An HO Scale Multi-Deck Steel Mill Layout Plan
#13
Finished off the Lower Deck, and i even have a little room to spare!

Ill make this post about both the Upper and Lower Decks, so everything will be in one post.

Upper Deck


Color Code for Upper Deck

Black Tracks - Mill or Mine Tracks
Red Tracks - Mainline Tracks
Yellow Tracks - Run-Around's
White Tracks - Yard Tracks
Purple Tracks - Yard Leads
Orange Tracks - Inbound Dis-Assembly/Outbound Assembly Tracks
Blue Tracks - Grade coming up from Lower Deck


Specs

Mainline is 26" radius or greater
All other tracks are 18" radius or greater
Grade is 3% with 28" radius on curves
All Turnouts are Central Valley #8's or larger
All Curved Turnouts are Walthers #7's or larger
3-Way Turnouts are Walthers #6's
Double Crossovers are Walthers #8's
Upper Deck Dimensions:
~Overall 10'x20'
~Far Left Leg - 24" wide
~Top Leg - 26" wide
~Far Right Leg - 26" wide
~Peninsula - 24" wide
~Bottom Leg - 26" wide


Description

The Upper Deck houses the 4 Blast Furnaces, or Blast Furnace Row. There is no Highline, which will be part of the backdrop behind the furnaces. This Peninsula will be the main focus of the layout. The entire Upper Deck will be at eye level, 64" from the ground to give the full perspective of the shear size of these mammoth structures. Along the top of the Upper Deck is the huge Boiler Houses, A Pump House and a Water Treatment Plant for each, a large Utilities Building, a Store House, a large Machine Shop. Along the bottom of the Upper Deck is a large Iron Ore Mine with 2 large Open Pit Mines, which will be an excellent spot to see some heavy mining equipment.

A track at the bottom of the Upper Deck (Blue Track) leads from the Lower Deck, a 3% grade traveling down 21", thus tripling the mainline run of the layout.

Each structure on the Upper Deck has a number that corresponds to the list below:

3. Gas Storage Tank
4. Dorr Thickener
5. Water Treatment Plant #1
6. Pump House #1
7. Blast Furnace A
8. Filter House
9. Stoves and Piping for Furnace A
10. Stoves and Piping for Furnace B
11. Settling Tank #1
12. Mechanics Office
13. Blast Furnace B
14. Blower Engine House
15. General Office
16, Locker and Washroom
17. Blacksmith Shop
18. Blast Furnace C
20. Stoves and Piping for Furnace C
21. Stoves and Piping for Furnace D
22. Central Steam Plant
23. Settling Tank #2
24. Blast Furnace D
25. Machine Shop #1
26. Water Treatment Plant #3
27. Pump House #3
28. Machine Shop #2
29. Store House #1
30. Power Plant #1
31. Broiler House #2
32. Utilities Building
33. Broiler House #1
34. Water Treatment Plant #2
35. Pump House #2



Lower Deck


Color Code for Lower Deck

Black Tracks - Mill Tracks
Red Tracks - Mainline Tracks
Dark Purple Tracks - Run-Around's
Orange Tracks - Outbound Assembly Tracks
White Tracks - Yard Storage Tracks
Yellow Tracks - Yard Inbound Dis-Assembly Tracks
Light Purple Tracks - Yard Leads
Bottom Yellow Tracks - Mainline Dis-Assembly Tracks
Blue Tracks - Grade going up to Upper Deck


Specs

Mainline is 26" radius or greater
All other tracks are 18" radius or greater
Grade is 3% with 28" radius on curves
All Turnouts are Central Valley #8's or larger
All Curved Turnouts are Walthers #7's or larger
3-Way Turnouts are Walthers #6's
Lower Deck Dimensions:
~Overall 10'x20'
~Far Left Leg - 24" wide
~Top Leg - 28" wide
~Far Right Leg - 26" wide
~Peninsula - 20" wide
~Bottom Leg - 26" wide

Description

The Lower Deck sits 21" below the Upper Deck at 43" from the ground. The Lower Deck's main focus will either be the large yard or the Basic Oxygen Furnace/Continuous Caster Building. The BOF/Caster takes up nearly all 20' of the top of the Lower Level, which should give you an idea just how large these things are. Along the bottom of the Lower Deck is a Rolling Mill and a couple Finishing Mills.

The Peninsula is home to a large yard. Trains can come in from the mainline, park on one of the yellow sidings at the bottom of the Lower Deck. Locomotives can then travel up to the Orange Tracks to pick up an Oubound Train already waiting. Meanwhile, with the train still parked on the mainline siding, yard switchers can being bringing the train in into the yellow tracks in the yard. From there, and once the mainline has been cleared, the yard switchers can break the train apart and sort into any of the 4 white yard/storage tracks, and then begin building a new outbound train. Purple tracks are the yard leads which will allow the yard switchers plenty of room to pull/shove cuts of cars into the various yard tracks. Oubound trains can either travel the mainline on the Lower Deck straight out of the Yard or start heading straight up the grade to the Upper Deck.

The Blue Tracks are the grade that leads to the Upper Deck. The Grade (3%) starts at the bottom right center of the plan and travels up 21" over roughly 50'

Each structure on the Upper Deck has a number that corresponds to the list below:

1. Teeming Platforms
2. magnetic Separation House
3. Scrap Unloading Warf
4. Heat Exchanger
5. West Penn Power Sub-Station
6. Pump House #5
7. Tundish Preparation
8. Bloom Cooling Beds
9. Locker and Washroom Building
10. Metallurgical Lab
11. Water Treatment Plant #4
12, Rail Finishing
13. Beam Finishing
14. Rail Shipping
15. Beam Storage/Shipping
16. General Office
18. Compressor Room
19. Electric Shop
21. Tube Mill
22. Rolling Mill (2 Walhers Kits)
24. Wire Mill
25. Boiler House #3
26. General Office
27. Carpentry Shop
28. Blacksmith Shop
29. Pattern House
30. Store House #2
31. Machine Shop #3



I think that about sums op the plan, please post you comments and suggestions. If you see something that needs to be changed, or could be changed to improve operations, please point it out and let me know so I can look at it and change it to possibly make the plan better.

Thanks again for everyone who has already offered their advise, and thanks again to Russ for suggesting the idea of the peninsula to eliminate the 3rd deck.


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Josh Mader

Maders Trains
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