In 2001, the East Kentucky Power Cooperative (EKPC) embarked on an initiative to add more than 800-MW of new baseload capacity. The key objective was to build plants that could burn a wide range of fuels cleanly, efficiently and economically. The new 286-MW E.A. Gilbert Generating Unit at the H.L. Spurlock Power Station was the first plant completed as part of this initiative.

Key to the new unit was a 650-foot tall tapered reinforced concrete chimney with one 15 foot ID insulated carbon steel liner. The job was mobilized in September 2002, but due to severe winter weather, the job site was shut down and not remobilized until mid-March 2003. Due to solid pre-planning, however, the project was completed on time. In order to reduce the time and cost associated with extensive field welding, the liner cans were fabricated and shipped in complete 10-foot sections.

More than 206 tons of reinforcing steel and 2,380 cubic yards of concrete were used to construct the chimney, and more than 266 tons of rolled carbon steel and 31 tons of structural steel were used for the liner system. At the time, it was one of the cleanest coal-burning plant in the United States.