experienced IAC engineers to extend equipment life and avoid unplanned downtime
- Data-driven best practices tailored to your specific system and process conditions to improve performance and reduce lifecycle costs
IAC’s full lifecycle support gives metal producers a reliable partner for maintaining safe, compliant, and efficient operations. Our field teams combine technical expertise with rapid response to keep critical systems performing as designed, helping facilities avoid unplanned outages and protect production targets.
Partnering with IAC
For metals and materials producers, choosing the right partner means more than finding an equipment supplier—it means securing a proven EPC contractor and OEM that can deliver reliable systems, fast-track projects, and long-term performance.
- EPC Expertise – IAC integrates engineering, fabrication, construction, and commissioning under one roof, backed by our wholly owned subsidiary Adelphi Construction. This single-source accountability streamlines project execution and reduces risk.
- Proven Track Record – With major installations for Nucor, Steel Dynamics, and Cerro Matoso, IAC has successfully executed some of the largest baghouse and ventilation projects in the metals industry.
- OEM Leadership – As one of the top five global baghouse manufacturers, IAC combines field-proven technologies with the ability to customize solutions for high-dust, high-temperature, and decarbonization-driven applications.
- Commitment to Sustainability – From hydrogen-ready DRI plants to green steel projects, IAC is actively supporting the energy transition and helping metals producers meet ambitious decarbonization targets.
- Lifecycle Reliability – With 55,000+ parts in stock, a nationwide 24/7 service network, and dedicated training and commissioning teams, IAC ensures systems stay compliant, efficient, and productive year after year.
Partnering with IAC means gaining a trusted ally with the scale, expertise, and innovation to deliver results—whether you’re building a next-generation green steel facility or optimizing emissions control at an existing smelter.
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