Somerset Wall Cracking and Spalling
Market: Coal-Fired Power Plant
Material Stored: Washed Coal
Silo Size: Jumpform, concrete silo 86' x 176'
Issue: Significant wall cracking and spalling, requiring a liner installation.
Project Background
When a coal facility needed a new 80' diameter, 176' tall concrete silo for washed coal storage, Marietta Silos was presented with a new design and construction challenge. The original silo was a Slipform reinforced concrete construction. Its unloader portion spanned the first 24', with a 5' reinforced floor containing seven stainless steel cones to discharge coal onto a conveyor system for customer loadout.
The project involved the design and construction of the first Jumpform cast-in-place reinforced concrete silo liner at this scale. Until now, Jumpform systems were limited to silos no larger than 65' in diameter. Expanding beyond that size required rethinking the entire rig engineering. While complex, the effort carried significant benefits to the customer as Jumpform silo construction is one of the most durable and cost-effective silo construction methods.
Silo Details
Over the course of two months, Marietta Silos' expert engineers redesigned and modified the proprietary Jumpform system to accommodate the expanded size. The result was a new platform, the largest Jumpform system in the industry, capable of supporting the construction and repair of silos up to 80' in diameter.
To keep the project on schedule and aligned with stringent quality standards, Marietta Silos partnered with local steel and stainless-steel fabricators. These partners produced all structural steel components and the seven stainless steel replacement cones. Local collaboration also extended to the concrete supplier, who assisted with mix design adjustments to ensure lasting strength and durability, quick set times, and consistent quality.
Marietta Silos' project engineers determined that an exterior liner would require the demolition of adjacent structures and additional measures to address harsh winter conditions typical at the site. A reinforced interior liner was therefore selected for the project. The new liner design covered 132' of the 147' storage area, the portion exposed to the greatest stressors of loading and unloading.
Conclusion
Despite the complexity of redesigning the Jumpform system, the demanding schedule, and adverse weather, Marietta Silos successfully delivered the project. With the work completed, the redesigned silo is expected to deliver another 20 years of service.
"Marietta was a great group to work with, very knowledgeable, and we look forward to working with them again." Customer & Site Project Manager.
