Hydro Aluminum New Facility Cassopolis

Hydro Aluminum Metals built a new plant in Cassopolis, Michigan, using next-generation recycling technology. It supports automotive innovation by producing aluminum for transportation, consumer, and building applications. This facility is also a steppingstone toward Hydro’s ambition to double post-consumer aluminum recycling by 2025.

Baker’s scope included deep pit foundations (caster pit furnaces, hot/cold wells), slab on grade, slab on metal deck, and several outbuildings. The caster pit required extensive sheeting, dewatering, and the installation of a 60-inch caisson, driven approximately 60 feet below grade.

Hydro’s new plant is the largest recycling-based producer of aluminum billet in the U.S., with the capacity to produce over 1 million metric tons annually. It’s also the country’s largest billet producer overall (primary or recycling-based).