New By Product Jumpform Silo Construction – Wisconsin
Market: Power Material Stored: Fly Ash Silo Size: 50′ diameter by 100′ tall, Quantity (2) Issue: Wet ash disposal to dry ash storage. Project Background Two completed fly ash silos with enclosed roofs. Two completed jumpform fly ash silos for a new coal fire power plant are pictured above. These poured in place silos are part of a vacuum system for fly ash. The permanent stair tower has been erected in between the silos for access to either and equipment has been placed on the roof and the external electrical & piping systems traverse up the silo walls. The material handling equipment on the roof is enclosed in an inexpensive, sheet metal head house. This inexpensive method of enclosure increases equipment longevity and operating efficiency by protecting it from the environment.
New Slipform Fly Ash Silo Construction – Kentucky
Market: Power Material Stored: Fly Ash Silo Size: 45′ diameter by 126′ tall Issue: Wet ash disposal to dry ash storage. Project Background Slipform silo, still under construction. Slipform technology is an around the clock operation in which the work deck, pictured at the top of the silos, is made of wood and constantly ‘slips’ or moves upward. Reinforcement steel, block-outs and penetrations have to be put in place while constantly pouring concrete and moving the deck up vertically. This method of Slipform construction poses unique challenges to the construction of industrial silos and is more expensive than Jumpform construction.
Stave Silo Inspection – Texas
Market: Manufacturing Material Stored: Aggregate Silo Size: 26′ diameter by 60′ tall Issue: Wall failure due to corroded hoops. Project Background Stave silo with wall failure. Pictured above is a stave silo constructed on a poured in place base, utilizing steel galvanized hoops around the silo for structural integrity. Marietta Silos was contacted after the failure for expert recommendation to repair the existing silo and establish the cause of failure. Our experts determined the failure was caused by deterioration of the steel galvanized hoops around the concrete staves that normally provide structural integrity for silo walls. Lack of routine inspections and maintenance led to hoop and concrete stave failure, though luckily no one was injured. Routine inspection and maintenance is required for the safe, efficient operability of any material handling equipment, including silos. This is a prime example of a failure that could have been prevented with a proper inspection and maintenance program by a professional silo company.
Cement Slipform Silo Wall Inspection – Alabama
Market: Manufacturing Material Stored: Cement Silo Size: 45′ diameter by 145′ tall Issue: Silo inspection, cracking walls Project Background A proactive maintenance and inspection program is crucial to increase the life of your concrete. The Marietta Silos team can be seen above sounding the silo wall to determine if there is delamination within the wall. Delamination compromises the integrity of the reinforcing steel. The wall of this jumpform fly ash silo was partially delaminated and required repairs. Prevention is the most effective method to ensure the integrity of concrete structures, surfaces and silos. A proactive maintenance and inspection program is crucial to increase the life of your concrete and ensure the safety of those working around your structures. Regular inspections, on annual, two- or five-year intervals, can help identify issues that increase the risk of structure collapse. Based on inspection results, preventive maintenance can be performed to avoid larger more expensive repairs later. The cost of preventive maintenance and repair is minimal when compared to the financial and physical toll that a full collapse can have on your company and team. A proactive safety program should always include annual or semi-annual inspections to check for concealed damage and to assess visible problems that could lead to structural failure. The same silo, from a different angle, almost complete. Collapses are often the result of preventable structural failures that would have been identified during routine inspection. Common issues that cause concrete structure and concrete silo failure include foundation deterioration, roof collapse due to roof beam structural issues, improper material filling and unloading procedures in silos, silo wall delamination or deterioration, and silo discharge cone or bin floor issues. Much of this damage is easily preventable through routine inspection and maintenance. Third-party inspections, maintenance and repair services are the best way to manage safety on any scale. Many structural issues can be easily and economically addressed if caught early.
Carbon Silo Inspection of Delamination and Spalling Walls – West Virginia
Market: Manufacturing Material Stored: Carbon Silo Size: 45′ diameter by 120′ tall Issue: Silo inspection, delamination and spalling walls Project Background A Jumpform concrete silo with delamination and cracking in the walls. Pictured above is a Jumpform concrete silo that Marietta Silos was called in to inspect. Heavy usage, original design and potential construction issues heave lead to clear delamination and spalling in the walls. Above the horizontal crack there is additional horizontal and vertical cracking. Under continued usage this silo's concrete will inevitably divide and lead to failure. Below is a closer look at the silo wall cracking and delaminating in another area. Delamination of the concrete is caused by the lack of bonding to the interior structural steel reinforcement which weakens the silo’s structural capacity. Issues of this nature require prompt repair. To repair delamination this serious, the affected area is cut out and the reinforcing steel is replaced. Once reinforcing steel is tied in and replaced, the wall is formed and poured with specific, non-shrink concrete per engineer specifications. A closer look at the same silo wall. Collapses are often the result of preventable structural failures that would have been identified during routine inspection. Common issues that cause concrete structure and concrete silo failure include foundation deterioration, roof collapse due to roof beam structural issues, improper material filling and unloading procedures in silos, silo wall delamination or deterioration, and silo discharge cone or bin floor issues. Much of this damage is easily preventable through routine inspection and maintenance. Third-party inspections, maintenance and repair services are the best way to manage safety on any scale. Many structural issues can be easily and economically addressed when detected early.
New Fly Ash Concrete Silo Construction – Minnesota
Market: Power Material Stored: Fly Ash Silo Size: 42′ diameter by 126′ tall Issue: Wet ash disposal to dry ash storage. Project Background Coal powered generation facility silo. Coal powered generation facilities have to plan for disposal or reuse of byproducts, such as fly ash, created from the coal burning process. In its dry form, fly ash is vacuumed or blown into storage silos and used as a filler material in numerous market segments. In the photo above the new fly ash silo constructed by Marietta Silos is finished. It includes a staggered external ladder with landings as a secondary means of access to the roof of the silo; equipment has been placed on the roof and the external electrical and piping systems traverse up the silo walls. The material handling equipment on the roof is enclosed in an inexpensive, sheet metal head house. This inexpensive method of enclosure protects the equipment from inevitable environmental conditions, increasing its longevity and operating efficiency.
Internal Silo Inspection of Deteriorating Beam Pocket – Pennsylvania
Market: Manufacturing Material Stored: Cement Silo Size: 30′ diameter by 115′ tall Issue: Deteriorating beam pockets Project Background A typical method utilized for internal silo inspections. Pictured above is a typical method utilized for internal silo inspections. The professional silo engineer is lowered into the silo in an OSHA approved man basket. All OSHA regulatory compliance programs are in effect during this operation, including all required personal protective equipment, all facets of fall protection and the confined space entry program, to complete the task efficiently without incident. Pictured below is an inspection photo showing a failing beam pocket and deteriorating underside of the silo roof slab. Materials are visible on top of the beam between the slab and the beam, which is the support structure for the roof. Cracking, spalled concrete around the beam pocket are obvious signs of a beam end that no longer has the structural integrity for weight capacities as originally designed. This situation is common in older concrete silos and has led to complete roof failures. Marietta Silos has extensive experience and standard engineering details that can be easily applied to repair this situation and prevent roof failure. It is imperative to have silos inspected regularly. It is imperative to have silos inspected regularly by an experienced, professional silo company. Preventive maintenance and inspections should be incorporated for all material handling equipment to ensure its safe and efficient operation for all industry. In this scenario, the issue was detected during a scheduled inspection so the pocket could be fixed before the beam pocket failed.
Silo Inspection of Deteriorating Suspended Cone – Mississippi
Market: Manufacturing Material Stored: Salt Silo Size: 28′ diameter by 60′ tall Issue: Deteriorating suspended cone Project Background A concrete stave silo that uses galvanized steel hoops around the silo for structural support. Pictured above is a concrete stave silo that uses galvanized steel hoops around the silo for structural support from the materials pushing out on the walls. As pictured, the hoops were not in good condition and the corroded hoops were replaced. This silo is constructed with a suspended cone that is welded to a steel ring girder that protrudes through the wall. Below is a closer look at the inside of the suspended cone which shows rusting of it and the steel ring girder due to water leakage. Anchoring cones into silos this way is not an accepted method; new silos are now constructed with vertically supported cones instead of horizontally suspended cones which are known to have a high rate of failure. It is imperative to have silos inspected regularly. This silo cone could have been repaired by pouring pilasters from the foundation up to the cone and attaching it, creating a suspended cone. However, the customer deemed it non-economical and took this silo out of service.
Silo Inspection of Multiple Discharge Asymmetric Flow Failure – Florida
Market: Manufacturing Material Stored: Phosphate Silo Size: 45′ diameter by 115′ tall Issue: Multiple discharges caused asymmetric flow and silo failure. Project Background An example of how asymmetric flow can cause silo failure. Pictured above are two silos with a concrete stave upper with structural steel hoops surrounding the outside vertical walls and a poured in place concrete base. The silo on the right exemplifies silo failure due to asymmetric flow. Marietta Silos was called in to inspect this particular silo after the damages had occurred. After inspecting the silo in its failed condition, it was determined that the flow of the material caused the failure. This silo had multiple discharges at the bottom of the cone in the silo. Due to the various discharges, the material flowed along the wall instead of down the middle, creating increased pressure the wall was not designed to handle. The silo pictured did not have regularly scheduled inspections by a professional silo company that could have determined the asymmetric flow prior to the silo failure. It is imperative to have silos inspected regularly. It is imperative to have silos inspected regularly by an experienced, professional silo company. Preventive maintenance and inspections should be incorporated for all material handling equipment to ensure safe and efficient operation for all industries.
Slipform Cement Silo Wall Spalling – Michigan
Market: Manufacturing Material Stored: Cement Silo Size: 46′ diameter by 110′ tall Issue: Silo wall cracking Project Background A Slipform concrete silo with a horizontal crack. Pictured above is a Slipform concrete silo that Marietta Silos was called in to inspect. Due to heavy usage, original design and potential construction issues the silo has a horizontal crack that coincides with the material floor inside. At the point of damage, there is reinforcing steel tied into the wall concrete inside the silo. Above the horizontal crack is additional cracking that is both horizontal and vertical. Under continued usage this silo's concrete would inevitably delaminate. Below is a closer look at the silo wall spalling and delaminating above the horizontal crack. Delamination of the concrete is caused by the lack of bonding to the interior structural steel reinforcement, thus weakening the silo’s structural capacity. Issues of this nature will require repair sooner rather than later. To repair cracks in a poured in place silo, an epoxy injection is used to fill in the cracks. After epoxy injection, it is recommended to add post-tensioned strands completely around the silo area of delamination to provide additional structural integrity. It is imperative to have silos inspected regularly.