Design and Build of Special Clinker Silo

Case Study

Design and Build of Special Clinker Silo, Philippines

The CEMEX Solid Cement Plant in Antipolo, Philippines, embarked on a major expansion project to increase its cement production capacity by 1.5 million tons annually. This ambitious project aimed to contribute significantly to the Philippines’ growing infrastructure needs. As part of this expansion, BEC was selected to construct a crucial component: the Special Clinker Silo.

The silo, with an outer diameter of 7.6 meters and a height of 35.3 meters, plays a pivotal role in storing high-quality clinker, a vital ingredient in cement production.

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Challenges

The project presented several complex challenges that required innovative solutions and meticulous planning:

Restricted Site Space: Limited working areas complicated logistics, material handling, and construction sequencing.

Tight Timeline: Pressing deadlines demanded efficient resource allocation and streamlined operations.

Concrete Transportation: The significant distance from the batching plant raised concerns over premature concrete setting, especially in hot weather conditions.

BEC's approach

BEC was responsible for the slipform construction of the silo walls, roof beam installation, concrete roof slab construction, and internal slab concreting. To tackle the project’s challenges, BEC implemented a phased approach to optimise site space, ensuring clear and organised operations for each construction stage. This strategy minimised congestion and improved workflow efficiency. By dynamically allocating resources, BEC maintained an adequately staffed workforce at every phase, quickly adjusting to project demands to stay on schedule. To address the challenge of concrete transport over longer distances, BEC introduced a special retarder into the mix. This additive slowed the setting time of concrete, ensuring that it maintained its quality and workability upon arrival, ultimately delivering a superior finish.

The BEC Advantage

Through strategic planning and innovative techniques, BEC successfully completed the special clinker silo on time. The project met the client’s stringent quality requirements and provided a durable and efficient storage solution, supporting CEMEX’s expanded production capacity and contributing to the Philippines’ growing infrastructure needs. Additionally, the project was completed with an exemplary safety record, achieving zero lost-time incidents, reflecting BEC’s strong commitment to workplace safety and operational excellence.