SLIPFORM SILOS

START DATE
December 2006

COMPLETION DATE
June 2011

OWNER
Holcim, Inc.

CONTRACT TYPE
Design-Build / EPC

CONTRACT VALUE
$56,359,376

MANHOURS
680,000

Ibberson teamed with MC Industrial to provide engineering, procurement and construction (EPC) services for this cement manufacturing facility.

The 18-month project consisted of building eight 275-foot-high by 79-foot-diameter silos with the capacity to store 260,000 tons of cement. Seven additional silos were built as well: Two 150-foot-diameter by 207-foot-high silos; two 60-foot-diameter by 275-foot high silos; one 40-foot-diameter by 207-foot-high silo; and two 45-foot-diameter by 180-foot-high silos.

To reduce the amount of labor on site, form subassemblies were built in the TEI shop and shipped to the site. The first structures, two 60-footdiameter by 275-foot-high blend silos, were slipped just four months after the contract award, and 2-1/2 months on site. The fast turn-around of the first slip allowed the client the ability to immediately begin on other critical construction activities.

The next two slips consisted of two massive 150-foot-diameter x 207-foot-high clinker silos and one 40-foot-diameter x 207-foot-high reject silo. The clinker silos contained 1,250 tons of reinforcement each and were post-tensioned. Once again, due to an aggressive schedule, the two slips were only separated by one week.

The cement presented the greatest challenge. Each slip consisted of four 79-foot diameter x 275-foot-high cement silos. Both slips were post-tensioned and each contained approximately 6,220 tons of reinforcement. The final slip form was the harbor silos for loading barges.

In all, the JV poured and placed more than 100,000 cubic yards of concrete to complete its portions of this project.