Capacity Expansion & Kiln Replacement Projects

Innovative Solutions

ITAC provided the client with integrated design and construction management services on a series of related projects valued at approximately $100 million. Specifically, ITAC was part of an integrated team with the owner and multiple technology providers to deliver the capacity expansion and kiln replacement projects from site development and deep pile foundations through equipment setting, process implementation, and balance of plant construction to successful completion and start-up. The projects installed new raw material receiving, handling, screening, and drying operations as well as multiple kiln replacements. With a peak construction force of approximately 75 craftsmen per shift and 10 contractors, we planned and managed a 28 day outage to replace a 100′ long kiln within a 5-story structure and the building foundations, all of which had been damaged by acid. Their production capacity was increased by adding new direct material handling systems, conveying, storage, and process equipment including bulk bag and unit packaging. The equipment was designed to operate continuously for 50 weeks per year and to handle flammable material. We also provided extensive structural changes including the replacement of gas burners, fuel tranes, ductwork, and conveyors as well as electrical and controls design. ‚ÄčITAC collaborated with the owner and OEMs to implement innovative layout solutions which increased the client’s plant-wide capacity. The projects were completed ahead or on schedule and $5 million under budget.