Air Products
HyCO4 Project
Project Highlights
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Performance Contractors executed three major mechanical construction packages for the HYCO 4 project in La Porte, Texas, totaling nearly $100 million in awarded work. The scope encompassed structural steel erection, pipe fabrication and installation, equipment setting and dress-out, civil foundation support, scaffolding, pressure testing, and commissioning support. At peak, Performance managed approximately 300 craft professionals and ultimately completed approximately 1.1 million work hours with zero OSHA recordable incidents.
Scope/Services
Civil
Equipment Assembly & Erection
Hydrotesting
Millwright Alignment Work
Module Installation
Pipe Installation
Rigging & Heavy Lifts
Site Work & Earth Moving
Soft Crafts
Structural Steel Erection
Industry
Oil, Gas & Chemical
Industrial Gases
Capability
Capital Construction
Pipe & Steel Fabrication
Module Assembly & Installation
Location
LaPorte, TX
The Challenge
Performance joined HYCO 4 after many of the project’s foundational engineering, planning, and constructability decisions had already been established. As Performance’s role expanded from early equipment and pipe rack module setting to both OSBL and ISBL mechanical construction, the team had to rapidly scale manpower, supervision, planning, fabrication coordination, and field execution while construction was already underway.
The project environment remained highly fluid, with ongoing engineering revisions, scope growth, material and information delays, congested work areas, multi-contractor coordination challenges, shifting priorities, and constant schedule pressure. Crews frequently had to resequence activities and relocate manpower while maintaining productivity, quality, and safety across multiple active work fronts.
What We Did Differently
Rather than relying on a fixed execution plan, Performance developed a field-driven, highly adaptive approach. Strong superintendent-level coordination, detailed workface planning, daily communication with the client, proactive material and equipment coordination, and flexible manpower deployment allowed the team to quickly respond to changing priorities and move resources among the three mechanical packages to support critical-path activities.
Performance also integrated safety and quality directly into field execution rather than treating them as separate functions. Daily pre-task planning, hazard assessments, supervisor audits, visible field leadership, and continuous craft engagement contributed to zero OSHA recordables across approximately 1.1 million work hours, while disciplined welding and quality processes resulted in zero rejects across approximately 6,000 welds.
Project Total Quantities
- Structural Steel Installation { 6,676 pieces
- Equipment Set { 92 pieces
- Pipe Installation { 59,891 LF
- Welds completed { 8,000+
- Manhours { 1.1MM
- Peak Manpower { 300
Item
Quantity
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