Silo Restoration and Silo Repair
Marietta Silos is the largest silo restoration and silo repair company in the United States.
All silo construction types are subject to deterioration and potential collapse without a proper inspection schedule and ongoing maintenance program. We are the only firm in the country that can take care of every aspect of your silo. From design to construction, we leverage our decades of knowledge to create a streamlined process. Our restoration services include a variety of repair and maintenance techniques that extend the life of your silo at a fraction of the cost of new silo construction.
Marietta Silos has a rich history of restoring silos for over 100 years. Many silo repairs need design and engineering input. We boast restoration supervisors with more than 50 years of experience designing and building a restoration project right the first time. In any silo restoration, we always try to identify the root cause of the damage to the silo and to incorporate those findings into our rehabilitation and design procedure to prevent further deterioration.
Whether you have an emergency silo issue or a silo restoration that has been a long time coming, our experts have the experience and expertise to fix the problem for good. Our team is prepared to act quickly and offers emergency services to meet all of your silo needs.
No matter your stored material, Marietta Silos can help with your restoration needs. We have extensive experience with steel and concrete silo restoration and silo repair. Some common silo restoration types are listed below, though our expertise spans even further.
Structural Silo Restoration
Structurally unsound silos jeopardize the safety of your stored materials. Whatever your silo restoration or modification needs, Marietta Silos is ready to help.
We perform services for facilities storing bulk materials such as borax, carbon, black cement, clay, clinker coal, fly ash, foundry sand, grain products, gypsum, lime, palletized fly ash, salt, soda ash, and more. No matter what type of structure you have or the material stored, consider Marietta Silos to solve your silo's structural problems.
Marietta Silos has more experience in silo restoration than any other company in the United States. If you have known or suspected problems, contact us for efficient, cost-effective solutions.
Composite Fiber Reinforcement
Marietta Silos is a certified installation contractor for the Wabo® Composite System. This system uses composite fiber reinforcements to strengthen existing concrete and masonry structures for a variety of applications. Available materials used include standard and vapor permeable resins and specialized fibers with low conductivity, chemical, and impact resistance that may be mounted on or near the surface of the structure with no heavy equipment needed.
Concrete Cracking, Spalling, and Delamination
When restoring concrete damage like cracking, spalling, and delamination, the root cause of the damage needs to be identified. Marietta Silos has the skills and experience necessary to restore concrete and prevent further deterioration. Through our A.I. Supplemental Inspection, we can perform faster, more accurate crack and exterior defect mapping and track changes overtime.
If your silo needs to be dismantled, Marietta Silos offers the latest demolition techniques to ensure a safe and economical work site.
Gunite is a mixture of sand, cement, and water, which is applied with air pressure. Not only is it as strong as poured concrete, but it is also very resistant to weather and chemicals and bonds 100% to well-cleaned concrete. The satisfactory application of gunite is not for the layman. Fortunately, Marietta Silos has the experience necessary to complete the job to your satisfaction.
Silo and Tank Liners
Marietta Silos believes it is important that you have options every step of the way and silo and tank liners are no different. Silo liners can help restore the structural integrity of your silo, seal walls and floors from leaking materials and prevent material contamination. We offer liners in several varieties, including concrete, steel, stainless steel, epoxy, PVC and waterproof coatings.
Silo Design Conversion
Silos that have been repurposed to store a different bulk material may need remediation to handle a heavier stored material as these can increase the loads placed on internal components, including walls and cones. Without remediation, the increased load coupled with pressure or vacuum loading and unloading strain a silo and can lead to silo failure.
Silo Discharge Cones
Silos that were constructed with outdated design methods, like steel suspended cones, carry a high failure rate. When suspended cones collapse, they can cause complete silo failure. Silos with suspended cone designs should be remediated as soon as possible to prevent failure.
Vertical silo spalling, cracking or wall separation due to overstress of the horizontal reinforcing are the main symptoms repaired with post-tensioning—a very common problem. To solve this issue, Marietta Silos will install high-strength post-tensioning strands around the wall exterior. These strands can replace all of the original steel reinforcing and, assuming the concrete is still sound. The silo can be returned to its actual load capacity economically. Marietta Silos uses a variety of techniques to replace, restoration or modify your silo roof so it can continue to meet your needs.
Marietta Silos has vast experience in rehooping concrete stave silos, whether they store foundry sand, lime, clay, cement, grain products or adapted for industry use. Older stave silos often have hoops that are corroded, damaged or missing altogether. To maintain the structural integrity of the silo, removing unsound hoops or replacing hoops with a full complement of new steel hoops may be necessary. If only a few hoops need to be restored or replaced, Marietta Silos can do that too. Rehooping can ensure your older stave silos regain or maintain their full storage capacity. A special waterproof coating may be applied after rehooping to ensure the long-term durability of the hoops.
Roof Beam and Beam Pocket
The roof slab is supported by internal roof beams that rest inside beam pockets. Spalling concrete around the beam pocket indicates a weakening of the concrete. If not restored, the pocket will no longer be able to support the roof beam and the silo roof will collapse.
Silo Roof Restoration
As with any structure, the roof of the silo generally receives the brunt of physical and environmental abuse. Proper roof maintenance is needed to keep the materials within the silo safe and dry. Roofs are subject to abuse from overfilling, explosions and overloading, as well as environmental abuse.
Steel Silo Restoration
Steel silo repairs typically involve cutting out and replacing worn or corroded portions of a silo and relining damaged silo sections. Marietta Silos handles the full design and engineering of steel silo restoration, with safety as our priority. Our experienced engineers understand your unique loading and load path requirements based on your silo type and stored material. We take loads on your silo and cone into account during every project, so you don't experience a silo failure.
Wall Bulging and Failure
Visible bowing of silo walls indicates a serious issue that can lead to wall collapse. Silos that were not purpose-built commonly experience bowing walls due to the added stressors they face in an industrial application. Bulging walls or bowing can also be caused by symmetric flow that increases pressure along the wall. Regardless of the cause, bowing or bulging walls can quickly lead to wall failure and silo collapse.
Proactive silo inspection and maintenance improves safety and cuts product losses. Concrete silos are used to store a variety of materials in energy, industrial and agricultural installations. Because concrete offers numerous advantages over steel in silo design and construction, concrete silos require minimal maintenance to sustain overall function. Predictive maintenance, however, is a critical factor in total life-cycle costs. A continuous silo inspection program supported by a proper preventive maintenance schedule will uncover inconspicuous wear or damage that compromise structural integrity, lead to unsafe working conditions and reduce silo utility value.
All silo construction types are subject to deterioration and potential collapse without a proper inspection schedule and ongoing maintenance program. Like any construction material, concrete and steel are subject to wear from environmental conditions and structural stress from loading, unloading and daily silo operations during normal usage. This stress can cause cracking and deterioration of silo foundations, walls and linings, roofs, discharge cones and floors. Many other issues can only be identified through a more in-depth inspection process. Many insurance underwriters are starting to require periodic silo inspections.
Our services are designed to recognize, understand and meet your project goals to provide high-quality service and economical pricing in a safe working environment.
USA Silo Service, Inc. is your resource for professional silo cleaning, bulk storage removal/clean-out and industrial coating. No matter the type of silo (concrete, steel, flat or cone bottom, funnel or mass flow) or type of material stored (cement, clay, fly ash, grain products and more), we are your team of experts servicing the needs of the industry for nearly 30 years. In addition, our specialists are trained to respond quickly to emergency silo cleaning needs, although our goal is to eliminate emergency plant outages related to silo blockages. USA Silos has performed silo cleaning services for all types of silos and materials. Some of our jobs include cement buildup on silo walls, slag silo wall buildup, fly ash silos, cement storage silos, air pads repair, hardened cement in silos, and vacuum truck services.
Silo cleaning is a necessary cost-saving benefit that removes buildup and recovers lost material while maximizing production, profit and safety. Unfortunately, despite the problems that may arise from a poorly maintained silo, cleaning is often postponed or deemed unnecessary maintenance. Though some facilities reason that silo cleaning is expensive or not worth the potential loss of production downtime, hung up, clogged or slow running silos are one of the biggest reasons for decreased efficiency and profitability.
Once silo blockages and material buildup start forming, they can easily accelerate over time and reduce silo capacity to as little as half. In addition to the safety concerns caused by silo blockages and material flow issues, production is directly impacted. However, a routine silo cleaning schedule will help avoid additional costs associated with emergency silo cleaning and emergency plant outages.
Professional silo companies rely on one of three different silo cleaning methods. The first method is whip cleaning, which is a slower cleaning method with limited capabilities. Pneumatic cleaning systems, the second method, is used by many silo cleaning companies throughout the US as it is faster than whip cleaning. When compared to the leading method, however, pneumatic systems are still only mid-tier.
THE BOSS™ SILO CLEANING MACHINE
Utilizing The Boss proprietary cleaning system, we deliver maximum cleaning efficiency in a safe environment while minimizing downtime, delivering cost savings to the customer.
The Boss silo cleaning machine is the leading method for fast, efficient silo cleaning. The proprietary cleaning method, offered exclusively by USA Silos, is two-thirds more powerful than conventional cleaning methods. As a result, the Boss moves more material per hour, saving time, money and downtime. The Boss is designed to accommodate variable unique clean-out head attachments selected by our field crews to match the type of material being removed.
The Boss operates in a systematic pattern within the silo to remove the toughest buildups. The Boss accelerates the cleaning process by removing more material faster and with more efficiency than any other clean-out method.
Types of Silos We Clean:
VACUUM TRUCK SERVICE
In addition to superior silo cleaning, USA Silos offers high-performance, industrial vacuum truck services to assist in the removal and relocation of silo debris.
Professional silo cleaning often results in loose, dislodged materials. USA Silos offers high-performance, industrial vacuum truck services to remove and relocate silo debris recovered during silo cleaning operations. Services move evacuated silo materials safely and efficiently when existing systems are not adequate.
Disposal of Materials
Materials recovered during our professional silo cleaning operations are assessed for future usability and handled accordingly. If your silo issues have resulted in lost material that must be discarded, USA Silo Services can assist with removing this material and proper landfill disposal when required.
Dome Cleaning Services
USA Silo Service can clean, inspect, and maintain your concrete storage dome.
Most domes are situated at a 35-degree angle and can range from 150 to 250 feet in diameter. The unique shape of the storage dome creates a non-standard flow pattern that makes material build up much more likely and much more difficult to remove from dome walls and fluidizing equipment.
Concrete storage domes suffering from restricted airflow need comprehensive cleaning and maintenance. Hardened stored material that is caked on dome walls needs to be removed through professional cleaning to return the dome to its original efficiency. Air pads and other fluidizing equipment may also need to be restored or replaced if there are signs of corrosion or defects affecting its usability.
CHOOSING A PROFESSIONAL SILO CLEANING SERVICE
It's vital to find the right silo cleaning professional. An experienced company understands the needs of your industry and considers all aspects of the situation, including materials stored, silo condition, and any difficulties you may be facing.
The goals of the silo cleaning company should include:
- Retaining a quick response time for all inquiries
- Properly assessing the problem and crafting a cost-effective solution
- Prioritizing thorough and open communication throughout the project
- Ensuring proper procedures and equipment are used across all platforms
- Guaranteeing optimum safety for all personnel, the facility and materials
- Minimizing downtime by operating quickly and efficiently
- Delivering continual improvement and innovation in all silo care procedures
- Providing regular cleaning services to prevent unplanned silo cleaning emergencies
- Handling emergency silo cleaning and maintenance needs skillfully
Silo cleaning using an untrained labor force can lead to injury or death, as well as silo damage. Since falling materials can lead to catastrophic structural failures and endanger those inside the silo, it is essential to employ qualified, trained silo cleaning professionals. A professionally cleaned silo is critical to maintaining workplace safety and decreasing the potential liability for work-related accidents.